Published on March 1, 2014
Understanding A New Process in Collision Repair Process
12 STEPS PRIOR TO CREATING ANY VALUE FOR YOUR COMPANY
Step 1 Qualifying Repairs / Estimate Owner signs authorization to repair Disassembly & blueprinting of vehicle Step 2 Repair Approval Step 3 Step 4 Parts ordered Received & Mirror Matched Step 5 SCHEDULE PRODUCTION
Understanding Collision Repair Process Qualifying Repairs
Step 1 : Qualifying Repairs / Estimate On drive-able vehicles, the vehicle is Qualified into 1 of 4 job classifications Express, Light, Medium or Heavy repair in our inspection area. On Express and Light repairs All damage is evaluated and entered into our computerized estimating system. This data is compiled into an repair plan that determines the cost of repair for all damage at this time. “An initial repair plan cost is helpful when deciding on whether to file an insurance claim or not.” However, Medium and Heavy repairs often there is hidden damage that cannot be seen or accounted for until after the vehicle is disassembled. Therefore the vehicle owner should be encouraged give authorization to repair and leave the vehicle for proper repair planning once the disassembly & blueprinting process, an accurate total cost of repairs can be determined. Express repairs - Parts can be pre ordered pre painted . On the schedule in date the vehicle will be put directly into the product flow line and delivered back to the vehicle owner with in hours or on the same day. Light repairs – A schedule in date for repair can be set . Parts can be pre ordered . On arrival of the schedule in date the vehicle will be put directly into the product flow line. In most cases the vehicle can be returned to the owner with in 48 hours. Qualifying Repairs / Estimate Express Pre Ordered Pre Painted Light Repair
Step 2 : Disassembly & blueprinting of vehicle After Qualifying Repairs of Medium or Heavy repair - At the vehicle dropped off our staff will fact find with the vehicle owner the damage associated with the collision claim to be repaired and any non-related damage is noted and discussed with the customer. The vehicle is then scheduled for disassembly and a disassembly date is set . “This should take place with in 48 hrs of the drop off date.” The vehicle owner is advised what date to expect a call from our staff member with a due in production date and a guarantee delivery date as well as a itemized cost of repair . During disassembly our team will expose all hidden damage. The inner structure of the vehicle is examined and measured to insure that the safety of the vehicle has not been compromised in the accident. All damaged parts are marked showing that they will either need to be replaced or repaired. The repair estimate and parts order is validated accordingly and is now a complete repair plan. Since the damage has now been fully documented, the vehicle and repair cost estimate are now ready for the insurance or customers . Disassembly blueprinting of vehicle Medium Repair Heavy Repair
Step 3 : Repair Approval Now that all damage has been identified, some insurance companies will send an appraiser to inspect the damaged vehicle and review our repair plan. There may be some negotiations regarding replacement part type, labor charges and what repair procedures are required to repair the vehicle properly. Most times our repair plan is so well validated and detailed that your insurance company is with in penny’s of our repair plan. The type of repair that will be performed may depend on the insurance company and will always include the customer final decision. Our repair plan are generally written utilizing new factory parts as pre the manufactures recommended repair procedures. occasionally insurance companies try to reduce the repair cost by only paying for parts that are either not made by the vehicle manufacture . Give a descriptive name as “aftermarket”, - “not made by the vehicle manufacture .” “LKQ” – “Used parts from salvage yards.” or “re-manufactured”- “previously damaged and repaired parts” After the negotiation process, we will notify and explain to our customer any differences between our repair plan and the insurers recommend repair procedure . We will also offer any repair options at this time. Once any repair differences are resolved, we obtain the parts can be ordered and the actual repair process can begin with in 24 hrs. All damage has been identified Insurance Appraiser inspect the damaged vehicle Parts ordered & Received repair process can begin with in 24 hrs
Step 4 : Parts ordered Received & Mirror Matched Dissembling the vehicle completely before placing the parts order, allows us to receive all necessary parts in one shipment. Our goal is to schedule JIT just in time parts delivery. Allowing for our team to have the proper amount of time to verified all parts for correctness “mirror match” and inspect any damage on used parts that may have been recommended by the insurer . In some cases we may need to be repaired or returned the damage used parts. Replacement parts are ordered electronically which improves part ordering accuracy and reduces delivery time. Depending on the vehicle make and type of parts needed, complete part orders can be received with in 24 hours. Having a complete part order on hand allows us to kit the repair prior to our technicians being dispatched the repair. Our technicians no longer have to share in the estimating of supplement and do not have to stop in the middle of a repair to wait for additional part’s. This allows for our technicians to work at an increase efficiency giving the customer ,insurer ,and our company a predictable and positive out come. Dissembling the vehicle completely Parts ordered electronically “Mirror match” Predictable & positive out come
Step 5 : Schedule Production Schedule repairs by job class opens us up to a wealth of control of scheduling and releasing work load to our team according to available resources and current production capacity. Allowing us to eliminating waste. In short, the Just-in-Time parts procurement inventory system and production scheduling ,focus is having “the right material, at the right time, at the right place, and in the exact amount” reducing excess inventory holding and handling. Decrease cycle time by 50 to 60 % or more.
