16: Implement Electric & Hybrid Vehicle Safety Protocols
17: Establish Employee Training & Development Plan
18: Optimizing Paint Matching & Mixing
19: Optimizing Paint & Drying Processes
20: Preparation Bay Process and Product Use
21: Optimizing De-nib & Polishing Process
22: Corporate Sustainability
23: Efficient Sales & Marketing Initiatives
24: Resolving Lighting Issues
25: Resolving Electrical Issues
26: Resolving Air Supply Issues
27: Optimizing Vehicle Lift Implementation
28: Optimizing Structural Body Alignment Equipment
29: Implementing Fume Extraction Equipment
30: Implementing Dust Extraction Equipment
31: Implementing Mist Extraction Equipment
32: Optimizing Work Bay Furniture
33: Optimizing Technician Hand Tools
34: Work Bay Cleaning Items & Protocols
35: Enhancing Masking Equipment Efficiency
36: Safety & General Signage
37: Clean & Orderly Work Environment
38: Optimizing Panel Stand Usage
Ensure mixing machines are run at least twice per day
Make sure the paint colour is matched and prepared before painting.
Initiate a ratio scan and apply it correctly during the colour-matching process.
Ensure colour chips are used.
In each case utilise colours that are checked with a colour lamp.
All paint materials need to be mixed using a software system.
Ensure paint scales and software systems are used for all jobs and job numbers are recorded.
Solid and metallic colours need to be sprayed out if the Spectro is not showing a good score.
A 2K clear coat is used on colour spray out cards.
Spray outs need to be placed in a spray out card cabinet.
Make certain a colour library is used and updated for all jobs.
All spray out cards need to be marked with a colour code, its formulations, and dates.
Make sure the colour match is checked, recorded and approved by the team leader before the repair is painted.
The Parts department needs to deliver the parts trolley with all new parts loaded
Ensure seat, floor, steering wheel and gear knob protectors are being used on every vehicle
Wheel dollies should be used for all non-driveable Electric Vehicles
Electric and Hybrid Vehicles electrical systems need to be disconnected and discharged
Ensure all vehicles are ADAS and electrical fault checked before vehicles are dismantled
Panel technicians should review the job card before beginning work on the vehicle
Use repair methods when stripping vehicles including EV/HEV electrical systems
Ensure seat belt tensioners have been checked
As parts are removed from vehicles - check for damage and document on job cards
Additional damaged parts missing on job card need damage assessor to request client approval
Idenify average repair cost
Quantify repair orders per week
Report Total Revenue last 5 fiscal years
Report Revenue per Work Provider last financial year
Identify Available working hours per technician
Quantify Average Hourly Labour Rate - Panel Repair
Quantify Average Hourly Labour Rate - Paint Work
Quantify Total parts sales last fiscal year
Approximate Annual Sales Revenue per Year
Estimate Annual sales turnover of paint shop
Calculate actual shop hourly rate
Set Budget for each financial year
Undertake Job costing estimation
Review Repair costs and budget monthly
Ensure P&L statement is reviewed monthly
Review Staff ratio - admin/productive
Review Staff ratio - panel beaters/painters
Identify Business Estimating systems usage
Identify if the Estimating systems are linked to insurance rates
Identify Body Shop Management System usage
Review business accounting system
Check how the business uses Vehicle Manufacturer Repair Methods
Ensure soft copies of MSDS available for all chemical products?
Check if the Estimating System, BMS, Paint System and DMS integratration
Ensure agreement terms have been formalized with all suppliers?
Identify if ADAS calibrations are carried out in-house?
Identify if all mechanical work is completed in-house?
Understand the importance of a dedicated Estimator and VDA
Understand the importance of having a dedicated Production Manager
Understand the importance of having a dedicated Parts Manager
Ensure separate bays for different work types
Facility Health and Safety questions?
Parking and exterior questions?
Reception and Office questions?
Estimating Bay questions?
Parts Storage and Handling questions?
Body Shop - General Workshop Area Questions?
Mechanical Repair Bay Questions?
Remove and Refit Bay Questions?
Light Body Repair Bay Questions?
Heavy Body Repair Bay Questions?
Aluminium Repair Bay Questions?
Preparation Bay Questions?
Masking Bay Questions?
Mixing Room Questions?
Spray Booth Questions?
Polishing Bays Questions?
Compressor Room Questions?
Wash Bay and Detailing Questions?
A safety meeting should be held each month?
