Why its important to implement
Ensures approved parts are ordered in advance with proper checking and labeling preventing mix-ups, uses traffic light systems for visual production readiness indication, provides secure organized storage for job-specific parts, and delivers ready-to-work setups eliminating technician searching time.
Visual Management System
Using a traffic light system to indicate visually and clearly to the production manager that the vehicle is ready for production minimizes the need for the production manager to waste time asking if everything is ready for each job.
Production Readiness
Once loaded and all parts on the trolley it should be delivered to the body repair bay ready for the technician to begin working on the vehicle without delays or searching for parts.
Secure Parts Storage
Using parts trolleys for each job ensures all parts are secure and together for each individual job with a safe place for all parts removed from the vehicle to be placed and stored.
Parts Organization and Control
Each estimate that is approved by work providers has an approved list of parts required to repair the vehicle, and these parts should be ordered in advance of the vehicle arriving on-site with proper checking and labeling systems.
Prevents Mix-ups and Time Loss
Parts labeling and trolley organization with job numbers prevents unnecessary mix ups with parts and causes a loss of time looking for them.
Business Impact
Negatively impacts profit if parts are lost or damaged requiring additional purchases. Severely affects throughput if production starts before parts arrive causing blockages. Extends cycle times if technicians waste time searching for parts. Creates idle time with vehicles waiting for parts. Reduces customer satisfaction through extended repair times.
Profit
If parts are lost or damaged the business will have to purchase additional at its own cost.
Throughput
If vehicles are allowed to enter the production area before all parts have arrived, if these parts are delayed then production will stop causing change in production plan and blockages in the shop for bigger repairs.
Key to Key (Overall Cycle Time)
If body technicians waste time looking for parts or walking back and forth from the parts area to pick up parts, the job will take longer.
Idle Time
Vehicle 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.
action steps
Purchase adequate trolleys and buckets for weekly volume. Implement parts checking, labeling, and trolley loading processes before vehicle booking. Train traffic light process for parts readiness indication. Implement parts delivery processes to work bays. Establish strong policy enforcement warnings.
Policy Enforcement Systems
Strong internal warnings if policy not followed once established.
Parts Delivery Process Training
Implement and train process where parts department deliver parts trolleys to the work bay for each job.
Traffic Light System Implementation
Implement and train traffic light process for parts trolleys.
Parts Management Process Implementation
Implement and train process where the parts manager checks every part has arrived according to the estimate before the vehicle is booked in for repair, labels each part and places them onto a trolley exclusively for that job.
Equipment Purchase and Setup
Purchase enough trolleys and parts buckets for weekly work volume.
Related tasks
Milestone:
07: Optimizing Parts Management & Storage