Why its important to implement
Parts should be organized on dedicated trolleys with clear job identification labels. This prevents mix-ups, provides visual management through traffic light systems, and ensures secure storage for removed parts, streamlining the entire repair process.
Parts Labeling
As the parts manager checks off each part, he should apply a parts label or sticker to each part with the job number to make sure it is very clear to which job the parts belong. This will stop unnecessary mix ups with parts and cause a loss of time looking for them. The Parts manager should then load the BMS /Estimating system with details of parts that have arrived.
Visual Management
The parts manager should use a traffic light system to clearly show the production manager when a vehicle is ready for production.
Parts Organization
Once parts are checked and labeled, they should be loaded onto a trolley specifically for that job with the correct job number.
Parts Trolley Benefits
Using parts trolleys for each job provides multiple advantages: 1) Parts Security - ensures all parts are secure and together (not in scattered piles), 2) Visual Management - creates non-verbal production control through traffic light systems indicating job readiness, and 3) Part Storage - provides a safe place for removed vehicle parts, preventing parts from being left on floors or in vehicles.
Efficiency Benefits
This system minimizes time spent asking if jobs are ready. The job number must be visible on trolleys for reference and to prevent mix-ups.
Delivery Process
Once loaded and all parts on the trolley it should be delivered to the body repair bay ready for the technician to begin working on the vehicle.
Small Repair Handling
If the repair is very small the parts bucket would be suitable and should be used but a storage area for these is important.
Business Impact
Lost or damaged parts require replacement at shop cost. Production stops when parts are missing, causing workflow blockages. Technicians waste time searching for parts, extending job length. Vehicles sitting idle waiting for parts delay completion and reduce customer satisfaction.
Productivity Impact
If vehicles are allowed to enter the production area before all parts have arrived, if these parts are delayed then production will stop causing change in production plan and blockages in the shop. If the process is not in place the production manager will have a lot more follow up or check ups with the parts manager to do to know what jobs are ready before bringing them into the production area. If body technicians waste time looking for parts or walking back and forth from the parts area to pick up parts, the job will take longer.
Key-to-Key Impact
If body technicians waste time looking for parts or walking back and forth from the parts area to pick up parts, the job will take longer.
Idle Time Impact
Vehicle sitting waiting for parts to begin or continue repairs.
Customer Satisfaction Impact
Customers lose confidence and brand happiness in the business with long 'key to key' time.
Profit Impact
If parts are lost or damaged the business will have to purchase additional at its own cost.
action steps
Purchase sufficient trolleys and parts buckets for three weeks' volume. Train parts manager to verify, label, and organize parts on job-specific trolleys. Implement traffic light system for production readiness. Establish delivery process to work bays. Enforce consistent policy compliance.
Equipment Investment
Purchase enough trolleys and parts buckets for three weeks work volume.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Delivery Protocol
Implement and train process where parts department deliver parts trolleys to the work bay for each job.
Traffic Light System
Implement and train traffic light process for parts trolleys.
Parts Process Implementation
Implement and train process where the parts manager checks every part has arrived according to the estimate before the vehicle is booked in for repair, labels each part and places them onto a trolley exclusively for that job.
Related tasks
Milestone:
07: Optimizing Parts Management & Storage