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Inventory process thoughts

Alphalpha

Well Known Member
When I did my kit arrival inventory like many there were a few things to sort out. But the other day I realized I had completely missed the “air”boat in one way and had to redo the inventory.

There are three things that affect our kit inventory. The first is a part isn’t there because it wasn’t available at the time of shipping and the mothership notes it as back ordered. The next is because it is simply missing. It got checked off but didn’t make it in the box for whatever reasons. The third is you got a part that the label says is the part but it is not the correct part.

It’s this latter condition that makes inventorying difficult. It usually occurs where parts look very similar. By example if you are slow building the tanks your kit contains eight different types of main ribs that look a lot alike. And in each wing they face in different directions.

The only solution is to also use the plans while inventorying to ensure each part is what it says it is.

Having said this I must emphasize that I am not denigrating the good folks at Vans. I have received mislabeled or mispackaged parts from every major aircraft and parts manufacturer over the years. Things like .010 over pistons in a standard box. Or alternators with the wrong data plate. The list of mistakes I’ve seen is really long and I’m not that old.

The industry (and FAA) expectation is that it is up to the installer to ensure that any parts installed are the correct part underneath its label. And, where a data plate is required, that data plate is correct.

To counter the haters before they jump in to bash, I’m very curious to know how many sub kits Van’s ships out every day. What I do know is they all vary based upon what they have in stock at each moment, they all have thousands of parts, and there are roughly five different sub kits across ten models of aircraft. And these different models don’t really share a lot of common parts. What Van’s does every day is pretty impressive.
 
Good thoughts. When I got into this I assumed inventory was "plug and play" and done in a few hours. Your post, and others, make me realize there is another dimension to it and will take substantially longer. I'm good with that to ensure accuracy. I'm in a hurry to get the kit, but that energy stops when I actually get it.
 
Most importantly, Van's does seem to be applying some grace to inventory problems on the -15. I have had do to more than one follow-up discrepancy email. This weekend I realized there is one more flap-end rib that I am missing. I had some duplicates or mis-labels that confused me during initial inventory. At least so far, they have not been strict about the inventory policy.

I kinda gave up on trying to be precise about inventory when random un-listed parts started showing up. I'm just building with what I have and communicating as necessary. It will be interesting to see if this is dialed in a little more on wing kits.
 
Hey all,

As I am currently waiting for my full RV-10 kit, i am gobbling up some tools to make my life easier during build. The first thing was a work time tracker with the possibility to implement images (for my former build I did everything with excel which took a lot of time I could have spent building). Now I am looking into a way to check the Kits when they arrive, to not stop and stare at a mountain of bags and parts thinking "how am I going to verify all of this?" The standard advice is to grab a buddy, print the packing list, and spend a weekend reading part numbers out loud while someone checks them off.

It's currently a web app (runs on your phone or tablet) that has the complete Van's RV-10 packing list (for now, if anyone wants to use it for another model, just forward me the packing list, preferably the empty template coming directly from Vans) built in as a manifest. You pick a kit, hit "Start Kit Check", and just start scanning. Point your camera at a part label, it reads the part number via OCR/barcode, matches it against the manifest, and checks it off. That's it.

When you scan a bag label (e.g. BAG 1145), it recognizes it and pops up a checklist of everything that should be inside. You can:
  • Scan each item inside the bag individually to verify it
  • Or just visually confirm and tap through the checklist
  • Mark items as confirmed, short, or backordered
  • Adjust quantities with +/- buttons (rivets are tracked by weight in lbs, hardware by piece count)
  • If something's missing, mark it backordered and move on
When you're done with the bag, hit "Done, Add to Inventory" and everything gets recorded.

The old way needs two people because one person is reading part numbers while the other is hunting through a printout. Most of the time, I am building late in the afternoon / night. With the tool, I can just pick up a part (or a bag), scan it, and the app tells me if it belongs. No hunting through paper, no calling out part numbers. Set it down, come back tomorrow, pick up right where I left off. The session remembers the progress.

