Why its important to implement
Detailed job cards prevent technician downtime searching for information. OEM repair methods essential for safety and efficiency, especially for EV/Hybrid vehicles with high-voltage safety risks.
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
Technician Access Importance
In addition to vehicle mapping, it is important the job cards are placed on all vehicles before entering the workshop so that technicians can have access to them
EV/HEV Critical Safety
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 injury or death in addition the expensive damage to batteries or electronic parts of the vehicles
Vehicle Complexity Challenge
There are many different brands and models of vehicles, and each have specific instructions for removing refitting each part of the vehicle
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
Comprehensive Understanding
The job card should be detailed enough that when the technician reviews it, they have a very accurate understanding of what must be done to repair the vehicle
BMS Terminal Access
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
Production Time Protection
If they are not placed on the vehicle the technicians will have to walk away from their bay and look for the production manager or VDA to see where the job card is, wasting valuable production time
Detailed Job Card Requirements
Job cards should be a detailed document showing all items that must be removed and refitted, body and paint labour the parts list and sublet
OEM Evidence Requirements
Evidence of the vehicle repair method being accessed by the technician is a requirement by some OEM's
Business Impact
Prevents production time waste, reduces trial-and-error costs, minimizes part damage risk, and protects against legal liability. Essential for maintaining throughput and customer relationships.
Profit
If staff do not have the job card ready on each card before it comes into the bay, they will go looking for it and waste production time costing money the business will not get back
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 will lose revenue if it has to pay for a third party to rectify the repair
General, Body and Paint Productivity
Every minute wasted looking or waiting for job cards once the vehicle is in the work bay will have an impact on the overall production plan and additionally the body and paint plans
Key to key
Wasted productivity will lengthen the time the job is in the shop
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
Comprehensive documentation placement prevents multiple forms of revenue loss and operational inefficiency. Missing job cards create costly downtime, while lack of OEM repair methods leads to trial-and-error approaches that increase repair times, part damage risk, and potential legal liability. For EV/Hybrid vehicles, improper methods create safety risks and expensive damage. Proper documentation protects profit margins, maintains throughput, and preserves customer and work provider relationships essential for business sustainability
action steps
Train Production Manager/VDA to place job cards and repair methods on vehicles. Establish OEM method usage verification systems. Strong enforcement and regular compliance checks.
Performance Monitoring and Enforcement
Strong internal warnings if policy not followed once established
Performance Monitoring and Enforcement
Regularly check that this is being carried out for every job, strong internal warnings if policy not followed once established
OEM Methods and Verification Systems
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
Documentation and Job Card Management
Implement and train the process of accessing repair methods and placing them with each job card
Documentation and Job Card Management
Implement and train a process for the production manager or VDA to print and place job cards on all vehicles before they enter the workshop
Related tasks
Milestone:
03: Streamlining Vehicle Prep Work