“Ding..Ding” Another email oohno circlerder comes in from the Collision Edge Website. We are addicted to the satisfaction that comes from helping shops.  The solutions we have brought to market came from many visits to great body shops across the country. We love to just go there and “Stand in the Circle”.  So before you ask if we are nuts on the whole Standing in the Circle” thing, Let me explain..Famous Toyota Executive, Taiichi Ohno, used to draw a circle on the ground and tell people to stand in it and observe a process for hours until they fully understood the challenges.

My name is Tim Briggs. I’ve had the unique opportunity of spending time with some of the most forward thinking people in the Body Shop Industry. I imagine by now you’ve probably seen at least one post from various Collision Edge social media sites. We started this whole deal to educate our kids on business and put them through college. My days are spent with customers, my nights are spent living with the bee like hum from a head full of insights and problems that plague our industry. This cycle has led my wife and I to invest in, innovate and launch several products that are focused on making a difference in the Collision Repair Industry. Our goal has been increasing shop profits by focusing on emerging processes like “Blue Printing Discovery” and “Point of Use” tools. 

Blend stick pic

The Blend Stick

The first problem we saw was the constant debate over “Blend within”. As a paint guy I’ve spent a countless hours trying to panel match colors that legitamatley needed to be blended but weren’t because there was not a standard process for defining the need to “Blend” adjacent panels. The Blend Stick is a high contrast, easy to read photo tool that assist the shop in documenting the need to charge for blends on adjacent panels.

Copy of Copy of DSC_0197The Estimating Sticks

Closely following The Blend stick where the Dent    Sizer and estimating sticks. These tools are used to add scale to photographs of panel damage. Right away people began using the tools to photo locate decals and emblems in the discovery process. How many times do you have a tech waste a half hour coming to the office for a photo showing emblem locations? I’ve watched it happen, and the process usually involves 2 or more people!

The Dent Viewer

Next on the list…“Subjective Damage”. How many hours should I charge for this and can I support the labor time with a photo? Soft dents, creases and rolls are hard to capture in photos.  We developed the Dent Viewer to solve this problem. The key innovation here was using a light gathering film commonly found on street signs.

The film grabs the flash at a 90 degree angle and reflects a line grid back onto the panel in the photo. Nothing hides from The Dent Viewer.

IMG_3569 IMG_3570

The Tape Thing

One day I was standing in a shop watching a guy mask a fender. He put the tape in his mouth and under his arms until he finally laid it on the fender. You know what happened next right? It slides off the fender and rolls 20 yards across the shop floor and flops in a puddle of water! I went home that night and laid awake thinking of how to solve that problem. At 6 am I was standing in front of Home Depot armed only with a roll of tape and the desire to fix this problem. I walked the isles that morning and spent over $100 on anything that looked like it might help me solve the problem. The result is now known as The Tape Thing. It’s a magnetic tape core device that allows tape to freespool effortlessly from the users hand.

Tape Thing LayoutDSC_0679DSC_0693Copy of 10559726_824594737581596_5153171753865951062_nCopy of Tape Thing Pic green car

Collision Edge is committed to bringing new solutions to old problems. Our products sell because they all offer a nearly an instant return on investment. We are all in with our little company. Our profits are split between the college funds and R&D for the next innovation. We will keep “Standing in the Circle” and bringing you new products.

Thank you for your support, we look forward to hearing from you.

Tim Briggs




So is sandpaper important? How much of your material budget do you spend on Abrasives? Do you know? We’ll get to the answer in a minute.

So why does our industry consume dizzying array of abrasives? What are the pros and cons of each type and how can your shop minimize cost without sacrificing quality?

Ok so the sandpaper gods have created every grit and attachment mechanism under the sun…its all around body shops every day. Sandpaper has a cost and a price. The price is what you pay and the cost is the net result of the effect the product has on your shops performance.

