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MILESTONE 15

Streamlining Heavy Damage Repairs

Standardized processes for heavy damage repairs improve efficiency, reduce costs, and enhance repair quality. By optimizing welding techniques, implementing advanced measurement systems, and streamlining workflows, body shops can ensure compliance with OEM standards, reduce repair times, and improve customer satisfaction. This milestone focuses on refining heavy damage repair procedures to maximize precision and operational efficiency.

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Impact of Standardized Heavy Damage Repair Processes

A structured repair process ensures that body shops reduce material waste, improve repair accuracy, and increase efficiency. By following OEM-approved repair methods, businesses can minimize errors, maintain compliance, and enhance overall service quality.

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Cost Savings

Efficient processes reduce wasted materials and labour hours, lowering operational expenses.

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Enhanced Repair Quality

Standardized repair methods ensure high-quality, manufacturer-approved repairs.

Improved Customer Satisfaction

Faster, high-quality repairs enhance trust and customer retention.

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Increased Efficiency

Eliminating unnecessary steps reduces repair times and improves workflow.

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Better Compliance & Safety

Adhering to OEM methods and industry regulations minimizes risks and ensures vehicle safety.

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Advanced Welding Techniques & Equipment

Train technicians on automatic inverter spot welders and pulse synergic inverter MIG welders, ensuring proper use and maintenance.

What we will focus on during the development PHASE 

Optimizing heavy damage repairs requires advanced tools, structured workflows, and specialized training. These key areas ensure higher repair accuracy, efficiency, and compliance.

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Client’s milestones & action steps to focus on  

The process begins with a clear summary of well-established good practices, followed by an evaluation of areas needing improvement. We analyze current challenges, explaining their negative effects on business performance. From there, we develop a structured solution with clear action steps.

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STEP 01

Assess Current Processes

Identify and document the GOOD processes that are effectively in place, followed by an evaluation of the BAD / NOT IMPLEMENTED processes that require improvement.

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STEP 02

Analyze Challenges & Impact

Examine the problems within the current setup, explain why they are important, and highlight the negative effects on business performance in areas such as efficiency, costs, and customer satisfaction.

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STEP 03

Implement Solutions & Action Steps

Develop a structured plan that includes:

  • Explanation of the solution and its positive impact on business operations.

  • Breakdown of action steps, with responsibilities assigned to specific owners.

  • Set due dates for accountability and timely execution.

Tracking Progress & Driving Continuous Improvement

After the completion of each milestone and associated tasks it's important to review  progress, address identified challenges, and reinforce the importance of the process improvements.

 

Continuous assessment of completed and uncompleted action steps, identifying any roadblocks or issues that may be hindering progress should be conducted. If necessary, the reasons behind these challenges should be revisited to ensure clarity and alignment to drive continuous improvement.

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Accountability Check

A review of assigned responsibilities and due dates ensures tasks remain on track.

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Problem Analysis

Any persistent issues in current processes are re-examined, highlighting their negative effects on business performance.

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Solution Reinforcement

The proposed solution and its benefits across key business areas are reiterated.

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Action Plan Updates

Steps are refined as needed, with clear assignments, owners, and deadlines to maintain momentum.

Related Tasks to Milestone 15

View related tasks linked to this milestone to track progress, identify dependencies, and ensure smooth execution of your development plan.

Identify if ADAS calibrations are carried out in-house?

Identify if all mechanical work is completed in-house?

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 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 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 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 vehicle structural body measurements are checked after the repair and recorded in the BMS job file

Ensure removed parts are listed on the job card before delivering the vehicle to the paint shop

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