Implement an incident report book
Ensure there is fire extinguisher signage above them
Ensure all fire extinguishers and hoses tagged and within compliance date
Ensure all staff aware of emergency evacuation protocols and meeting points
Implement safety signs in place throughout the office and workshop
Ensure safety clothing and shoes used
Protective welding and grinding shields need to be used
Make certain vehicles internally cleaned to remove viruses using certified products and equipment
Ensure all vehicles keys are cleaned chemically or using a UVC enclosed sterilising box
Implement hand sterilisation stations throughout the workshop
The vehicle damage assessor (VDA) uses a camera for vehicle damage assessments
Make sure the vehicle damage assessor (VDA) has access to all work provider rates, times and allowances
Ensure vehicle damage assessors (VDA's) aware of the ACTUAL shop rate required
The vehicle damage assessor (VDA) checks for correct paint grouping
The vehicle damage assessor (VDA) checks for previous painting on the damaged area
The vehicle damage assessor (VDA) needs the ability to check for special colour formulations
Vehicle damage assessor (VDA) enters all required information fields into the vehicle damage / estimating system
Vehicle damage assessor (VDA) checks all electric and hybrid vehicles for any safety issues prior to beginning the vehicle damage estimate for minor accidents
Ensure all electric and hybrid vehicles been discharged prior to damage estimate being carried out for heavy body damage
Vehicle damage assessor (VDA) makes sure all vehicles are cleaned before carrying out the vehicle damage estimate
Vehicle damage assessor (VDA) looks for upselling opportunities
Vehicle damage assessor (VDA) must have access to Vehicle Repair Methods for all repairs
Ensure all essential documents are assembled into a job file or BMS
Vehicle damage estimates are reviewed and checked before submitting to work provider
Include a blank supplementary sheet with the job sheet
Vehicle damage assessor confirms all vehicle damage estimates are approved by the work provider before work begins
Vehicle damage assessor checks for additional damage supplementary on each job after disassembly stage
Vehicle damage assessor submits the additional damage supplementary to the work provider for approval
Vehicle damage assessor confirms approval for all additional damage supplementary before work is carried out and is the BMS updated
Parts ordered after the approval from the work supplier and confirmed in writing?
Ensure all parts ordered electronically
Check suppliers confirm receipt of the order and the availability of the parts
Ensure parts are ordered in a timely manner and delivered prior to the customer dropping off the vehicle for repair
Ensure someone is responsible for accepting all parts coming in and checking all invoices for price increases
Return parts (credits) should be sent back to supplier before the invoice is completed
Ensure a credit note sent to the accounts department immediately upon receipt
All visitors acknowledged when they enter the office even if the reception staff are busy
Visitors are required to sign in before entering the workshop
Customers should be offered refreshments and shown the way to the waiting area
Ensure customer is informed of Wi-Fi availability and password
Ensure all phone calls answered within 4 rings
Customer emails are attended to within 4 hours
Ensure customers are contacted at least 24 hours before the appointment to confirm vehicle drop off
At vehicle drop off the customer is given a repair completion date - they will receive - status update calls - dates updated in the BMS
Serivices - 24 hours emergency towing available
Ensure customers are made aware of any insurance gap and payment method at the time of dropping vehicle off
Explain alternative transport options for customers and display?(Bus, train, taxi, driver)
Services - Loan cars available for customers
Ensure loan cars have appropriate legal agreements in place
Ensure electronic or hardcopy "Pre-Inspection Sheets" noting any old damage completed
Customer vehicles are checked for personal valuable items before the customers leave the premises
Ensure customer drop off form completed and signed by the customer when vehicles are dropped off
The estimator carries out vehicle mapping before the vehicle enters the workshop
Visible windscreen sticker applied to alert technicians that the vehicle is an Electric or Hybrid Vehicle
BMS used to remind staff fo ensure customer follow up call made and are time-stamped along with simple notes
Ensure a file is created either in the BMS or on a hardcopy with the relevant information
Ensure job cards are printed and prepared for the technicians and placed on the vehicles
Ensure Vehicle Manufacturer repair methods placed with the vehicle job card. If the vehicle Electric or Hybrid the relevant instructions are highlighted to the technicians
A clear vehicle scheduling system is in place showing all bookings - Are vehicles scheduled through the workshop prior to drop off
Vehicles are scheduled to be dropped off and delivered evenly throughout the week
Ensure ob descriptions are in place for all roles in the business
Ensure all relevant technician trade certificates and licenses up to date and recorded
A formal induction process is in place for all new staff
An up to date organisation chart is required
Ensure all employees receive formal periodic performance reviews with good two-way communication