Sandpaper has been around since the ancients used shark skin or crushed shells bonded to papyrus with tree gum. The technology has made huge advancements, but the same limits still apply to all the products. The heat from friction is one of the main enemies of abrasive life. Heat is generated by clogged paper and excessive DA speed. Slow down a bit and wipe/smack your paper frequently to make it last longer. Pay attention to the “throw” of your DA orbit also. DA’s are available in orbits from 3/32″ to 1/2″ or more. The tool matters. I prefer a 5/16″ even on detail grits. Keep it cool, keep it clean.

Which one is right for your shop depends on the system you set up to use your abrasives.

Typically the average shops body technician is going to have his own open box of 80, 180, 240 or 320 grit da paper, duplicated grits of file paper and 24,36,50 grit Roloc and 5 inch grinding disk. Contrast that with the average paint shop that keeps DA AND/or flat paper grits of 240,320,400,600,800,1000,1200,1500, 3000 and now even 5000 grit finishing abrasives.

Can you see now why the average shop spends 9-10% of its material budget on abrasives? Following are a few steps you can take to choose a system and maximize your dollar for abrasives.

1. Streamline Inventory. Everyone likes different stuff, but all the techs in your shop can agree on a limited list of part numbers if you try. Example which roloc will you use?

Shops really don’t need 24,36,50 and now even 80# Roloc. You will find that finer grits like 50 and 80 cut faster than the 24 and 36 and leave far less collateral damage. Test this for yourself…i didn’t believe it either until my rep showed me.

Anything over 3 DA prep grits for paint is a luxury. If your painters need anything coarser than 320 then they are body men! Most shops have been able to get the range down to like 320, 600 and 800.

Take an inventory of the products in your shop. Once you make your list, get rid of everything else. Most of the customers Ive worked with say, “we will just use those others up”. It never happens. 3 months later when that odd grit is gone, your salesman will unknowingly reorder you more because he doesn’t know any better!

2. Build process carts – I have a client with 6 body techs who to date only has 1 Gallon of Bondo, 1 bottle of glaze, and 1 box of each grit of Body abrasive open. The cart is visually organized and stays centrally located to all the techs and rolls everything needed to fix dents right to the car. Why not put a dust free system on your cart? How much money does sanding dust cost? Ask your clean up guy, He catches all the evils created during the repair process. He is the unsung hero of your organization!

3. Pick a system. If you have a cart or another set up where techs can keep partially used abrasives then it makes sense to use velcro. Typically velcro will cost 20% more. Just like any other premium product, If its used correctly it is more than cost effective, it’s a no brainer.

Proper abrasive selection is very important to your material bill and executing consistent, quality repairs.

10 percent of the money you spend is on abrasives. It’s 4th on the list in cost priority yet many shops overlook its importance or default to the cheapest box they can buy. Consider all the cost and the end goal and you’ll find that abrasives are a cornerstone to your material profit goals.


The Color of Money.

Posted: January 29, 2015 in Uncategorized


I remember the day in 1999 when I first saw a color shift paint job. Everyone went crazy over it. I believe then it was $32 an ounce to buy…crazy right? Todays custom finishes have evolved further and more and more these colors are finding their way into OEM formulations.

Color is the number one highest material cost that body shops encounter and yet we focus on everything but that! I need a cheaper clear, cheaper tape, cheaper razor blades or cheaper sandpaper. Color is 30-35% of what you buy. Control color cost and you are well on the way to solid profitability on materials.

Specialty pigments are popping up everywhere and if you don’t charge for them you will loose a lot of money. Most of the paint companies have quick reference guides available that will help identify these colors containing specialty pigments. Pay close attention and you will see what we are talking about here.

Why do we pick colors in the paint shop? Why not do it when we write the estimate? Ive seen jobs that $30 an hour wouldn’t even cover the cost for the color, much less the rest of the paint and materials…Create a simple repair order invoice and the problem is solved.

Forget specialty colors for a minute…why do we edge parts with the “Prime/Standard” mix? Why not pick the variant and mix the right color to begin with? Chances are we throw away enough product to paint the whole part because we got in a hurry to edge a part for a body man to hang. Why is it so hard to mix paint once for a job? Waste paint is ok because it will get used eventually right? WRONG. It will sit in huge fire cabinets forever and just wait to be dumped out.

