Why its important to implement
Essential for safe, efficient repairs on diverse vehicle brands/models. Prevents trial-and-error approach. Critical for welded panels and EV/Hybrid high-voltage safety. Some OEMs require usage evidence.
Welded Panel Safety
This problem is even more serious when removing and refitting welded panels, without the directions from the OEM it is highly likely the technician could cut the panel in the wrong place, weld or rivet in the wrong places or with the wrong type or use glues and sealers that are not approved and could reduce the vehicles integrity in the case of another accident
Experience Limitations
It is impossible for a technician even with much experience to know the safest and most efficient way to remove and refit every part especially complex parts on new models like tailgates and doors without referring to the OEM repair methods, everything else is trial and error and this is a slow and costly approach
OEM Evidence Requirement
Evidence of the vehicle repair method being accessed by the technician is a requirement by some OEM's
EV/HEV Safety Criticality
This situation even more important with the introduction to more and more EV and HEV entering body shops as the voltage on these vehicles increase the risk of serious death or injury in addition the expensive damage to batteries or of he electronic parts of the vehicles
Access Requirements
For these reasons it is important that each vehicle entering the workshop should have a vehicle repair method with the job card or each technician should have access to the BMS on a terminal in their work bay
Vehicle-Specific Knowledge Requirements
There's many different brands and models of vehicles and each have specific instructions for removing refitting each part of the vehicle
Business Impact
Trial-and-error repairs increase costs, damage risk, and liability exposure. Incorrect repairs trigger expensive rectification, legal claims, and reputation damage. EV/Hybrid improper methods create catastrophic safety risks.
Profit
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked they experience longer repair times in all remove and refit areas, this costs the business revenue
Profit
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked they are at a higher risk of damaging parts and the business having to pay for them without charge out to the work provider
Profit
If there is a claim against the business because a a vehicle was repaired incorrectly through incorrect welding processes or by using methods to repair vehicles that not approved, like using heat on chassis rails the business would lose revenue if it has to pay for a third party to rectify the repair
Throughput, general, body and paint productivity
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked they experience longer repair times in all remove and refit areas, this mean lower throughputs
Customer satisfaction
If there is a claim against the business because a a vehicle was repaired incorrectly through incorrect welding processes or by using methods to repair vehicles that not approved, like using heat on chassis rails the business would lose its reputation with work providers and customers
Overall Business Impact
OEM repair methods are fundamental to profitability, efficiency, and reputation protection. Without proper methods, repair times increase significantly, reducing throughput and revenue while increasing risk of costly part damage. Incorrect repairs can trigger expensive third-party rectification, legal claims, and reputation damage that destroys relationships with customers and work providers. For EV/Hybrid vehicles, improper methods create additional safety risks and potential catastrophic consequences. This requirement is essential for OEM compliance and business sustainability in modern automotive repair
action steps
Train repair method access and placement processes. Establish usage verification systems for production managers. Regular compliance monitoring with strong enforcement warnings.
Performance Monitoring and Enforcement
Strong internal warnings if policy not followed once established
OEM Methods and Technical Requirements
If the shop uses the OEM systems directly or a BMS for the technicians to access repair methods it must establish a way for the production manager to prove they were used
Policy Implementation and Staff Training
Implement and train the process of accessing repair methods and placing them with each job card
Related tasks
Milestone:
03: Streamlining Vehicle Prep Work