Why its important to implement
Vehicle models have specific disassembly procedures that even experienced technicians cannot memorize. EV/HEV systems carry high voltage risks requiring strict adherence to manufacturer guidelines. Proper methods prevent injury, death, and component damage.
Manufacturer Requirements
Evidence of the vehicle repair method being accessed by the technician is a requirement by some OEM's.
Safety and Damage Risk
Improper handling can cause injury, death, or expensive damage to batteries and electronic components.
Documentation Requirements
Each EV/HEV needs repair methods with the job card or via BMS terminals, and technicians need specific pre-repair requirement reminders.
Technical Complexity
Vehicle models have specific disassembly instructions. Even experienced technicians can't know every procedure, especially for EV/HEV systems with high voltage risks.
Business Impact
Trial-and-error approaches extend repair times and reduce revenue. Parts damaged during improper removal become shop expenses. Productivity suffers from extended repair times. Time wasted seeking information extends job duration. Improper repairs damage reputation with providers and customers.
Repair Time Impact
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked on, they will experience longer repair times in all remove and refit areas, this will cost the business revenue.
Damage Risk Impact
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked on, they are at a higher risk of damaging parts and the business having to pay for them without charging to the work provider.
Productivity Impact
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked, they experience longer repair times in all remove and refit areas, this mean lower throughputs.
Key-to-Key Impact
Wasted productivity due to waiting for information to begin working on the vehicle will lengthen the time the job is in the shop.
Reputation Impact
If there is a claim against the business because a vehicle was repaired incorrectly through incorrect welding processes or by using methods to repair vehicles that are not approved, for example mishandling of electrical systems causing extensive damage would lose its reputation with work providers and customers.
action steps
Implement processes for production managers to remind staff of EV/HEV requirements. Provide repair methods with job cards or via terminals. Establish verification systems to prove methods were accessed. Regularly audit process compliance and enforce consequences for non-compliance.
Policy Enforcement
Strong internal warnings if policy not followed once established.
System Verification
If the shop uses the OEM systems directly or a BMS for the technicians to access repair methods, it must establish a way for the production manager to prove they were used.
Documentation Process
Implement and train the process of accessing repair methods and placing them with each job card.
Process Verification
Regularly check that this is being carried out for every job, strong internal warnings if policy not followed once established.
Safety Process
Implement and train a process for the production manager or VDA to remind staff of EV and HEV requirements check when they enter the workshop.
Related tasks
Milestone:
12: Vehicle Stripping & Identification