What’s wrong with dumping waste paint into similar color gallon cans and using it “base up” with? If you use every drop of color you mix, you will be well on your way to controlling your expenses.


google splash

We have all been there. A peaceful morning in the shop office is shattered by a single phone call.  The callers question? “When will my car be ready?” Off to the races, receptionist says “Hold on a minute,let me check!” Then we proceed to interrogate everyone in the shop office, head to the body shop and ultimately we end up in the paint shop asking the painter when he is going to get that car done…(which by the way he just got a few minutes ago because of everything else that delayed the car for the last 10 days!)…and then we talk about needing faster paint or a better painter or someone to come fix our “bottleneck” in paint!

Hello! I Tim Briggs and I feel your pain. If this has never played itself out in your shop office, stop reading here and check out another post on our blog at https://collisionedge.wordpress.com

So…why is communication so hard? Its hard because in Body Shops have tough jobs that involve many different people both inside and outside our business.

Common Answer: I’ll just “buy a management system”. This is not a bad idea, but don’t waste your money unless you intend to build your communication process first. These free tools from Google will help you with that…

Years ago I bought a day planner thinking “This will organize me”…I doodled in it, made notes, carried it around and finally threw it in the trash because I found I didn’t have time to be organized because I was too busy! I bought a solution to a problem, but failed to execute the solution because it was someone else’s system and I didn’t take the time to wrap my activities around it.

If you can’t draw your process in crayon on your office wall, don’t expect a piece of software to do any better. (Seriously, don’t draw on your walls with crayon, the guys with white coats will find you and dart you!)

Google Apps offers some serious benefits to shop owners with ZERO cost.

I’m not a paid Google spokes person.  When I find simple solutions for my customers that work I’m going to talk about them! Google has created software versions similar to Word, Excel and Powerpoint. These programs are offered free to registered users. They are not as pretty as other programs, but boy are they powerful. Here is why. We all use excel to create to go lists, process sheets and if we get really fancy financial tracking. These sheets are typically locked away on one computer in the shop or maybe they are even on a shared server. Even still edits are painful because of versioning and other issues. Google sheets looks ordinary, even cheap compared to Excel…with one exception…50 people can be on a single sheet at one time editing cell by cell beside each other LIVE with autosave every time you click out or hit the enter button. So what is the win? You can now create and share your production sheet with your entire organization simultaneously and allow your people to edit the sheet live. Here is an example.

Screen Shot 2015-01-12 at 11.45.42 PM

We created this for a customer to track jobs through various production phases. All of these files are stored in another App called “Google Drive” your password protected Google Drive holds all types of files. You can even create subfolders for say “each customer” and have all of your people upload or view vehicle pics right from their smartphone over your wireless for Free. This stops the question “You got a picture of where these emblems go boss?”

I’ve used this app to set up parts return logs, parts room inventories of “leftover un-returnable items” whatever. Its very easy to work with once its set up.

Google calendars offers the ability to create individual employee calendars as well as shared calendars and email reminders to coordinate all of your staff together. Schedule cars in and out, keep up with booth maintenance items and remember your anniversary or spouse’s birthday all at once, totally secure, with the ability to display multiple calendars on top of each other all driven by your log in. You have total control of who sees what, when and where.

Google communities and Google Groups, offers you the ability to create a closed group that stream post like other social media outlets. Your people can collaborate 24/7 from any device.

Google Hangouts even allows you to video chat with anyone or any group of people anytime or anywhere you wish, even in your own building! Again, Free.

How cheap are big screen TV’s today? Any store you go to will have a 8 Zillion inch “old tech” tv for surprisingly cheap. Go out in your shop, hook up a $200 computer with a browser and your done. Put one in every department…It will pay for itself immediately and it raises the image of our collision centers.

