Kitting & assembly at scale: when, why, and the cost model

The 3-strategy fork

Pre-kit when demand is predictable and AOV lifts justify carry. On-demand when SKUs vary by customer (build-your-box). Skip-kit when bundles are mostly storage convenience, not customer perception.

Cost model

Pre-kit: $0.18–0.32/unit assembly + carry. On-demand: $0.42–0.65/unit assembly, zero carry. Skip-kit: $0.04/unit handling, customer assembly. Pick the model that matches your demand volatility, not the cheapest line item.