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Continuous Production Model (FIRST DRAFT)

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Continuous Production Model SAMPLE

Continuous Production Model SAMPLE


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  • 1. PRECISION AUTO BODYContinuous Production Model
    The hours of operation are as follows:
     
    Monday thru Friday
    8am – 5pm
  • 2. COUNTINUOUS PRODUCTION MODEL:
    a designed process of interconnecting events that allow production to flow freely with predictable consistent results.
    Everyone must have a clear understanding of our process so the consistent desired predictable result can be achieved.
  • 3. Model Overview
    # 1 :
    The production model is broken into four color coded process zones. Everyone must understand that each process zone within our shop shall have goals and tasks that will require completion before the vehicle can move to the next process zone.
    # 2 :
    Each step in our process reduces the size of the vehicle to enter the fast track process zone. The repair no matter what the original size of the repair was. Building the vehicle up in the red process zone, with 2 to 3 hours of hands-on repair work, qualifies
    # 3 :
    Visual management controls in place will aid the production process so that it can be understood at a glance.
    # 4:
    throughout the process there will be four repair verifications within our process, the repair check point will help aid in quality audit and pace the pulling of work from each process department zone.
  • 4. THE FOUR COLOR PROCESS ZONE
    Red
    Orange
    Green
    Purple
  • 5. How the Red Process Zone is Designed
    To make this more visible, the areas within the Red Process Zone should be color coded.
    Red Stripes on the floor.
    Red color overhead signs with the name of the area.
    This will make it easier to see and understand what zone the vehicle is in, plus what needs to be completed on the vehicle before it can move to the next colored zone.
    Red Process Zone
  • 6. How the Red Zone Process Works
    The Red Process Zone works much like a modified traditional body shop.
    Work in this zone can be anything from body work that will take longer than 3 hours to repair, suspension repair, body panel replacement, frame pulling to structural repair or replacement.
    Within the Red Process Zone you may work on vehicles that have not received all the parts.
    Red Process Zone
  • 7. Strategic Disassembly/Repair Planning
    Based on what needs to be done to the vehicle and the size of the repair and how much time it will take to complete the repair to a certain point.
    In Repair Plan Disassembly it will be determined if the vehicle meets the criteria to be placed directly in the Orange Process Zone for repair.
    Repair Plan Disassembly is very much tied to the Pulling Department.
    If you have a vehicle that requires pulling and measuring the estimate should not be locked until pulls are made.
    These pulls should be done the same day where possible.
    Once the pulls are made, times for conjunctive repairs can now be determined.
    Damaged welded panels that need to be replaced are removed where possible.
    Mechanical and Suspension damage identified and diagnosed.
    Red Process Zone
  • 8. REPAIR PLAN AUDIT IS CONDUCTED THROUGH THE VISUAL MAPPING PROCESS AND ALL ON VEHICLE NOTES ARE APPLIED
    Reducing the possibility that anything downstream from that point could stop the vehicle from going forward.
    Repair plan is finalized and all parts ordered.
    Vehicle is then placed in the Parts Waiting area.
    Red Process Zone
  • 9. Structural Repair and Building Area
    If no parts are needed to complete the next part of the repair, the vehicle may move to the next Red Process Zone building repair area.
    Under no circumstances should the vehicle be allowed to move to the Orange Process Zone area without 100% of all the parts received and verified to be the correct parts.
    If parts are needed…once the parts arrive and are verified correct, the vehicle is moved to the Structural Repair Area in the Red Process Zone.
    All structural repairs are completed at this time
    All welded on panels are install
    i.e. Core supports, Aprons, Rail, Quarter Panels
    Vehicle is re-measured on the floor to verify correctness and printout placed in file and vehicle
    Vehicle is move to Red Process Zone Paint Cut-In
    Red Process Zone
  • 10. Paint Cut-In
    All paint cut-in of the vehicle is complete in this process…
    Door openings
    Core support
    Aprons and rail
    Trunk openings
    Once all cut-in has been completed the vehicle can be moved to the build area.
    Red Process Zone
  • 11. Build
    All pre-build takes place at this time, insuring proper fit of parts.
    All Mechanical build
    Radiators and A/C condensers
    Vehicles that come from the Red Process Zone have had all the variables taken out of the repair.
