Work Order Kitting & Pick List

The problem this kills

A job hits the floor, the operator starts, and three hours in everything stops: one component is short by 40 pieces and nobody knew until the bin was empty. Now the line is idle, the planner is firefighting, and the half-built WO is parked in a corner taking up space and tying up the parts that were available.

The root cause is almost never the missing part itself - it's that nobody checked the whole kit against on-hand stock before the job was released. That check usually lives in someone's head, a printed BOM, and a stock report from a different screen. It doesn't get done under pressure, and when it does, it misses the location detail (the part exists - just in the wrong building).

This tool makes the pre-flight kit check automatic and impossible to skip, and it won't let a job be released until a person has actually confirmed the parts are there.

What you'll build

A small, secure internal web app for your stockroom and planners. You pick a work order, and the tool:

• Explodes the BOM: required qty per component = component-per-unit x build quantity.
• Nets against allocations if you track them (so committed stock isn't double-counted).
• Compares required vs on-hand by location, and suggests a pick location (FIFO or bin priority).
• Flags every shortage with the exact short quantity - before the job is released.
• Lets the stockroom record the actual picked qty per line (which may differ from required).
• Holds release behind a hard approval gate: the planner approves only when the kit is complete, or makes an explicit, logged short-release decision.
• Exports a clean pick list and a shortage report every time.

If you don't have an API into your ERP yet, you'll import a BOM CSV and a stock-on-hand CSV and export a pick-list CSV - fully working today, no integration required.

What's inside the Implementation Plan

The plan is a runbook you paste into an AI coding agent (Claude Code), and it builds the tool with you step by step.

It opens by interviewing you about your business - your work order and BOM shape, your item/SKU naming, your locations and bins, whether you track allocations, your pick rules (FIFO vs bin priority), your typical and peak volumes, and your messy edge cases (substitutes, phantom assemblies, partial kits). It reflects a short tailored spec back to you and waits for your thumbs-up before building anything. You get a tool shaped around how you actually run kitting - not a generic template.

Inside you'll find: the discovery interview, the exact data model, the BOM-explosion and shortage logic, the stockroom pick-confirm screen, the planner approval gate, the audit trail, and the CSV import/export fallback - each step ending with a ready-to-paste prompt.

The governance it includes (this is the point)

• Login so only your team can open the tool.
• Row-level security so each user only ever sees their own organization's work orders and stock.
• A complete audit trail - who computed the kit, who picked, who approved release, and when.
• A hard human-in-the-loop approval gate before a job is released to the floor: the tool drafts the kit and the shortage call, a person reviews and approves, and only then is the WO marked released.
• Duplicate guards so the same work order can't be kitted or released twice (dedupe key = WO + component + pick line).

Who it's for

Material handlers and stockroom staff who pull the parts, and planners or production schedulers who decide when a job is safe to release. If you live in spreadsheets and ERP screens and you've been burned by a job stalling for a missing part, this is for you. No coding background needed.

You've got this - paste the first prompt and let the agent interview you.