Why its important to implement
Proper job number labeling ensures fast visual reference and prevents wrong parts usage. Traffic light system minimizes production manager time waste checking readiness.
Small repair bucket option
If the repair is very small a parts bucket would be suitable and should be used but a storage area for these is important.
Trolley system advantages
Using parts trolleys for each job has many benefits: 1. Ensure all parts are secure and together for each individual job (not sitting in piles in the parts room or next to the job). 2. Non-verbal process for production management controls (traffic light system for indicating jobs ready to begin production). 3. A safe place for all parts removed from the vehicle to placed and stored (stops parts ever being left on the floor, in the bay or in the vehicle).
Trolley preparation and traffic light system
Once the parts have been checked off and labelled the parts department should then load all parts onto a parts trolley that is exclusively for that job and labelled with the correct job number in preparation for the vehicles arrival and for work to begin. Once all parts have arrived, been checked and labelled and loaded on the parts trolley the parts department should use a traffic light system to indicate visually and clearly to the production manager that the vehicle is ready for production. Using this system will also minimise the need for the production manager to waste time asking if everything is ready for each job prior to production being started. It is important that the correct job number is also visible on the parts trolleys for fast visual reference and to make sure the wrong parts trolley and parts are not used for another job.
Job number labeling system
As the parts department checks off each part, they 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.
Parts verification and checking
Each estimate that is approved by work providers has an approved list of parts required to repair the vehicle. These parts should be ordered in advance of the vehicle arriving on-site. When these parts arrive, each part should be checked against the order and or estimate to make sure every item has arrived and is correct and not damaged.
Business Impact
Profit loss from lost/damaged parts, productivity issues from production delays and excessive coordination, extended key-to-key times from poor storage, increased idle time.
Profit
If parts are lost or damaged the business will have to purchase additional at its own cost
Throughput, all productivity
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 for bigger repairs. 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
Key to Key
If parts go missing or are lost or damaged due to poor storage production will be delayed causing overall key to key time to be affected
Idle Time
Vehicle sitting 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 parts are lost or damaged, requiring additional purchases at the business's own cost. Throughput and all productivity suffer when vehicles enter production areas before all parts arrive, causing production stoppages, plan changes, and blockages for larger repairs, while production managers waste time with excessive follow-ups to determine job readiness. Key to Key times are extended when parts go missing or are damaged due to poor storage, delaying production schedules. 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 prolonged key to key delivery times.
action steps
Purchase trolleys/buckets, train parts department on verification and labeling, implement traffic light process, establish delivery procedures, enforce with warnings.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Trolley Delivery System
Implement and train process where parts department deliver parts trolleys to the work bay for each job.
Traffic Light Implementation
Implement and train traffic light process for parts trolleys.
Parts Department Process
Implement and train process where the parts department 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.
Equipment Purchase
Purchase enough trolleys and parts buckets for weekly work volume.
Related tasks
Milestone:
07: Optimizing Parts Management & Storage