Why its important to implement
Detailed disassembly prevents missed revenue from undiscovered damage. VDAs must communicate approvals immediately to avoid production delays and maximize billable work capture.
Detailed disassembly process importance
Detailed disassembly is one of the most important processes for the body shop to implement and follow. Fundamentally, removing parts from vehicles is quite easy and is often seen by body technicians as something to complete quickly but without much attention to detail. This attitude in the disassembly area will cost the business time and money as the vehicle goes through the repair process. After the body technician has reviewed the job card against the repair and if everything is included on the job card the parts on damaged area should be disassembled carefully and thoroughly. As each part is removed if it is not down for replacement it should be checked carefully for damage that would be unseen prior to removal. If damage is found it should be documented on the additional sheet with the job card or directly into the BMS, VDA's should regularly check with the technicians for any additional items found during the repair process. It is also important to check areas that are down for repair and see if they were included in the hours given for labour to repair. This process will assist with minimising down time at the end of the repair process because missing parts will be ordered well in advance and missed labour will be added and approved for repair. VDA's should inform the production manager and the body technicians when approval is received for additional work and parts to minimise time wasted with vehicle on hold in production.
Business Impact
Profit loss from missed parts/labour revenue, productivity waste from approval delays, extended key-to-key times, workshop blockages, reduced customer satisfaction.
Profit
If disassembly is not done in a detailed way the repair the business will miss out on revenue for parts that could be needed
Profit
If disassembly is not done in a detailed way the repair the business will miss out on revenue for additional labour for repairs that could be needed
Throughput, general, body and paint productivity
If parts that are damaged are not picked up and added to the job the work shop will be blocked up by jobs that are waiting for parts
Throughput, general, body and paint productivity
Wasted productivity time due to waiting for confirmation of approval if it has already been received but no one is informed
Key to key
Wasted productivity time due to waiting for parts not reported as damaged immediately will lengthen the time the job is in the shop
Key to key
Wasted productivity time due to waiting for confirmation of approval if it has already been received but no one is informed
Customer satisfaction
Long key to key times and delays in repair will cause customer dissatisfaction
Overall Business Impact
Profit is affected when disassembly is not done thoroughly, causing the business to miss revenue for both parts and additional labour that could be needed. Throughput, general, body and paint productivity suffer when parts that are damaged are not identified and added to jobs, causing workshop blockages from jobs waiting for parts, and when productivity time is wasted waiting for approval confirmations that have already been received but not communicated. Key to key times are extended when parts not reported as damaged immediately cause delays and when productivity time is wasted waiting for approval confirmations. Customer satisfaction decreases due to long key to key times and repair delays.
action steps
Train detailed stripping process, implement BMS/additional sheets, establish VDA monitoring, create immediate approval communication protocols, enforce compliance.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Communication Protocols
VDA's should inform the production manager and the body technician immediately when approval is received.
Regular Monitoring
VDA's should regularly check if there is items added by the technicians.
Documentation Systems
Ensure there is a blank additional sheet in place or a BMS system that allows direct additional adding for the technicians.
Detailed Disassembly Training
Implement and train detailed stripping process into the body shop.
Related tasks
Milestone:
04: Production Management Optimisation