The document outlines a 12-step process for collision repair, detailing various stages from qualifying repairs and disassembly to repair approval and part ordering. It emphasizes the importance of thorough damage evaluation before repairs begin and highlights differences between express, light, medium, and heavy repair classifications. Efficient scheduling and parts procurement are key to minimizing repair times and ensuring a smooth workflow.

1. Understanding A New Process in Collision Repair Process

2. 12 STEPS
PRIOR TO CREATING
ANY VALUE
FOR YOUR COMPANY

3. Step
1
Qualifying Repairs / Estimate
Owner signs authorization to repair
Disassembly & blueprinting of vehicle
Step
2
Repair Approval
Step
3
Step
4
Parts ordered Received
& Mirror Matched
Step
5
SCHEDULE
PRODUCTION

4. Understanding Collision Repair Process
Qualifying Repairs

5. Step 1 : Qualifying Repairs / Estimate
On drive-able vehicles, the vehicle is Qualified into 1 of 4 job classifications Express, Light,
Medium or Heavy repair in our inspection area. On Express and Light repairs All damage is
evaluated and entered into our computerized estimating system. This data is compiled into an repair
plan that determines the cost of repair for all damage at this time. “An initial repair plan cost is
helpful when deciding on whether to file an insurance claim or not.” However, Medium and Heavy
repairs often there is hidden damage that cannot be seen or accounted for until after the vehicle is
disassembled. Therefore the vehicle owner should be encouraged give authorization to repair and
leave the vehicle for proper repair planning once the disassembly & blueprinting process, an
accurate total cost of repairs can be determined. Express repairs - Parts can be pre ordered pre
painted . On the schedule in date the vehicle will be put directly into the product flow line and
delivered back to the vehicle owner with in hours or on the same day. Light repairs – A schedule in
date for repair can be set . Parts can be pre ordered . On arrival of the schedule in date the vehicle
will be put directly into the product flow line. In most cases the vehicle can be returned to the owner
with in 48 hours.
Qualifying Repairs / Estimate
Express
Pre Ordered Pre Painted
Light Repair

6. Step 2 : Disassembly & blueprinting of vehicle
After Qualifying Repairs of Medium or Heavy repair - At the vehicle dropped off our staff will fact
find with the vehicle owner the damage associated with the collision claim to be repaired and any
non-related damage is noted and discussed with the customer. The vehicle is then scheduled for
disassembly and a disassembly date is set . “This should take place with in 48 hrs of the drop off
date.” The vehicle owner is advised what date to expect a call from our staff member with a due in
production date and a guarantee delivery date as well as a itemized cost of repair .
During disassembly our team will expose all hidden damage. The inner structure of the vehicle is
examined and measured to insure that the safety of the vehicle has not been compromised in the
accident. All damaged parts are marked showing that they will either need to be replaced or
repaired. The repair estimate and parts order is validated accordingly and is now a complete repair
plan. Since the damage has now been fully documented, the vehicle and repair cost estimate are
now ready for the insurance or customers .
Disassembly
blueprinting of vehicle
Medium Repair
Heavy Repair

7. Step 3 : Repair Approval
Now that all damage has been identified, some insurance companies will send an appraiser to inspect
the damaged vehicle and review our repair plan. There may be some negotiations regarding
replacement part type, labor charges and what repair procedures are required to repair the vehicle
properly. Most times our repair plan is so well validated and detailed that your insurance company is
with in penny’s of our repair plan. The type of repair that will be performed may depend on the
insurance company and will always include the customer final decision. Our repair plan are generally
written utilizing new factory parts as pre the manufactures recommended repair procedures.
occasionally insurance companies try to reduce the repair cost by only paying for parts that are
either not made by the vehicle manufacture . Give a descriptive name as
“aftermarket”, - “not made by the vehicle manufacture .” “LKQ” – “Used parts from salvage yards.” or
“re-manufactured”- “previously damaged and repaired parts”
After the negotiation process, we will notify and explain to our customer any differences between our
repair plan and the insurers recommend repair procedure . We will also offer any repair options at
this time. Once any repair differences are resolved, we obtain the parts can be ordered and the
actual repair process can begin with in 24 hrs.
All damage has
been identified
Insurance Appraiser inspect
the damaged vehicle
Parts ordered &
Received
repair process can begin
with in 24 hrs

