Body Shops – Stop Chasing Your Tail – Visual Organization Part 2

Posted: January 5, 2015 in Uncategorized

Buffing Cart

Why is it so hard to keep things straight in our shops?

How much time do you waste looking for all the things you need to get cars done?

The example pictured above is a Buffing Cart.  It’s an example of a “point of use cart” that has been very effective in saving time and wasted materials. I’ve worked with a lot of customers to develop custom solutions for visual organization. Any time you work in a group of people with overlapping tasks, staying organized is a challenge. The true test of an organizational system is how long it stays that way!

Anyone can clean up a work area and increase the appearance of orderliness, but it takes thought to build a system that produces consistent results. Experience has led me to a few simple rules that will hopefully help you in your business.

1. Keep it simple.

What are you trying to accomplish? What are the steps to make that happen? What products will be involved? You need to know every product that could be involved, don’t leave anything out. List out the tools, consumables, personal protective equipment, etc. (Take note of all the duplicated products that each person in your business keeps. How many gallons of body filler do you have open at one time? Compound? Glaze? Rolls of Tape?)

2. Make it easy.

If you are trying to influence people to a shared vision, start by making the solution benefit each of them. After all, they will be the one to use the solution day in day out. If you involve the people in the creation of the solution, they will contribute and accept the final process as their own.

3. Optimize. Focus on the cost not the price.

Every process creates waste that effects another process. Example, if you are building a plastic filler cart, put a vacuum sanding system on it. Expensive? Yes, but cheap compared to the labor involved in cleaning bond dust out of a car or creating a dissatisfied customer. The buffing cart above has a plug in power supply for the cart that energizes a surge strip that feeds an electric DA, Flood Light, variable speed buffer and a radio. (DA never gets used for dirty prep work this way)

4. Make it Visual and Vertical.

Every product needs to be organized visually on the cart. Don’t leave any question as to the precise location of each product. If you have 3 boxes of sandpaper, cut square holes where they go and put a picture of the box in the bottom of the hole! Oversimplified? Yes. Effective? Absolutely. You will notice in the picture, we streamlined the products to 2 compound bottles, a trigger bottle of 50/50 alcohol and water (cool trick for final cleanup to make sure you didn’t just fill swirl marks instead of eliminating them), a trigger bottle of plain water, glass cleaner, and trim black. Notice that these round cutouts are on a flat surface? Every other surface is vertical with good reason. Its hard to pile trash on sloped surfaces. Notice the cutout for the dedicated detail DA? Its round like the pad so it says to everyone “the DA goes here”. The plastic box holds 4 microfiber towels, one for each step of cleanliness. Have you ever had a tech final wipe a car with a rag that had compound on it? What about buffing pads? They need to be ultra clean. Put them in a dedicated plastic box, again with a picture of the pad on the box. (How many times have you walked through your shop and seen a buffer laid on its back with a pad facing a sky full of flying dirt,metal and other nasty scratchy particles?)  Organize everything on the cart this way, use magnets, velcro strips, zip ties whatever it takes to make it easy and visual. If you want the cart to roll around the shop, rip those little 3″ plastic wheels off and put some 10″ 4X4 cushion tires on it.  Many shop owners I’ve worked with try to solve problems by adding rules that no one will follow after the boss gets tired of enforcing them! Don’t expect your people to use a solution that makes their job harder! Just make it easy and they will love it.

5. Don’t expect to just buy your solution on the internet. 

There is not a company out there that can offer your shop the perfect organization solution. Buy something that is 75% there and make the rest work for you. Home Improvement and Craft stores have lots of solutions, just keep your eyes open when your out. We found the DA pad boxes at Hobby Lobby! The Container Store is also a great place to find storage solutions.

primer cartPrimer Cart2Priming Cart

I truely hope that you enjoyed this information. We love to solve problems for customers. If you enjoyed this, feel free to share it. Also, you can subscribe to our blog by just clicking the subscription button and entering an email. Collision Edge will do our best to keep bringing you New Solutions to Old Problems!

Our website is http://www.collisionedge.com Check out “The Tape Thing” if your there!

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