If you scan something that's not in the manifest, you get a clear warning: "This part is not in the manifest for [kit name]." It won't silently add mystery parts to your inventory. You can still add it if you know what it is, but it makes you confirm first (or just put the part on a "mystery part pile".
When you're done (or done for the day), you can see exactly what's been verified, what's missing, and what's still unchecked. In the end, you can just export a list in order to sent it to Vans to claim the missing items.

The only thing I try to solve would be the point Alphalpha mentioned, parts labeled incorrectly. Maybe it would be best to have a cutout of the part in the plans, or link to the page in the plans where the part is used? Still something to improve.

The code is open source and available at Github (link) to host it yourself (however I am thinking to offer it as a already hosted solution as well). As I am still working on the Inventory part, its not implemented on Github yet but you can check out a live demo at https://demo.benchlog.build/ (where the camera tool is also not implemented yet :) . I try to fix the last bugs and hope to be able to show the demo within the next days. )

I attached some screenshot. If anyone has any suggestions how to improve it, just let me know.

Cheers

Patrick
 

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Does Vans still send a packing list?
I remembernit helped a lot to see what was packed, deleted or back ordered.
I too have a full inventory, but it's for 7 and 7A. The tricky part was entering it exactly matching the packing list. Made searches more reliable.
 
When I got into this I assumed inventory was "plug and play" and done in a few hours. Your post, and others, make me realize there is another dimension to it and will take substantially longer.
It has taken my wife and I several hours to inventory each of the RV-14 kits we've received. Generally just a couple of pieces of hardware missing (e.g. nuts, washers, etc). although I have received a couple of parts that were mis-labeled. Considering how many parts are in many of the bags, they do a pretty good job overall.
 
Thing is, Vans does send a packing list. But the lists get updated and new parts get added or original parts deleted about as frequently as the KAIs get updated (the new lists are with the KAIs) So you may have parts that you won’t need, or may not have parts that you will need but don’t know about unless you have the latest packing list.

I believe Vans has a running list of items that they owe each customer, and they seem to be pretty accurate, unless items get marked as having been sent to you and they actually get missed and not shipped.

I am sure the lists will stabilize, if they haven’t already, but by being a Dec 31st pickup (maybe the 5th kit out the door?) we had a fair amount of book keeping to do.

I have a spreadsheet developed from my original packing list. Then a column for how many of each item I got and another column for how many I was supposed to have gotten, color coded whether they were back orders or missing or incorrect. Then I went through the new packing list(s) and added all the new items at the bottom and noted all the deleted items in another column. Then columns for each shipment of parts I get with how many of which items that contained, color coded for whether items were missing or incorrect from the packing list that comes with the shipment. Finally a summary column with how many of each item are still needed, now mostly zero.

It sounds worse than it is, but without the spreadsheet and quite a lot of time keeping it updated, I would be clueless as to what I still need. At least until I get to that point in assembly and realize I haven’t got it
 
I likely have the most recent 15 kit from Van's. Received yesterday. I am half way through my inventory and it has been spot on. I have confirmed all quantities under 100 units in the 3 tackle boxes and all has been accurate. I am impressed. Crating has been impressive. Everything well protected using a lot of paper and foam. No more gorilla tape.
I only have bigger pieces and skins left to inventory so I am not anticipating any problems. They have communicated very well to me including what was back ordered.
 
No more gorilla tape.
Is this true. I had ruined some parts because of that damn stuff that was hidden. I thought i had it all and lifter the skin wondering why it wouldn’t lift out and pulled harder bending the expensive part. Then i saw the dam tape under the edge. Ticked me off severely.
 
Hey all,

As I am currently waiting for my full RV-10 kit, i am gobbling up some tools to make my life easier during build. The first thing was a work time tracker with the possibility to implement images (for my former build I did everything with excel which took a lot of time I could have spent building). Now I am looking into a way to check the Kits when they arrive, to not stop and stare at a mountain of bags and parts thinking "how am I going to verify all of this?" The standard advice is to grab a buddy, print the packing list, and spend a weekend reading part numbers out loud while someone checks them off.