    The randomness of different size repairs has been reduced to a very predictable size.
    Special needs have been addressed i.e. air bags, codes cleared, suspension and wheel alignments, all mechanical.
    The Red Process Zone allows vehicles to move through the balance of the repair process at a very predictable pace.
    Red Process Zone
  • 12. Goal and Repair Verification Audit
    Prior to “Ready For Production” repair verification hand off, the vehicles requires only 2 to 3 hours of hands on repair or parts replacement or less to be complete.
    Proper operation, fit and gaps of all repaired or replaced areas.
    All suspension replacement and Wheel Alignment completed.
    All Mechanical and electrical repairs completed.
    All structural repairs completed.
    All paint cut-in completed
    Air Bag replacement and codes cleared.
    All repair verification audit met.
    Red Process Zone
  • 13. TELL ME THE RULES AND I WILL SHOW YOU HOW TO WIN THE GAME
    Red Process Zone
  • 14. Rules
    Damage Analysis of all vehicles
    Complete disassembly of all damaged areas
    Paint color variant obtained and Color mixed
    Color spray out
    All Structural Pulling and Measuring
    Repair Plan Finalized
    All Parts ordered and received
    All Structural Repair
    All Pre-fit of bolt on parts
    All welded-on parts replaced and measurements verified
    Proper operation, fit and gaps of all repaired or replaced areas
    All vehicle paint cut-in
    All damaged parts identified and replaced
    Wheel Alignment completed
    All mechanical and electrical repairs including engine R&I
    Cooling and AC systems recharged and checked
    Damaged Air Bag and Sensors replaced and codes cleared
    Interior Build if needed
    All Quality Standards met
    Red Process Zone
  • 15. How the Orange Process Zone is Designed
    To make this more visible, the areas within the Orange Process Zone should be color coded.
    Orange Stripes on the floor.
    Orange color overhead signs with the name of the area.
    This will make it easier to see and understand what zone the vehicle is in, plus what needs to be completed on the vehicle before it can move to the next colored zone.
    Orange Process Zone
  • 16. How the Orange Process Zone Works
    The Orange Process Zone starts outside in the parking lot, in the area we know as “Ready for Production”.
    In order for a vehicle to be in this area, three things must be true
    It will take less than two or three hours of work to prepare the vehicle for Paint and Reassembly.
    100% of ALL the parts needed have been received and verified.
    ALL the Goals of the Red Process Zone have been met.
    Orange Process Zone
  • 17. Goals
    Deliver to the Green Process Zone ONE vehicle every 60 to 90 minutes or less.
    Deliver to the Green Process Zone (Paint) vehicles that meet all Quality standards, free of defects i.e. sandpaper scratches and pinholes.
    Deliver to the Green Process Zone vehicles requiring only 60 to 90 minutes or less of hands on parts installation in the reassembly area.
    Verify that any issue that could stop the vehicle from going forward has been addressed and completed.
    Orange Process Zone
  • 18. Goal and Repair Verification Audit
    Body repair
    Parts replacement
    Panel alignment and proper operation
    Meet all Quality Standards, free of defects i.e. sandpaper scratches and pinholes.
    Anything that is required to reduce the size of the vehicles to require only 60 to 90 minutes or less of hands on parts installation in the Reassembly area.
    Verify that no issue could stop the vehicle in Reassembly.
    Orange Process Zone
  • 19. Rules
    No vehicles in this zone without ALL 100% of their parts received and verified.
    No repairs that will take longer than 3 hours to complete.
    All quality check points prior to entering the production flow line have been completed, passed and signed off.
    Only pass to paint quality repairs that won’t need rework.
    Only pass to reassembly vehicles that can be reassembled in less than 90 minutes.
    Orange Process Zone
  • 20. How the Green Process Zone is Designed
    To make this more visible, the areas within the Green Process Zone should be color coded.
    Green Stripes on the floor.
    Green color overhead signs with the name of the area.
    This will make it easier to see and understand what zone the vehicle is in, plus what needs to be completed on the vehicle before it can move to the next colored zone.
    Green Process Zone
  • 21. How the Green Process Zone Works
    The Green Process Zone starts in the Paint Buffer.
    In order for a vehicle to be in this area, three things must be true
    Items remaining for Reassembly to install on the vehicle will take less than 90 minutes to install.
    100% of ALL repairs have been completed and quality has been verified.
    ALL the Goals of the Orange Process Zone have been met.
    Green Process Zone
  • 22. Goals
    Paint Department