Select a pay incentive scheme
Ensure production staff presentable and dressed in company uniforms
Implement a succession plan for leadership roles
Production Manager has a production meeting every morning with the Parts Manager, Body / Paint Foremen and customer relations manager
Ensure all required parts onsite before work begins on vehicle
Ensure the paint technician checks the colour code, carries out a Spectro check and makes the colour before the vehicle enters the workshop
Production manager makes sure all vehicles are washed before entering the workshop
Production Manager ensures that all car protection is fitted on every vehicle. (Seat, steering wheel, gear selector, handbrake and floor covers)
Ensure vehicles are checked for "mapping" to indicate actual repairs before entering workshop
Production Manager makes sure a detailed job card; repair method and all relevant documents are with the vehicle before work has started
Production Manager ensures staff are reminded of Electric and Hybrid vehicles pre-repair requirements prior to starting work
Ensure staff aware of job priorities
Production manager does a production walk through in the Body and Paint Shops two times a day
Production Manager checks with Panel Staff for supplementary parts and labour
Ensure supplementary parts and labour authorised by work provider before work starts
Ensure Third party supplier tasks are booked to fit job schedule and recorded in BMS
Ensure Third party sublet companies certified and produce official documentation
Wheel alignment is carried out with every ADAS calibration
Production Manager checks wheel and chassis alignment data filed in BMS
Production Manager checks each repair stage and signs off before next stage
Production Manager regularly checks and updates vehicle repair schedules
Production targets and performance displayed and shared with staff
Production targets and efficiencies measured and reviewed daily/weekly
Metal panels and fragile parts unpacked and checked for damage when received
Job cards checked to ensure all parts received according to estimate before booking vehicle for repair
Parts labelled and placed onto dedicated parts trolley
Parts trolleys labelled with correct job number
Traffic light system used to indicate parts received and repair ready to begin
Parts are stored in dedicated parts room/area
Sufficient parts trolleys/buckets available for weekly job capacity
Technicians receive confirmation that supplementary parts or repairs have been approved
Open A/C and radiator system pipes sealed to prevent dirt and debris entering
Lubricants and A/C gas captured, handled and stored per environmental policy
Fuel tanks/fuel stored in Dangerous Goods area when removed
Small parts (nuts, bolts, clips) placed in bags/cardboard in removal order
Removed parts need to be stored outside vehicle, not on seats or in luggage compartment
Ensure larger parts (tailgate, hood) stored in designated labeled area if too large for trolley
Third party tasks listed on job sheet and/or written on vehicle windscreen
Old panels need to be stripped completely of clips/items and discarded
Parts trolleys moved to repair bay with vehicles
Ensure the bays are cleaned and any rubbish at the completion of each repair removed to relevant bins
Ensure seat, floor, steering wheel and gear knob protectors being used on every vehicle
Ensure technicians use safety equipment. Eye, hearing, feet, clothes and hand protection
Panel technicians need to review the job card before beginning work on the vehicle
Ensure vehicle protection is being used to reduce additional damage from cutting, welding and grinding. Welding blankets, external panel protection
Ensure vehicles electrical systems are being surge protected if any welding, dent pulling or shrinking equipment is being used
Ensure the technicians follow the sanding process chart located in each bay for sanding repair areas
Ensure nearby undamaged panels protected when sanding
All repairs kept as small as possible
Ensure the multi-pulling dent system being used to reduce time and improve repair quality (Bridge Puller)
Make sure damaged panels repaired properly to reduce the thickness of plastic fillers
Need for new parts trial-fitted before going to the paint shop
Ensure door locks and seals trial fitted as part of the repair process
Ensure all new and repaired parts needing paint work are delivered to the paint shop with the vehicle
Ensure all removed parts listed on the job card are removed before delivering the vehicle to the paint shop
All repairs signed off before moving to next stage
Ensure the aluminium bay doors or curtains closed prior to beginning any work
Only pneumatic tools used on Aluminium repairs
Ensure all repairs completed using tools exclusively dedicated to aluminium repairs
Technicians should follow the sanding process chart in each bay for vehicle sanding and used exclusively for aluminium repairs
Ensure the parts trolley delivered back to the dedicated parts area
The bays are cleaned and any rubbish at the completion of each repair removed to relevant bins
Seat, floor, steering wheel and gear knob protectors need to be used on every vehicle
Ensure technicians use safety equipment. Eye, hearing, feet, clothes and hand protection
Ensure panel technicians review the job card before beginning work on the vehicle.
Ensure technicians receive and follow the Vehicle Manufacturer Repair Methods related to the repair section of the vehicle.
