Why its important to implement
Parts are valuable revenue stream requiring proper management. Dedicated space prevents damage, ensures organization, and supports efficient delivery to production teams.
Fragile component storage risks
Many head lamps, tail lamps, moulds and other parts are fragile and are easily broken or damaged when storing them.
Body panel storage challenges
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 when storing them.
Parts business revenue importance
Selling spare parts is a valuable revenue stream for most body shops, any business that handles and sells products must manage them in a way that will reduce loss and damage to the products. It is also important that the product is delivered in a way that services the customer best. The customer of the spare parts department is the production manager, body shop technicians and painters and the responsibility is to deliver the spare parts in the fastest and most efficient way so that the production plan is maintained. The only way to carry out this task is for the spare parts department to have a dedicated room or area that is large enough for them store all parts required daily and weekly in a well organised and non cluttered way. If the area is just a space at the side of the workshop or near an entrance it may become crowded with other items from the workshop, increasing the risk of damage to the parts.
Business Impact
Profit loss from damaged/lost parts, productivity affected by poor organization and delivery, extended key-to-key times from storage issues, 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 there is no dedicated area for parts management the organisation and delivery of parts to the productive teams will affect throughput and productivity
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
Vehicles 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 there is no dedicated area for parts management, affecting organization and delivery of parts to productive teams. 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
Analyze building for suitable parts area, investigate racking systems, provide manager office space, ensure trolley storage capacity, create specialized storage areas.
Specialized Storage Areas
There should be an area to safely store: Windscreens on racking, Large parts like bumper bars, hoods, boot lids, tailgates, doors, All other parts that fit in boxes.
Trolley Storage Capacity
There should be enough room for all parts trolleys that are waiting for some parts to be stored in the room, including spare trolleys for upcoming jobs.
Manager Office Space
There should be enough room for the parts manager to have his desk or office in the room.
Racking Systems
If space is limited, investigate racking systems to utilise the space as efficiently as possible.
Space Analysis
If there is no dedicated parts room or area analyse the building floor plan and find a suitable area for a parts area.
Related tasks
Milestone:
07: Optimizing Parts Management & Storage