Why its important to implement
Body shop dust and debris contaminate open cooling system pipes during repair. Welding sparks and cleaning debris cause expensive system damage requiring complete replacement.
System contamination prevention
When there is the need to strip down air-conditioning condensers and piping and or radiators and piping it is important that the pipes that remain open are covered and protected from dust and debris. The body shop and preparation areas can be quite dusty and if pipes are left open this dust and dirt can float into any open pipes, this dust will then remain in the system when the condenser and or radiator is refitted and recharged. Also, during the body repair process, large pieces of debris when removing sealers and glues with certain cleaning tools could land in the open pipes. Additionally, sparks from welding and grinding can also cause major problems to moving parts with the cooling or air-conditioning systems along with the possibility of corrosion problems in aluminium air-conditioning pipes.
Business Impact
Profit loss from contaminated system repairs, productivity waste removing/repairing damaged components, extended key-to-key times, customer dissatisfaction from delays.
Profit
If cooling systems and air-conditioning compressors or any parts of the system are damaged as a result of dust and debris entering the system the business will have to pay for the new parts and labour to repair
Productivity
Wasted productivity time the technicians has to remove and repair cooling systems and air-conditioning compressors or any parts of the system that are affected
Key to key
Wasted productivity time the technicians has to remove and repair cooling systems and air-conditioning compressors or any parts of the system that are affected
Customer satisfaction
Long key to key times and delays in repair will cause customer dissatisfaction
Overall Business Impact
Profit is affected when cooling systems and air-conditioning components are damaged due to dust and debris contamination, requiring the business to pay for new parts and labour to repair the damage. Productivity suffers when technicians must spend time removing and repairing affected cooling systems and air-conditioning compressors. Key to key times are extended due to the additional repair work required for contaminated systems. Customer satisfaction decreases as a result of long key to key times and repair delays.
action steps
Train technicians to seal all open piping, establish Production Manager oversight and enforcement, implement strong policy compliance measures.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Management Oversight
Production Manager should check and enforce this process.
System Protection Training
Implement process and train technicians to seal off all open piping.
Related tasks
Milestone:
12: Vehicle Stripping & Identification