It's currently a web app (runs on your phone or tablet) that has the complete Van's RV-10 packing list (for now, if anyone wants to use it for another model, just forward me the packing list, preferably the empty template coming directly from Vans) built in as a manifest. You pick a kit, hit "Start Kit Check", and just start scanning. Point your camera at a part label, it reads the part number via OCR/barcode, matches it against the manifest, and checks it off. That's it.

When you scan a bag label (e.g. BAG 1145), it recognizes it and pops up a checklist of everything that should be inside. You can:
  • Scan each item inside the bag individually to verify it
  • Or just visually confirm and tap through the checklist
  • Mark items as confirmed, short, or backordered
  • Adjust quantities with +/- buttons (rivets are tracked by weight in lbs, hardware by piece count)
  • If something's missing, mark it backordered and move on
When you're done with the bag, hit "Done, Add to Inventory" and everything gets recorded.

The old way needs two people because one person is reading part numbers while the other is hunting through a printout. Most of the time, I am building late in the afternoon / night. With the tool, I can just pick up a part (or a bag), scan it, and the app tells me if it belongs. No hunting through paper, no calling out part numbers. Set it down, come back tomorrow, pick up right where I left off. The session remembers the progress.

If you scan something that's not in the manifest, you get a clear warning: "This part is not in the manifest for [kit name]." It won't silently add mystery parts to your inventory. You can still add it if you know what it is, but it makes you confirm first (or just put the part on a "mystery part pile".
When you're done (or done for the day), you can see exactly what's been verified, what's missing, and what's still unchecked. In the end, you can just export a list in order to sent it to Vans to claim the missing items.

The only thing I try to solve would be the point Alphalpha mentioned, parts labeled incorrectly. Maybe it would be best to have a cutout of the part in the plans, or link to the page in the plans where the part is used? Still something to improve.

The code is open source and available at Github (link) to host it yourself (however I am thinking to offer it as a already hosted solution as well). As I am still working on the Inventory part, its not implemented on Github yet but you can check out a live demo at https://demo.benchlog.build/ (where the camera tool is also not implemented yet :) . I try to fix the last bugs and hope to be able to show the demo within the next days. )

I attached some screenshot. If anyone has any suggestions how to improve it, just let me know.

Cheers

Patrick
I like what you’re doing with this. In the bigger kits there is a ton of parts and like you say if theres an easier way to go through it to cut down the time spent and also confirming what might be missing. Had this problem on my 9 emp. Wrong parts. Vans replaced but took 2 weeks to get right ones sent out.
 
I likely have the most recent 15 kit from Van's. Received yesterday. I am half way through my inventory and it has been spot on. I have confirmed all quantities under 100 units in the 3 tackle boxes and all has been accurate. I am impressed. Crating has been impressive. Everything well protected using a lot of paper and foam. No more gorilla tape.
I only have bigger pieces and skins left to inventory so I am not anticipating any problems. They have communicated very well to me including what was back ordered.
Sounds like the pipeline is getting smoothed out. Consider that Van's has produced nearly 125 wing kits, continue to produce parts to support the SLSA RV12is line (35-40 this year?) as well as RV-9, 10, 14 kits shipping plus supporting a growing flying fleet, I think they may be the second largest single engine plane manufacturer by numbers going right now. How many single engine Cessna's got built last year? Cirrus is jugging planes out with 691 in 2025. Point is to go from zero to 125 plus wing kits in essentially 4 months is frankly pretty impressive. I suspect that as other RV-15 kits come out there will continue to growing pains as the unique parts count goes up. I also suspect RV-15 kit sales will remain strong.
 
it might be my grumpy old man's opinion only, but I just can't fathom why a company such as Vans is delivering incomplete kits in this day and age.
If yes, what is the point, more work and expenses for all parties, including buyers of other models?

As an example all big stores around here have a live inventory registering all sales, either those done online or at the cashier. The result is thru the use of bar or QR coding, and IMHO Vans could very easily apply those methods, even if there is a necessity for BOs... resulting in no need for an inventory from either side to start with.

I started building my -4 end of 1987, and today we're pushing thru 2026, has the only progress achieved in this time those ready to assemble kits... really?
 