Ensure the vehicle's electrical system is protected against electrical surges if any welding, dent pulling or shrinking equipment is used
Ensure the electrical system is disconnected for Electric and Hybrid Vehicles
Ensure the vehicle body and ADAS mounting measurements are checked as per Vehicle Manufacturer requirements prior to carrying out work and saved in the BMS job file
Ensure the vehicles mounted onto the pulling system safely and in the proper way without causing additional damage
Make sure new parts are trial fitted during the pulling process where possible
Ensure safety wire used on the pulling arm
All undamaged parts need to be protected prior to operations
Ensure cuts and panel joins are located according to manufacturer methods
High speed air hacksaws should be used for cutting AHSS panels
Ensure low speed, high torque drills used for AHSS panels
Ensure new parts are trial fitted before and after welding
Coating removal required from both sides before welding
Ensure cleaning discs are used to reduce galvanic coating removal
Ensure correct welding adhesives used where required
Weld through primer should be applied on all bare metal surfaces prior to welding
Ensure door locks and seals trial fitted as part of the repair process
Ensure Vehicle Manufacturer repair methods closely followed for welding and riveting
Ensure spot welder settings are checked and test welds carried out before welding
Ensure welding gloves are used
Ensure welding helmets used
Ensure welds are carried out to reduce heat, Heat monitoring tools used
Ensure grinding practices are used to avoid weakening parent metal
Ensure foam dams refitted/replaced with approved products when necessary
Use Anti-Flutter product (not Urethane)
Ensure all sound pads replaced on new and repaired panels
Ensure the MiG welder settings are checked and a test weld is carried out before welding the job
Ensure that the technicians follow the sanding process chart located in each bay for sanding repair areas
Ensure the multi-pulling dent system is being used to reduce time and improve repair quality (Bridge Puller)
Ensure all new and repaired parts needing paint work are delivered to the paint shop with the vehicle
Ensure that damaged panels are repaired properly to reduce the thickness of plastic fillers
Vehicle structural body measurements need to be checked after the repair and recorded in the BMS job file
Ensure vehicle structural body measurements are checked after the repair and recorded in the BMS job file
All repairs signed off before moving to next stage
Ensure removed parts are listed on the job card before delivering the vehicle to the paint shop
Ensure all aluminium repairs are carried out in the aluminium bay
Ensure the aluminium bay doors or curtains closed prior to beginning any work
Ensure only pneumatic tools used on Aluminium repairs
Ensure all aluminium repairs are carried out in the aluminium bay
Ensure all repairs completed using tools exclusively dedicated to aluminium repairs
A clean down process needs to be completed prior to beginning work on aluminium jobs
Ensure all welded panels are stripped of clips and brackets and then the old parts sent to recycling
Ensure the parts trolley is delivered back to the dedicated parts area
Ensure the bays are cleaned of any rubbish at the completion of each repair and removed to relevant bins
Ensure seat, floor, steering wheel and gear knob protectors are being used on every vehicle
Ensure a wax and grease remover is used prior to applying body filler
Ensure technicians use dust extraction when sanding filler
Ensure the technicians are following the sanding process chart located in each bay for sanding repair areas
All areas where body filler is used are checked for pinholes and filled before going to paint shop
All new and repaired parts needing paint work need to be delivered to the paint shop with the vehicle
Ensure repairs signed off before moving to next stage
Ensure seat, floor, steering wheel and gear knob protectors being used on every vehicle
Ensure painters check the job card to confirm what parts require paint work
Ensure the painters are using a mechanical / dustless sanding system for preparation
Ensure the technicians following the sanding process chart located in each bay for sanding repair areas
Ensure masking for Primer Filler are done efficiently to reduce overspray
Ensure seam sealers are applied per Vehicle Manufacturer Repair Method
Ensure primer filler areas are kept to minimum size
Ensure vehicles individually are primed in continual process (no batch)
Make sure the technician is following primer application process chart
Ensure Primer Filler areas are degreased immediately prior to application
Painters should use Transfer efficient or HVLP spray guns
Ensure correct flash off times are used per TDS sheet
Primer filler should be applied in prep area with extraction
Primer can be applied by lower skilled technicians
UV primer used in most repair applications
Ensure a Wet-on-Wet System is used on new panels
Utilise the correct flash off times according to product TDS sheets
Ensure Infra-red curing equipment is available and being used on most jobs
Ensure the infra-red unit is programmed as per manufacturer direction
Technicians need to be following the TDS for infra-red drying processes
Make sure UV Drying equipment available
Ensure the UV Equipment suitable for large and small repair areas
Make sure technicians are following the TDS for UV drying processes