    Paint to deliver to the Green Process Zone (Reassembly) ONE vehicle every 60 to 90 minutes or less.
    Deliver to the Green Process Zone (Reassembly) vehicles that meet all Quality Standards, free of defects i.e. color match.
    Free of needing any correction of any kind.
    Green Process Zone
  • 23. Re-Assembly Department
    Reassembly to deliver to the Green Process Zone (Detail) ONE vehicle every 60 to 90 minutes or less that has achieved all Quality Standard.
    All customer needs and concerns addressed and corrected.
    A vehicle that has passed all quality check points.
    Detail to deliver to the Purple Process Zone ONE vehicle every 60 to 90 minutes that has been properly cleaned and has passed the Fit and Finish Inspection.
    Goals
    Green Process Zone
  • 24. Goals
    Detail Department
    All customer needs and concerns addressed and corrected.
    A vehicle that has passed all Quality Check Points including the CSR Fit & Finish check.
    Detail to deliver to the Purple Process Zone ONE vehicle every 60 to 90 minutes that has been properly cleaned.
    Green Process Zone
  • 25. Goal and Repair Verification Audit
    All paint prep work
    All paint work
    Meet all Quality Standards, free of defects i.e. color match, correction of any kind.
    Paint to produce ONE vehicle every 60 to 90 minutes.
    Reassembly to install all parts remaining on parts cat i.e. bumper, headlamp, grille, moldings, door handle, weather strips, etc.
    Quality met and Quality inspection completed.
    Reassembly to deliver to the Green Zone (detail) ONE vehicle every 60 to 90 minutes.
    Vehicles cleaned inside and out, including under hood if we worked on the front or inside trunk if we worked on the rear of the vehicle.
    Fit and Finish Inspection complete.
    Green Process Zone
  • 26. Rules
    Never place a vehicle in the Purple Process Zone that has something that has not been completed.
    All Quality Standards met and verified.
    Green Process Zone
  • 27. How the Purple Process Zone is Designed
    To make this more visible, the areas within the Purple Process Zone should be color coded.
    Purple Stripes on the floor.
    Purple color overhead signs with the name of the area.
    This will make it easier to see and understand what zone the vehicle is in, plus what needs to be completed on the vehicle before it can move to the next colored zone.
    Purple Process Zone
  • 28. How the Purple Process Zone Works
    In order for a vehicle to be in this area, three things must be true.
    There are NO items remaining to be completed on the vehicle.
    Quality has been achieved and verified; customer concerns have been addressed and verified.
    The collective Goals of all the process zones have been met.
    Purple Process Zone
  • 29. Goals
    Is to provide the best possible customer experience and service that far exceeds the customer’s expectations.
    A controlled area to deliver to the customer their properly staged vehicle.
    No Surprises!
    Delivering from the Purple Process Zone enables the CSR to schedule the time of vehicle pick up with the customer so we can provide a focused attention to the customer that makes them feel valued.
    The customer is never notified that the vehicle is ready for pick up until the CSR or person that will be delivering the vehicle back to the customer, has been able to review the vehicle and complete the Final Inspection Checklist.
    This gives the CSR the opportunity to complete the a final fit and finish review of the vehicle without having the pressure of the customer picking the vehicle up in 10 minutes.
    This helps prepare the CSR to resell the vehicle to the customer during delivery.
    Allows us to take pride and have confidence in knowing that we have done everything with quality.
    Purple Process Zone
  • 30. Goal and Repair Verification Audit
    CSR’s to complete a final review of the file and repairs made to the vehicle.
    Complete a Fit and Finish inspection of the vehicle.
    Verify that we have done everything with quality.
    Double check that ALL the customers concerns have been addressed and corrected.
    Once all these tasks and Goals have been achieved the vehicle is considered “Complete”.
    Contact the customer and schedule the vehicle delivery.
    Purple Process Zone
  • 31. Rules
    There are NO items remaining to be completed on the vehicle.
    Quality has been achieved and verified, customer concerns have been addressed and verified.
    The customer Must Not be notified that the vehicle is ready for pick up until, the CSR or person that will be delivering the vehicle back to the customer, has been able to review the vehicle and completed the Final Inspection Checklist and everything is ready for the customer.
    Purple Process Zone
  • 32. Contact Information
    RANDY S FERRESE SR.
    824 BLUE BIRD CIRCLE
    MAYS LANDING, NJ 08330
    609 553 4244
    FERRESEWV77@HOTMAIL.COM

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