I know many of you have already taken the technology plunge, this was not for you. If you have invested in I.T. make sure you are utilizing the functionality and getting good information out of your system. If you are not sure you are, then why are you paying for it each month? Keep it simple.

I hope this information was helpful to you. Please feel free to comment, subscribe and share our little blog. Find more information about us at http://www.collisionedge.com. We are always available to assist you in setting up your system.

Check out the Collision Edge Facebook page…we have a fun offer going on right now.https://m.facebook.com/story.php?story_fbid=1587549124815410&id=1491825211054469

Have a good day yall!


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!

Green Car

If you want to get paid, get organized!

Increased OEM competition has driven the complexity of our car color palette to a whole new level. New technology has our painters spraying more and more highly specialized colors that contain pigments can be crazy expensive. You may not realize this, but 30% of the materials you buy are toners. Color is one of the main components that makes or breaks a shops material profitability.

Today we are going to briefly explore a few points that will immediately change the game for your shop.

The Average Process:

So here is a scenario I’ve seen many times. A car comes in the shop. We rip it apart, order some parts and work on it typically 1.5 hours a day for 10 or 12 days. (another subject entirely) When parts come in and we send them to paint. Now the paint shop just wants to get the parts back to the bodyshop asap so they hunt up and mix a paint code. (Hopefully its on the part or we are going to waste 30 minutes hunting for the car and the code!) We then mix the main formula and “cut in” the part. Have you ever thought about this process? “Cut in” is the process where the painter edges the parts with sealer, color and clear so it can be hung on the car. The leftover catalyzed sealer and clear ends up in the waste drum and most likely the left over base coat goes into a big cabinet I like to call the “Color Graveyard”.

Lets evaluate the waste here.

1. No paint code supplied. How much time does that cost?

2. We guessed at the color variant to mix (this is good for later when we are tying up a booth matching the paint)

3. We had enough material left in the gun to seal, base and probably clear the entire part but because the body men don’t like to install painted sheet metal we only did the edge or underside.

4. This process guaranteed a second booth cycle. Have you ever calculated what a booth cycle cost your shop in time and money? In a month where you are not using a lot of building heat, take your gas bill and divide it by the number of cars you paint in a month. I’ve seen $30 a car or more and it gets worse if you don’t change booth filters often enough. (a topic for another day)


Take control of the job in the beginning. 

As a part of your disassembly process:

1. Identify the exact color that you need. Put the color chips in your tear down bay if you have to, but get the color picked early. Add a visual communication cue to the paint shop that a color needs to be picked in the body shop. It can be as simple as a colored bulb in the mixing room 3 way switched from the body shop. Whatever you can do to stop walking, make it happen. There is nothing wrong with preparing a spray out card at this point, changing the order of operations can save a lot of headache later.

2. Document the paint code visually wherever you decide, but put it in the same place every time. Many shops use the windshield.

3. Check with your paint manufacturer for their list of codes that contain specialty pigments. Cross reference your code with that list to determine if you need to add a supplement for materials. Use your paint computer to track your material cost on those jobs, print an invoice and you will get paid. Just a suggestion, don’t beat up your insurance guy for nickels. It only makes it tougher to get paid when it’s time to collect legitimate dollars. I got involved with a job that required a $1500.00 material supplement on a a Porsche. The car had color shift pigment in it and the shop owner told me that the major insurance company would never pay it. I called the adjuster myself and explained the situation. A phone call plus an invoice from PPG’s Paint Manager saved this job from being just painting practice. The shop didn’t lose money, in fact the supplement included a legitimate markup for materials.

In the Paint Shop:

1. Try to mix only what you need to do the job

2. Paint entire parts off the car. If they match and they don’t get damaged during assembly you just saved a booth cycle. If it gets damaged or doesn’t match perfect its ok, because its easier to spot or blend adjacent panels than to seal, base and clear entire panels.  Remember each coat of product applied in the booth takes on average 5 minutes. Painting parts up front complete eliminates a lot of booth time even if the car has to go in for a second cycle. Ideally the blend panels go in the booth at the same time as the part and the car never goes in the booth at all. This is a stretch for shops that are still paying techs to produce hours instead of cars, so I don’t talk about it a lot. Either way the goal is to improve booth utilization.