Express Repairs DISASSEMBLY IS NOT NEEDED TO WRITE THE REPAIR PLAN. Express Repairs are jobs that require bolted-on parts replacement and refinishing only. 1 Express vehicle parts must be pre-ordered . 2 Express vehicle refinishing can typically be completed prior to the vehicles arrival for repairs Express vehicles can not require any panel straightening. Express vehicles can not require any structural repair at all. Express vehicles can not require the replacement of any welded on panel(s). Express vehicles can not require any sublet work. Bumper covers Mirror covers Express vehicles Express vehicles must be able to be placed directly into the Production Line without interruption. •Damage Appraiser must be confident that they have identified 100% of the damage at the point of sale. •This requires placing the vehicle on a lift to inspect under the bumper cover area and removing splash shields etc to see “hidden” damage.
Light Repairs DISASSEMBLY IS NOT NEEDED TO WRITE THE REPAIR PLAN. Light Repair Express - are jobs that require 8 hours or less tech Labor only repair and / or refinishing only. 1 Light Repair vehicle parts must be pre-ordered . 2 Light Repair vehicle typically go right the rapid repair team or paint prep. Express vehicles will have 8 hrs of tech repair straightening and or refinish panel. Express vehicles can not require any structural repair at all. Express vehicles can not require the replacement of any welded on panel(s). Express vehicles can not require any sublet work. Average labor hrs 8 – 16 + • Light repairs must be able to be placed directly into the Production Line without interruption. •Damage Appraiser must be confident that they have identified 100% of the damage at the point of sale.
Medium Repair Medium vehicles Require full Dismantling & Blue Printing procedures in order to write a complete repair plan. 1 Medium vehicles will require limited build down and or build up. 2 Medium vehicles may require a combination of floor pulling and/or repairing of structural damage . 3 Medium vehicles may require panel straightening time. 4 Medium vehicles may require one panel replacement of welded on radiator support, tie bar, baffles, apron extension, door skin, or body panel. 5 Medium vehicles may require minor suspension parts replacement such as a lower control arm, and/or strut assembles. Average labor hrs 20 - 40 6 Medium vehicles sublet repairs must not exceed alignments, glass, or indicator lights turn off . • Parts orders should take place after complete dismantling and documented repair plan is completed. • Complete overhaul of one suspension assembly or multiple suspension areas ,multiple welded on panels, frame rails, or full aprons, replacement requires reclassification to Heavy Repair.
Heavy Repair Heavy vehicles Require full Dismantling & Blue Printing procedures in order to write a complete repair plan. 1 Heavy vehicles will require Engineering builddown and/or build up. 2 Heavy vehicles may require a combination of pulling and/or repairing of structural damage. 3 Heavy vehicles may require multiple structural welded on panels or replacement of radiator support, apron extensions, complete apron less frame rail, frame rail outer sectioning only, or body panel with one quarter panel. 4 Heavy vehicles may require multiple panel straightening time. 5 Heavy vehicles may require suspension and/or frame cradle replacement. 7 Heavy vehicles may require moderate sublet work however; the vendor must be able to complete the work with-in twenty four hours maximum in order for us to meet our cycle time goal. Average labor hrs 40 – 90 + • Parts orders should take place after complete dismantling and documented repair plan is completed. • Complete frame rail, floor section, or multiple quarter panel replacement require.
Randy Ferrese Training consultant and has more than 20 years of experience in the Auto body industry. For more information contact Randy Ferrese Sr Randy@bodyshopinabox.net 609 576 4244 BodyShopinabox.net
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