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Identifying bottlenecks in the repair process and correcting them

Thursday, June 14, 2018 - 06:00
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In most shops, back-ups can happen during the various stages of the repair process. The goal of any repair shop should be to increase output through improved efficiencies. In order to maintain productivity repair shops must identify and remove the issues causing the bottleneck.

A bottleneck in the repair process occurs when the number of damaged vehicles entering the repair shop exceeds the production capacity. Installing proper front office procedures, back shop processes, management systems, scheduling rules, and daily production goals are key to eliminating the issues that limit production capabilities and reducing bottlenecks.

Reduced delays
Diagnosing diagnostic and vehicle electronic damage with a vehicle scanning device can save repair time, because all of the repair issues, including missing or damaged parts, are identified before repairs begin. Unfortunately, a vast majority of collision repair facilities do not have technicians equipped with a strong mechanical background, mechanical expertise, or experience fixing the complex systems showing up more frequently on today’s vehicles.

Using the patented asTech™ device provides collision repair shops with OEM factory scan tools, the vehicles original build data, ASE certified master technicians to perform the service, comprehensive reporting, and an asTech™ warranty with every completed service request. The asTech™ solution reduces the frequency repair shops will need to outsource services to the dealership.

A high percentage of DTCs are not illuminated or identified by a Malfunction Indicator Light (MIL). Performing a pre-scan using the asTech™ device identifies all of the issues including those that do not trigger a MIL. This important process reduces unnecessary time spent searching for alternative repair solutions; helping reduce the likelihood of back shop bottlenecks.

Processes and checklists
Repair shops should create standardized front office and back shop processes to manage the day-to-day production. Shops need to create checklists to help stay on track. Some checklists to consider for implementation are as follows:

  • Document the steps in each process
  • Identify duplication of responsibilities and effort
  • Identify unneeded steps
  • Look for breaks in processes
  • Look for bottlenecks
  • Plan the change implementation
  • Execute the plan
  • Monitor the results
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