Re:Build Manufacturing delivers custom-designed kitting solutions for our aerospace partners. Our fully integrated kitting services support everything from high-volume production to complex, mission-specific applications including retrofitting, MRO, provisioning, forward stocking, and product improvement programs.
Aerospace kitting organizes and pre-packages all necessary components, hardware, and tools into a single, ready-to-use kit. This approach streamlines workflows, minimizes errors, and accelerates maintenance, ensuring that the end user has exactly what they need, when and where they need it. With decades of experience, we understand the complexities of aerospace manufacturing and have developed kitting solutions that help our customers maximize efficiency without compromising quality.
Our Phase Maintenance Kits are designed for discrete issuance, meaning each kit contains the exact number of parts required for the job, no more, no less. Each kit consolidates hundreds of different part numbers into one streamlined order, so customers only request a single part number to receive everything required for maintenance. Our AS9100-certified process incorporates color-coded packaging, zone/installation-based organization, and full lot traceability to ensure accuracy, compliance, and ease of use.
The Details
Industry
Aerospace & Defense
CAPABILITIES APPLIED
In 2018, a major helicopter OEM approached us to address a growing concern: the widespread use of unauthorized Phase Maintenance Kits for their military rotorcraft platform. These unauthorized kits varied significantly in quality, content, and configuration, leading to inconsistent maintenance outcomes and compliance challenges with OEM standards.
One government entity faced lead times of up to 250 days for their maintenance kits, causing significant delays in operations and aircraft availability. Beyond the long wait times, operators struggled with the administrative burden of sourcing, negotiating, purchasing, stocking, and managing hundreds of individual components. Every part ordered separately added to procurement overhead, inventory management costs, and handling complexity.
The OEM needed a reliable, configuration-controlled solution for scheduled phase overhauls across all helicopter variants that would mitigate risks from non-compliant third-party kits while improving fleet readiness.
Re:Build Manufacturing developed the only OEM-authorized Phase Maintenance Kit for this military helicopter platform, using certified materials with full lot traceability. Each kit is OEM-validated and aligned with the manufacturer’s latest maintenance standards.
The kits feature a comprehensive, color-coded packaging system that supports intuitive installation during scheduled maintenance intervals. Supplemental kits are also available, which can be tailored to customer-specific needs, offering further flexibility and adaptability across different operational environments.
Since we became the supplier, lead times have dropped to as little as 30-45 days. By streamlining sourcing, packaging, and logistics, our kits ensure critical components arrive on schedule, drastically improving operational readiness. The U.S. government is conducting cost-benefit studies demonstrating how our kitting solutions deliver substantial savings by lowering administrative costs, minimizing waste, and accelerating maintenance workflows.
By consolidating everything into a single package, we reduce the workload on purchasing teams and warehouse staff. With all parts readily available and organized, technicians spend less time searching for materials, leading to lower labor costs and faster completion times.
