Why its important to implement
Starting work without complete parts creates dead bays when vehicles become immobile. Vehicles can't return outside after part removal, causing shop blockages and workflow disruptions.
Dead Bay Prevention
If work is started on vehicles before all the parts have arrived, then there are delays of ordered parts that need to be trial fitted the work bay that the vehicle is in will become a dead bay especially if the vehicle has mechanical parts removed and it's no longer be mobile
Weather Protection Issues
Additionally, the vehicle may not be able to go back outside in the weather as it may have had parts removed that mean the car can longer be parked outside in the weather causing a blockage in the shop
Business Impact
Prevents bay blockages, maximizes sold labor potential, reduces idle time and key-to-key cycles. Maintains smooth production flow essential for profitability and customer satisfaction.
Key to Key
Vehicle will be dropped off by the customer prematurely and then sit onsite
Key to Key
Production team delayed in beginning or continuing work on vehicles onsite
Idle Time
Vehicle siting waiting for parts to begin or to continue with repairs
Productivity
Vehicles blocking bays will stop maximisation of potential sold labour and affect the flow of the entire shop
Body Shop Productivity
Vehicles blocking bays will stop maximisation of potential sold labour and affect the flow of the entire shop
Customer Satisfaction
Customers lose confidence and brand happiness in the business with long 'key to key' time
Overall Business Impact
Parts availability verification prevents costly bay blockages and workflow disruptions. Vehicles without complete parts create dead bays, extend key-to-key times, and reduce overall shop productivity. This systematic approach maximizes potential sold labor hours, improves customer satisfaction through reliable delivery times, and maintains smooth production flow essential for profitability and operational efficiency
action steps
Production Manager blocks vehicle entry until parts loaded on trolleys. Parts Manager uses stop-light system with visible job numbers. Parts approval required in daily meetings.
Performance Monitoring and Enforcement
Strong internal warnings if policy not followed once established
Parts Management and Visual Systems
This will be part of the parts manager role within the daily production meeting, so no job is even dropped off until he has agreed to it
Parts Management and Visual Systems
The Parts Manager should use a stop light system with trolleys with clear job numbers visible so that the Production Manager can clearly see that the job proceed and be repaired
Parts Management and Visual Systems
Production Manager should not allow any vehicle into the production area until all parts have arrived and loaded onto the parts trolley
Related tasks
Milestone:
04: Production Management Optimisation