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Is this true. I had ruined some parts because of that damn stuff that was hidden. I thought i had it all and lifter the skin wondering why it wouldn’t lift out and pulled harder bending the expensive part. Then i saw the dam tape under the edge. Ticked me off severely.

Almost true, as I got to the bottom of the crate some of the skins were taped together with what appeared to be normal less aggressive duct tape. Certainly came off easier the Gorilla Tape.
 
Most importantly, Van's does seem to be applying some grace to inventory problems on the -15. I have had do to more than one follow-up discrepancy email. This weekend I realized there is one more flap-end rib that I am missing. I had some duplicates or mis-labels that confused me during initial inventory. At least so far, they have not been strict about the inventory policy.

I kinda gave up on trying to be precise about inventory when random un-listed parts started showing up. I'm just building with what I have and communicating as necessary. It will be interesting to see if this is dialed in a little more on wing kits.

Well, so much for this. We are now at '30 days is 30 days' on inventory problems. I had two part sets that were incorrect and threw me off, a flap end rib and the nuts for the counterweight tube attach. I have to buy those parts now. The nuts being wrong is particularly troubling, because you wouldn't know until you tried to thread them on. I guess now Van's can send wrong parts, and if you don't build the whole darn kit in 30 days to make sure everything fits together, it's your own problem.

They didn't even have their own inventory straight until weeks ago, but I was supposed to be ahead of them back in mid Feb. What a crock. 🤦‍♂️
 
Well, so much for this. We are now at '30 days is 30 days' on inventory problems. I had two part sets that were incorrect and threw me off, a flap end rib and the nuts for the counterweight tube attach. I have to buy those parts now. The nuts being wrong is particularly troubling, because you wouldn't know until you tried to thread them on. I guess now Van's can send wrong parts, and if you don't build the whole darn kit in 30 days to make sure everything fits together, it's your own problem.

They didn't even have their own inventory straight until weeks ago, but I was supposed to be ahead of them back in mid Feb. What a crock. 🤦‍♂️

Interesting. I wonder when the 30 days start. I picked mine up from ABF freight near my place. Also I was surprised that I did not receive any documentation in my kit other than the shipping list. Nothing said to even do an inventory let alone a time frame associated with it. Perhaps because I'm a repeat offender???
 
Interesting. I wonder when the 30 days start. I picked mine up from ABF freight near my place. Also I was surprised that I did not receive any documentation in my kit other than the shipping list. Nothing said to even do an inventory let alone a time frame associated with it. Perhaps because I'm a repeat offender???
Doubt it's that. I'm a repeat offender too. I think a lot of us in the -15 camp are.

To be transparent, I had replied that this was a rotten position for Van's to take on these kits that they have been struggling to understand inventory on themselves. I got a response that they would send the parts, but this would be an exception and the 30 day rule will stand going forward. A few nuts is a pretty low value part, but it's the principle.

Anyway, the point is to be aware that the inventory rule has gone hard on -15 kits. This was to be expected at some point, and in a world where they have their stuff together it's a fair rule. Fingers crossed that the tail kit I order tomorrow is better developed and these things don't happen.
 
My wing kit arrived 5 days ago and have not found (did not find) a packing list in the "big box", are they supposed to have one? The posted inventory general list for the wings is greatly appreciated, but no help knowing what each box contains. The spar box has not been opened, as I am stumbling through the first one.

Any guidance on where this list of shipped parts is located?

To the 30 day "rule" - - - It is only logical to assume the clock starts when the boxes are in my possession.

An iphone barcode app (generic) does read the code and yields the number and part name. Is there an app (Orca?) that will compare to the inventory list and assist builders in this task?

Unfortunately, I am less perfect in my inventory process than Vans in the packing - but still working no deeper than the SUBKIT level.
 
My wing kit arrived 5 days ago and have not found (did not find) a packing list in the "big box", are they supposed to have one? The posted inventory general list for the wings is greatly appreciated, but no help knowing what each box contains.
Pretty sure you should have had a paper copy of the inventory marked to show what was packed and what may be back-ordered. Talk to Van's.
 
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