3. Control your inventory. Create a visual system that keeps mixed color only as long as its needed. (I’ve seen some shops come up with some cool ideas on this, we can talk about offline anytime.)

3. When you are sure the paint is not needed anymore, don’t dump it out! If you are not using catalyzed color, combine left over base coat into 6 or 7 gallon containers with with agitator lids installed. This way you can use your Whites, Blacks, Reds, Silvers, etc. as base colors for other jobs. The result, you won’t have to mix as much of the right color for the next job. Try not to ever waste color, its too expensive.

I hope this information was helpful. Please feel free to Comment, Share or Follow out little blog. We can all learn a lot from each other.



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If you want to get paid, get organized.

Lean – I spend a lot of time working with shops and I refuse to use the word. It's the most overused buzzword in our industry today. Its what everyone wants to be, what some claim to be and what I'm convinced no one fully understands! Common Sense. Now there is a concept we can wrap our heads around.

Common Sense tells us that our process is broken when the average shop only produces 1.5 flag hours per day, per job across their entire business. Insurance score cards are great, but the numbers rarely represent your entire business performance unless you only do work for one company. (If you do, I'm scared for you.)

I have sat and watched both shop and insurer try to figure out how to fix their problems…In the end mainly by passing the buck around. 80 percent of every process is waste. Documented evidence suggest that the average RO involves 2.5 miles of walking by the sum total of steps involved in the repair process.

Everyone wants to complain about problems, because that is the easiest way to make ourselves feel better about whats wrong with our industry. How many times does the technician walk in the office with a widget and say “boss i need one of these” Why does he have to waste the shops $2 a minute in gross sales to come and tell the office about a $2 part that was missed on the insurance guesstimate most shops blindly work from? Not beating up the insurance people, no one can write a complete sheet without thorough disassembly. The people fixing the car need to be the ones writing the complete repair plan up front instead of figuring it out as we go! A good discovery process visually organizes and identifies everything that is wrong with a car up front. Its way more than piling parts on shiny new parts carts. If its broken or going to break, find that out up front…down to the clip. We cant afford to leave anything to chance, this is the time to identify it all. We all know at some point the job becomes about getting the car out so we just fix the little stuff for free because after a dozen days the customer by now is screaming “When will my car be ready!”

Consider a $2000.00 RO. If we loose $50 in labor or parts what is the impact? If a shop normally net nets 10% (easily do able) the business made $200.00. Now take out the $50 and you've just given away 25% of the reason your in business!

Our industry is being held back by the mass of shops that are fixing cars for practice because they don’t know any other way. Shops that are organized and do a good job with disassembly write better tickets and have better cycle times (cash flow) than the market. As a result these shops have a slightly higher severity than the rest of the market and are unfairly judged against a market full of shops who are unknowingly giving away their thin margin to massive disorganization.
This whole process is feeding consolidation at an unprecedented rate.

I want this blog to be a place for us to solve problems. I believe there is strength in us helping each other because no one has all the answers. If you and the other big shops in your market are into learning and sharing, subscribe to this blog and lets solve problems together.

I may be the only one that feels like this, I hope you’ll see the point here.

Next topic “What do you get paid for?” First up “Prime and block”

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<img src="https://





If someone were to tell you that you they had documented damage under your home that you needed to pay to have repaired, you would want to see the evidence, right? The proof of the damage in a photo would have match with the money you would pay to fix the problem. So if your repair person came to you with dark inconclusive images of the damage they discovered, how likely are you to pay them to do the work?

Exactly. Yet every day body shops are sending up inconclusive evidence of subjective damage and complaining about the time that is paid on repairs. Now before some of you get upset, I'm not here to side with our insurance community or collision centers. In my time, I've come to realize that both parties have process issues. Agreement on labor time for subjective damage begins with clear, accurate pictures.
I invented "The Dent Viewer" to aide both the body shop and insurance company in agreeing on at least "the extent" of the damage.

