Bespoke Kitting Services

Pugh & Sanders offer bespoke kitting services, built around your needs. Our customised SAP production software offers ultimate flexibility to your kitting configurations, often leveraged for complex and diverse material requirements, and to efficiently assist specific production tasks. These complex kits can incorporate Free Issue material and Ancillary C Class components, expertly sourced by us.

What are Kitting Solutions?

Kitting involves the pre-assembly of individual parts and components into ready-to-use kits tailored to specific tasks or production processes. In the context of rail industry operations, this means that all parts required for a particular maintenance or assembly task are grouped together, facilitating efficient workflow and reducing the time spent searching for individual components.

All manned in-house by a team of experienced & trained staff working at our dedicated production facility in Burton on Trent.

To find out more, please see our Bombardier Class 170 Case Study.

Increased productivity
Cost allocation & control
Minimise wastage
Consolidate suppliers

Features	Benefits
We offer a bespoke kitting facility	Dedicated to your business with flexible layout options
In house trained staff	Safety critical
Stock holding	Reliable supply partner
Using bill of materials	Call off / Schedule – Cash flow enhancement
Using bill of materials	We can incorporate free issue items, consumables and all customer part numbers
Bogie / Rail Specialists	Safety critical supplier, quality assurance across our business

Kitting for Rail Rolling Stock Overhauls

Rail rolling stock requires regular maintenance and overhauls to ensure safety and efficiency. Our kitting solutions provide pre-assembled kits with all necessary components, eliminating delays and reducing the risk of missing parts.

Our kitting services support bogie overhauls
Wheelset changes are streamlined
Braking system upgrades are simplified

By providing all parts in a single kit, we reduce downtime, simplify inventory management, and improve workflow efficiency.

Custom Kitting for Compliance and Safety in the Rail Industry

Our kitting solutions help standardise parts and processes, reducing the risk of errors and ensuring maintenance teams always have the correct components.

We help rail operators by ensuring regulation-compliant parts with every kit pre-checked to meet safety and quality standards
Consistency is improved with pre-packaged kits that ensure the same approved components are used for every repair
Human error is reduced as pre-sorted sets eliminate the need to cross-reference multiple suppliers
Audit and traceability are enhanced through clear documentation and reporting that support compliance tracking

What’s Included in a Rail Kitting Solution?

Every rail operator has unique requirements, so our kitting solutions are fully customisable.

A typical kit includes fasteners and fixings such as nuts, bolts, washers, rivets, and specialised fasteners for rail applications
Braking and suspension parts including brake pads, hydraulic fittings, air suspension components, and bushings are pre-packed for seamless repairs

Each kit is assembled based on demand planning to ensure the right parts are always available. By reducing waste and improving turnaround times, our kitting solutions keep rail maintenance teams working efficiently.

Our bespoke kitting process begins with understanding your logistics and operations in detail. We propose innovative, tailored solutions, ensuring your inventory is monitored and replenished as frequently as required. Through detailed reporting and stock movement analysis, we continuously refine the process to deliver the most efficient and cost-effective package expert tailored to your business.