Why its important to implement
Parts are fragile and susceptible to transit damage. Unchecked acceptance exposes business to repair costs and delays. Late damage discovery during final fit-up causes production delays.
Fragile component vulnerability
Many head lamps, tail lamps, moulds and other parts are fragile and are easily broken or damaged in transit.
Late damage discovery consequences
If other parts are damaged and it is only discovered during the final fit up stage of the repair process, there will likely be a delay waiting for new parts affecting production and key to key times to affected.
Parts fragility and transport damage
Most of the parts delivered to a body shop are fragile and most body panels are not uniform enough to be placed in a solid box. Body panels such as hoods, doors, boot lids and tailgates can be heavy, awkward to handle by delivery staff and are highly susceptible to damage in transit.
Unchecked parts acceptance risk
If the body shop accepts these parts unchecked, they are exposed to the possibility that they will have to repair any damaged panels at their own cost and take away paid production work or pay for new parts again.
Business Impact
Profit loss from double purchasing and repair time, productivity drop from bay blockages and disrupted wet-on-wet processes, extended key-to-key times, increased idle time.
Throughput, all productivity
Vehicles blocking bays because of panel re-ordering mid-way or at the end of a job will affect productivity
Throughput, all productivity
The metal panel that was going to be a wet-on-wet process will now need to be repaired
Key to Key
If damaged parts must be repaired in-house waiting times can affect the key-to-key time
Key to Key
If damaged parts must be replaced the waiting times can affect the key-to-key time
Idle Time
Vehicle siting waiting for parts to begin or continue repairs
Customer Satisfaction
Customers lose confidence and brand happiness in the business with long 'key to key' time
Overall Business Impact
Profit is affected when the business must buy parts twice due to unreported delivery damage or spend time repairing parts instead of generating revenue. Throughput and all productivity suffer when vehicles block bays due to panel re-ordering mid-repair and when wet-on-wet processes are disrupted by damaged panels requiring repair. Key to Key times are extended whether damaged parts require in-house repair or replacement ordering, both causing delays. Idle Time increases as vehicles sit waiting for parts to begin or continue repairs. Customer Satisfaction decreases as customers lose confidence and brand happiness due to extended key to key timeframes.
Profit
If the business buys parts twice if damage is not reported immediately upon delivery or must spend time repairing parts, revenue will be affected
action steps
Train parts manager/staff on damage inspection before production, immediately reorder damaged parts, negotiate cost reductions when possible, enforce with warnings.
Parts Inspection Training
Implement and train process where the parts manager/staff checks every part for damage before the vehicle enters the production area and parts are loaded onto the parts trolleys.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Cost Negotiation
Negotiate reduction in parts cost if no other metal part available.
Immediate Reordering
Reorder any damaged parts immediately.
Related tasks
Milestone:
07: Optimizing Parts Management & Storage