The Dent Viewer is a waterproof pvc board with a printed reflective film that grabs the flash and casts light and a grid across the panel. The results are impressive.

Find us at Collision Edge
We are working hard to bring solutions to the Collision Industry. Also check out The Tape Thing

Please keep sending your comments and suggestions for new solutions or products!

Thanks tB


Why do we make things so hard? I’ve been fortunate to have observed technicians working all over North America for years, as a whole they are hardworking people who are driven to make ends meet. Generally paid when work is produced, they churn through as much work as possible daily for a paycheck on Friday.

What is getting in their way? …EVERYTHING!
Have you ever calculated what a minute of a technicians time is worth to your shop in gross sales? Do the math and you’ll see how much disorganization is costing your business. (Could be $2 a minute or more)

People (especially men) are visual, so organize that way. Where is the broom and dustpan? If the techs have to look for it, are they going to use it? “NOT!” The best solutions are the simplest. Put the tools at their “point of use” and store them in a way that makes it easy to visually verify that they are stored properly. We invented the cleaning station above to solve this very problem. The combination of numbers and shapes along with some thought on tool storage solved this problem nicely. The only true success test is if people actually use and maintain the solution presented to them. The 1 square contains the 1 trash can, the 1 detail broom, the 1 push broom, the 1 oil dry bucket, the 1 sweeping compound and the 1 dust pan. Yes this is over simplified, but very effective.

When one fixes a problem permanently the payback is ongoing. If the tech has easy access to the cleaning tools he is 100 times more likely to use them. A clean shop is the first step toward an organized shop. The easier you make to process the more likely you are to reach your goals.


For this and other solutions, contact us on the web at Collision Edge

Lets face it…production painting is hard work. Why make it harder?

My name is Tim Briggs. I have been standing and watching paint shops across North America run for years. During that time I’ve come to realize that getting cars done is all about the order and number of operations we perform. Cars don’t care how many times we touch them or how much time it takes to get them done.
Take the priming process for example. Lets assume we are priming a quarter panel with plastic filler just out of the body shop. How many times will we prep that car? You may have said “1”. I hope that is the case. Here is the reality. Many times we fail to plan the whole process because we are focused on the part of the job at hand. So here is how it goes…1. We check the filler for pinholes (a whole separate topic in itself). 2. We feather back the scratches around the filler. (Hopefully minor if the plastic process is right.) 3. We sand back to where we estimate the primer will end. 4. We soft line mask the primer area. 5. We clean and prime the car. 6. After dry time we unmask the car, block the primer, decide if we need to re prime (production killer) 7. We sand or scuff the rest of the quarter, sail, roof, etc. 8. We mask the car. 9. We catch any prep issues in the booth 10. We paint.

Sound pretty typical? Ok so here is the point. In this example alone, we turned one process into 3. Why do we sand for primer, sand for prep and sand to touch up in the booth. Its the same operation but it starts and stops 3 TIMES!

New process, 1. Check the filler. 2. Prep the entire job booth ready pay attention to detail. 3. Refine your scratches around the filler. 3. Do minimal masking, use short plastic instead of building tents out of 36″ green. Be smart with the way you prime, HVLP or even roll prime if the repair is small. 4. When the job is cured, block the primer and wrap up the car. 5. Paint.

Problems this solves.
1. If you have to go larger than you thought with the primer, there is no tear back from unprepared surface.
2. The sanding operation is done 1 time. (Hopefully from a prep cart so materials are handy and not wasted by throwing stuff on the floor between steps) less sandpaper used is important since 8-10% of a shops purchases are abrasives.
3. The bulk of the prep work is completed before the cure time wait. This gets the car in the booth faster once its dry.
4. Sanding the bulk of the job early reduces the sanding dust later in the process for cleaner paint jobs.
5. The biggest win…higher booth utilization. More cars, same effort, different order of (streamlined) operations.

Please feel free to comment and share as we all learn together.