Why its important to implement
Quality control through staged sign-offs prevents downstream issues. Technician accountability and manager oversight essential for efficiency.
Management oversight
The role of the production manager or Panel/paint foreman is to sign off on each stage to show that he checked and approved the work before moving to the next stage. If vehicles are allowed to be moved before this important step additional vehicle movements will be required if the vehicle must go back to the last stage again for rework or if the rework must be done by the technician at the next stage.
OEM requirements
Some OEM's will require these check sheets are recorded for each job and kept on file.
Quality control process
As each vehicle moves through the stages of repair a physical or digital sign off sheet should be completed and checked and signed off by the production manager or Panel/paint foreman. There are a variety of ways to break the stages down but commonly it is done as follows: Disassembly, Body Repair (Metal Work and Body Filler), Preparation (Primer filler application, sanding and masking for application), Paint Application and drying, De-nibbing and polishing, Reassembly, Cleaning, Final Inspection.
Staff accountability
When productive staff are required to sign off on their work completion and quality, they are taking responsibility for the output of their work and its overall quality and effect on the next stages of repair. These signed documents can be used to assist the business to see where quality issues are coming from and who is causing them so that further training can be offered.
Business Impact
Profit loss from rework and vehicle movements, productivity decline from unchecked errors, extended key-to-key times, customer dissatisfaction.
Profit
If quality issues continue the business will be lose revenue with productive time being used for excessive reworks and vehicle movements
Throughput, General, Body and Paint Productivity
If technicians are allowed to send jobs to next stages without a check being done by the production manager or Panel/paint foreman each following stage will be delayed and have additional work to perform causing lost time on each technicians planned work and affecting throughput
Key to Key
Every time a repair is done incorrectly or not completed and moves to the next stage of repair it will cost the business time as the vehicle will travel back the last stage or must be done in the next stage area causing blockages and work to stop. This will then lengthen the repair process
Customer satisfaction
If the vehicle is delayed or if there are quality issues found the perception of the business will be diminished and customers may look for alternative repairers
Overall Business Impact
Profit suffers when quality issues continue, leading to lost revenue from productive time being used for excessive reworks and additional vehicle movements. Throughput, General, Body and Paint Productivity are all affected when technicians send jobs to next stages without proper checks, causing delays and additional work that impacts planned schedules. Key to Key times are extended every time repairs are done incorrectly, requiring vehicles to travel back to previous stages or creating blockages that lengthen the entire repair process. Customer Satisfaction decreases when vehicles are delayed or quality issues are found, diminishing business perception and potentially driving customers to seek alternative repairers.
action steps
Define repair stages, set up BMS or physical sheets, implement digital/physical sign-off processes, train staff, invest in BMS.
Quality Control
Regularly check that this is being carried out for every job, strong internal warnings if policy not followed once established.
Technology Investment
If the business does not have a BMS it should invest in this software.
Training Implementation
Implement and train usage of the check sheet system used.
Physical Documentation
If on physical paper the check sheet should be placed with other documentation on the vehicle.
Digital Integration
If on a BMS the signature is digital when the technician clicks 'completed' on the task and the production manager approves the completion by moving the vehicle to the next stage.
System Setup
These stages should then be set up correctly into the BMS or on a physical sheet.
Process Development
The business should work out the stages of repair it follows or analyse new ones to gain efficiency.
Related tasks
Milestone:
04: Production Management Optimisation