8. Step 4 : Parts ordered Received & Mirror Matched
Dissembling the vehicle completely before placing the parts order, allows us to receive all necessary
parts in one shipment. Our goal is to schedule JIT just in time parts delivery. Allowing for our team
to have the proper amount of time to verified all parts for correctness “mirror match” and inspect
any damage on used parts that may have been recommended by the insurer . In some cases we
may need to be repaired or returned the damage used parts. Replacement parts are ordered
electronically which improves part ordering accuracy and reduces delivery time. Depending on the
vehicle make and type of parts needed, complete part orders can be received with in 24 hours.
Having a complete part order on hand allows us to kit the repair prior to our technicians being
dispatched the repair. Our technicians no longer have to share in the estimating of supplement
and do not have to stop in the middle of a repair to wait for additional part’s. This allows for our
technicians to work at an increase efficiency giving the customer ,insurer ,and our company a
predictable and positive out come.
Dissembling the vehicle completely
Parts ordered electronically
“Mirror match”
Predictable &
positive out come

9. Step 5 : Schedule Production
Schedule repairs by job class opens us up to a wealth of control of scheduling and releasing work
load to our team according to available resources and current production capacity. Allowing us to
eliminating waste.
In short, the Just-in-Time parts procurement inventory system and production scheduling ,focus is
having “the right material, at the right time, at the right place, and in the exact amount” reducing
excess inventory holding and handling. Decrease cycle time by 50 to 60 % or more.

10. Express Repairs
DISASSEMBLY IS NOT NEEDED TO WRITE THE
REPAIR PLAN.
Express Repairs are jobs that require bolted-on
parts replacement and refinishing only.
1 Express vehicle parts must be pre-ordered .
2 Express vehicle refinishing can typically be
completed prior to the vehicles arrival for repairs
Express vehicles can not require any panel
straightening.
Express vehicles can not require any structural
repair at all.
Express vehicles can not require the replacement
of any welded on panel(s).
Express vehicles can not require any sublet work.
Bumper covers
Mirror covers
Express vehicles
Express vehicles must be able to be placed directly into the Production Line without interruption.
•Damage Appraiser must be confident that they have identified 100% of the damage at the point of sale.
•This requires placing the vehicle on a lift to inspect under the bumper cover area and removing splash
shields etc to see “hidden” damage.

11. Light Repairs
DISASSEMBLY IS NOT NEEDED TO WRITE THE
REPAIR PLAN.
Light Repair Express - are jobs that require 8
hours or less tech Labor only repair and / or
refinishing only.
1 Light Repair vehicle parts must be pre-ordered .
2 Light Repair vehicle typically go right the rapid
repair team or paint prep.
Express vehicles will have 8 hrs of tech repair
straightening and or refinish panel.
Express vehicles can not require any structural
repair at all.
Express vehicles can not require the replacement
of any welded on panel(s).
Express vehicles can not require any sublet work.
Average labor hrs 8 – 16 +
• Light repairs must be able to be placed directly into the Production Line without interruption.
•Damage Appraiser must be confident that they have identified 100% of the damage at the point of sale.

12. Medium Repair
Medium vehicles Require full Dismantling &
Blue Printing procedures in order to write a
complete repair plan.
1 Medium vehicles will require limited build down and or
build up.
2 Medium vehicles may require a combination of floor
pulling and/or repairing of structural damage .
3 Medium vehicles may require panel straightening time.
4 Medium vehicles may require one panel replacement of
welded on radiator support, tie bar, baffles, apron
extension, door skin, or body panel.
5 Medium vehicles may require minor suspension parts
replacement such as a lower control arm, and/or strut
assembles.
Average labor hrs 20 - 40
6 Medium vehicles sublet repairs must not exceed
alignments, glass, or indicator lights turn off .
• Parts orders should take place after complete dismantling and documented repair plan is completed.
• Complete overhaul of one suspension assembly or multiple suspension areas ,multiple welded on
panels, frame rails, or full aprons, replacement requires reclassification to Heavy Repair.

13. Heavy Repair
Heavy vehicles Require full Dismantling & Blue
Printing procedures in order to write a complete
repair plan.
1 Heavy vehicles will require Engineering builddown
and/or build up.
2 Heavy vehicles may require a combination of pulling
and/or repairing of structural damage.
3 Heavy vehicles may require multiple structural welded on
panels or replacement of radiator support, apron
extensions, complete apron less frame rail, frame rail outer
sectioning only, or body panel with one quarter panel.
4 Heavy vehicles may require multiple panel straightening
time.
5 Heavy vehicles may require suspension and/or frame
cradle replacement.
7 Heavy vehicles may require moderate sublet work
however; the vendor must be able to complete the work
with-in twenty four hours maximum in order for us to
meet our cycle time goal.
Average labor hrs 40 – 90 +
• Parts orders should take place after complete dismantling and documented repair plan is completed.
• Complete frame rail, floor section, or multiple quarter panel replacement require.

14. Randy Ferrese
Training consultant and has more than 20 years of experience in the Auto body industry.
For more information contact
Randy Ferrese Sr
Randy@bodyshopinabox.net
609 576 4244
BodyShopinabox.net