Is the industry structurally sound in 2013?

Jan. 1, 2020
The collision industry continues to have to keep up at its own pace without any bailouts.
The automobile marketplace has seen vehicle manufacturers saved by government loans, the job market shrink and become leaner in production and costs, but the collision industry continues to have to keep up at its own pace without any bailouts.Like this article? Sign up to receive our weekly news blasts here.

Where are we now and have we yet arrived? The answer is no! Those of us who don’t adapt to change might as well pull over and let our competitors pass because without keeping up we can’t compete.

We can start by looking at vehicle design and content. As fuel economy regulations continue to rise by government mandate, changes are needed to reduce the weight of the vehicle. Most reductions have been taken out in the weight of steel. As steels lose weight, they must also add strength. Changes are constant in steel manufacturing and trying to meet the next demand for strength and durability by the vehicle manufacturer comes from millions of dollars of research and testing. Since materials are constantly changing, the process should also change.

Repairs are constantly changing, because research changes, procedures change or are adjusted by the manufacturer as they find new ways to improve procedures. That brings us to training and technology, are they also affected?

Training is constant, everyday new information comes from the manufacturers about the next innovation. And as the build of the vehicle changes so must the repairs. New designs and processes in repair require training from the vehicle maker, structural repair equipment provider, welding equipment company, or shop material and paint supplier. They are constantly updating their training to address the vehicle and industry needs.

What’s changing besides high-strength steels, and how do new steels affect repairs? With so many changes in steels, technology must take over and analyze the materials we are working with. Resistance welders have taken over 70 percent of panel replacement now joining panels at the factory spot welded seams. So here comes the “smart spot welder.”

Many “smart welders” have hit the market recently promising to fix the future, but be careful, because humans are still controlling welders. There are settings of some sort on all welders, and technology for resistance welding is not point and shoot like the old Polaroid cameras. While sales and marketing types claim that it’s a “click and weld” process, many factors are involved. Material thickness, material type, electrode length, power settings, distance to material, and forging PSI all are important. There are so many factors that go into the milliseconds it takes to complete a weld. In reality, what is really necessary is to have a welder that can measure what is going on between the tips and quickly adjust to compensate and change the affect of the next weld on the fly. We are using multiple types of materials, many thicknesses, along with adhesives to build a Uni-side consisting of a side hit replacing an A,B,C pillar and rocker panel that in certain vehicles need many parameters to complete the proper fusion of welding. Without a unit that analyzes and adjusts a technician will constantly be adjusting the welder to complete the repairs.

One key factor that goes into any welder is the power. Many facilities still do not have the correct power to make a quality weld. While it may appear to fuse the panels together, only a destruction test will prove the weld is correct. Welders themselves have changed over the years, and studies have proven that inverter technology is necessary and 3-phase power is the main power source. The inverter stores power in its capacitors so the power is not totally drawn from the power source during the weld process.

Transformer guns take this process further because they have the power made at the tips instead of it being forced through cables to the tips. Although there are big differences in “transguns” that are being marketed so a close look is necessary. Some are big and bulky with more weight than the standard spot welders. But big advantages of a Transgun unit includes longer gun cables because the power is made in the gun instead of pushed to the gun making it easier to reach areas on the vehicle with the long cables.

With all the vehicle manufacturer requirements for proper repairs, looking at manufacturer approvals is necessary on any equipment purchase today. Beyond welding, straightening prior to that point is even more important when it comes to new metals. We have grown beyond an analysis printout of the structural damage to a process that must include before, during, and after when it comes to structural repairs. This documentation is required for any insurance claim to get the damage and repairs correct. Also with the stronger materials being used in manufacturing, more panels are being replaced since they cannot be put back to the correct structural integrity.

But even if the panel is replaced that doesn’t mean straightening is out of the process. It actually is very important, because adjoining panels that are not being replaced need to find their original position within the vehicle. Vehicles involved in collisions will require pre-pulls, which are hard to explain unless you understand both the repair process and the accident process. The accident damage is not just the noticeable hit area (direct damage), but also the movement of the rest of the vehicle that causes inertia damage (indirect). Both will require attention to get a quality repair. Without the pull or repair prior to cutting off the damage the new panels may not fit right, and adjoining panels may not be in the correct position.

Pulling equipment also is changing and the need for a big machine is being substituted by a mini-rack that also serves as a working platform, improving a technician’s ability to work off the ground and increasing productivity. These mini-type platforms also take up less space so when they are added to the structural area, production space can be found, or more throughput labor is possible in less space. Larger machines will still be necessary for heavy hits and full frame repairs.

Repairers need to continue to become more efficient. Many companies offer training to implement lean practices at your shop. Don’t take this process on alone. Many different concepts exist for lean, but they all start the same and most important task. The first priority in adopting a lean atmosphere is to clean and organize your shop, and keep it that way. Sometimes lean adoption does not work because it’s a discipline that must be adhered to by everyone in the facility. Normally this is where weak links are exposed and sometimes will require additional coaching to refine the process. For example, technicians in a flat-rate working atmosphere do not always embrace lean processes.

You can expect 2013 to be another year of change in equipment, process and training.

Sponsored Recommendations

ZEUS+: The Cutting-Edge Diagnostic Solution for Smart, Fast, and Efficient Auto Repairs

The new ZEUS+ simplifies your diagnostic process and guides you through the right repair, avoiding unnecessary steps along the way. It gives you the software coverage, processing...

Diagnostic Pre- and Post-scan Reports are Solid Gold for Profitability

The following article highlights the significance of pre-scans and post-scans, particularly with Snap-on scan tools, showcasing their efficiency in diagnosing issues and preventing...

Unlock Precision and Certainty: TRITON-D10 Webinar Training for Advanced Vehicle Diagnostics

The TRITON-D10 lets you dig deep into the systems of a vehicle and evaluate performance with comparative data, systematically eliminating the unnecessary to provide you with only...

APOLLO-D9: Trustworthy Diagnostics for Precision Repairs

The APOLLO-D9 provides the diagnostic information and resources you need to get the job done. No more hunting through forums or endlessly searching to find the right answers. ...

Voice Your Opinion!

To join the conversation, and become an exclusive member of Vehicle Service Pros, create an account today!