Why its important to implement
Organized small parts storage during disassembly prevents assembly delays. Proper sequencing and labeling reduces technician time searching for correct fasteners.
Small parts storage methodology
A part of this through process is ensuring that a good process is used for storing the clips, screws and bolts when removing them so that refitting them will be simpler and quicker. There are a number of ways of doing this, some examples are: Adding bolts to a sheet of cardboard in the sequence they are removed, this way the process can be reversed for assembly without the need to sort all the bolts out. Using different bags or small containers for each major item being removed and then labelling them. For example if you remove the bumper bar all clips and screws from this item would be put into a bag or container and then labelled "bumper bar", this way assembly time is reduced.
Small parts organization 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.
Business Impact
Profit loss from assembly time waste, productivity decline from sorting/searching, extended key-to-key times, customer dissatisfaction from delays.
Profit
If this disassembly process is not used time will be lost when assembling vehicles
Throughput, general, body productivity
If this disassembly process is not used time will be lost when assembling vehicles. Much time is wasted with technicians sorting and searching for missing bolts or bolt types
Key to key
If this disassembly process is not used time will be lost when assembling vehicles. Much time is wasted with technicians sorting and searching for missing bolts or bolt types
Customer satisfaction
Long key to key times and delays in repair will cause customer dissatisfaction
Overall Business Impact
Profit is affected when poor disassembly processes lead to lost time during vehicle assembly. Throughput, general, and body productivity suffer when technicians waste time sorting and searching for missing bolts or bolt types during reassembly. Key to key times are extended due to assembly delays caused by disorganized small parts storage. Customer satisfaction decreases as a result of long key to key times and repair delays.
action steps
Train detailed stripping with organized storage methods, establish Production Manager oversight, implement strong policy enforcement and compliance measures.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Management Oversight
Production Manager should check and enforce this process.
Policy Enforcement
Strong internal warnings if policy not followed once established.
Small Parts Organization Training
Implement and train detailed stripping process to include a set method for storage of screws, clips and bolts into the body shop.
Related tasks
Milestone:
12: Vehicle Stripping & Identification