Ensure technicians are following the sanding process chart located in each bay
Make sure only dry sanding being done using dry sanding equipment
Use a guide coat in-between sanding grits
All rub through areas are recoated with correct products
Ensure all dust and dirt removed from repair area before masking bay
Ensure repairs are signed off before moving to next stage
Seat, floor, steering wheel and gear knob protectors used on every vehicle
Ensure the technician is following masking process chart for vehicle masking using correct products
Make sure all vehicles are masked for top coating in workshop/masking bay (not booth)
Ensure all painters using back masking techniques and products
When windscreens stay on vehicle, they need to be taped with appropriate back masking
Ensure a colour spray out card is placed near the paint area for painting and loading into the colour library
Utilise door aperture foam and fine line tape in the masking process
All waste needs to be removed from the Spray Booth before the next vehicle enters the work bay
Ensure the technician is following the Topcoat Application process chart in the Spray Booth and using the correct products
The complete product range needs to be used without the introduction of generic lines (e.g. Primers and clears)
Ensure plastic film is cut and placed on or with the vehicle before moving into Spray Booth
Make sure airline hoses are cleaned down before spraying in the booth
Ensure all jobs tack ragged before base coat is applied
Painters use transfer efficient spray guns to apply topcoats
Ensure the air pressure checked and the appropriate pressure used for the spray gun
Use grey shade concept where required
Implement correct flash off times and observe according to the product TDS
Spray Guns are cleaned immediately after spraying
Ensure the Vehicle Manufacturer Repair method checked for every job for the maximum baking temperature limits in relation to Electric, Hybrid Vehicles, fibre optics and sensors
The correct temperature and drying time are used for the product being applied as per the product TDS
Ensure Infra-Red drying used
Ensure vehicles are removed from the Spray Booth immediately after the baking cycle is complete
The spray out card needs to be removed and vehicle colour code, job number recorded and placed in colour library
Ensure the next vehicle masked and waiting to enter the Spray Booth before the drying cycle is complete
Non-essential items need to be removed from the spray booth when baking (Thinners, aerosols etc.)
Ensure the quality check has been carried out for colour match, mottle and peel before de-nibbing and polishing
Ensure the car left partially masked for de-nibbing and polishing
Ensure the technician is following denibbing and polishing process chart and using correct products
Make sure the de-nib area kept to a minimum
The vehicle is completely de-masked before leaving polishing bay
Painted parts are checked for denibbing and polishing requirements
Ensure repairs are signed off before moving to next stage
Quality check is carried out for colour match, mottle and peel before de-nibbing and polishing
Cutting pads need to be washed daily
The Parts Department delivers parts trolley with all new parts loaded
Seat, floor, steering wheel and gear knob protectors used on every vehicle
Ensure technician is following reassembly process chart and using correct products
Make sure bolts, screws and clips grouped to reduce fit up time
Ensure all sound pads replaced on new and repaired panels
Air conditioning fittings need to be fitted with new O-Rings for reassembly
Ensure cavity wax and stone guard applied where required
The security, pin codes, ADAS, Air bags are checked and calibrated per manufacturer methods
Make sure all relevant liquids been checked (radiator, brake, windscreen washer)
Ensure a road test carried out when required
Ensure repairs are signed off with all tasks including third party sublets completed before next stage
Bays are cleaned and rubbish removed at completion of each repair
The Parts Trolley is cleared of parts, vehicle info and rubbish, then returned
Ensure all vehicles detailed inside and out
Technician will be following vehicle cleaning process chart and using correct products
Make sure brush touching iscompleted where required
Ensure detailer completing check sheet for each job and signing off
Vehicles are quality checked and estimate tasks completed before customer contact
Make sure the work carried out is xplained to the customer
Ensure a customer complaint resolved immediately or within reasonable timeframe
Ensure there is acustomer complaint record and improvement process in place
Ensure the customer is given a vehicle hand over pack when the vehicle is handed over
Ensure all insurance gap payments paid in full and/or any private work with invoice and release forms signed at vehicle handover
When a loan car is supplied, ensure the vehicle is checked for damage and return paperwork completed
On vehicle departure ensure the BMS job card completed so that the correct time stamp is recorded
Implement sending a customer follow up email after each repair
Ensure all final invoices reviewed before submitting
All invoices need to be submitted within 7 days of completion of repair
Ensure administration staff process parts credits in a timely manner
Ensure there s a customer complaint record and it is analysed for improvements
Ensure all job files are completed and archived in the BMS or in hardcopy filing system
