Title Page
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DEALER
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Quarter
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Conducted on
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Prepared by
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Location
Foundation
Safety
Availability of Safety Records and Items
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▪ Availability of [Records]: Safety Calendar & Dates of Checking, Periodical Safety Meeting, Accident Report & Prevention Plan<br>▪ Availability of [Items]: Fire Extinguisher, First Aid Box, Evacuation Route & Assembly Point
Wearing of Required Protective Gear for each BP Process
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▪ [Spot Cutting] Safety Glasses, Dust Mask, Leather Work Gloves, Safety Shoes, Overall<br>▪ [Panel Cutting] Safety Glasses, Ear Protector, Face Shield, Dust Mask,<br>Leather Work Gloves, Safety Shoes, Overall"<br>▪ [Washer Welding] Safety Glasses, Dust Mask, Cotton Gloves, Safety Shoes, Overall<br>▪ [Spot Welding] Safety Glasses, Face Shield, Dust Mask, Leather Work Gloves, Safety Shoes, Overall<br>▪ [CO2/MIG Welding] Safety Glasses, Welding Mask, Respirator, Welding Gloves, Arm Protector, Fire Proof Apron, Leg Covers, Safety Shoes, Overall<br>▪ [Putty Application] Safety Glasses, Respirator, Solvent-Resistant Gloves, Safety Shoes, Overall<br>▪ [Putty Shaping / Sanding] Safety Glasses, Dust Mask, Cotton Gloves, Safety Shoes, Overall<br>▪ [Paint Application] Safety Glasses, Respirator, Solvent-Resistant Gloves, Safety Shoes, Spray Suit, Sprayer’s Cap
Kaizen Culture
Availability of Hoshin Kanri
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▪ Service Hoshin Kanri posted in Obeya Room (Must have at least 1 KPI for Safety, 4S, Quality, and Employee Satisfaction)
Management of SGA
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▪ Small Group Activity (related to Body & Paint) posted in Obeya Room<br>▪ Must include SGA Organization, KPI, TBP Steps and MOM every SGA Meeting
KPI Management
Employee Satisfaction
Turnover Rate Monitoring of SAs and Technicians
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▪ Record of Service Advisor and Technician Turnover Rate on monthly basis, with target and proper visualization
Evidences to Improve ES based on ESI or Employee’s Voice
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▪ Employee Satisfaction Survey conducted on regular basis<br>▪ Evidence of ES Activities
Annual Health Check-Up for In-House Technicians
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▪ Record of Annual Health Report
Estimation Quality
Monitoring of Service Advisor Certification
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▪ Record of Service Advisor Certification on monthly basis, with target and proper visualization
Monitoring and Management of Estimation Accuracy KPIs
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▪ Record of Estimation Accuracy Rate on monthly basis, with target and proper visualization
Repair Quality
Monitoring of Customer Satisfaction Scores
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▪ Record of Customer Satisfaction Score on regular basis, with target and proper visualization
Monitoring and Management of Repeat Repair (from Customers)
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▪ Record of Repeat Repair from Customers on monthly basis, with target and proper visualization
Management of BP Technicians Proficiency and Certifications
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▪ Record of Technician Certification on monthly basis, with target and proper visualization<br>▪ At least 1 technician can perform repair to all Light, Medium and Heavy Repair based on their skill map
Management of Technician Skill
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▪ Availability of Technician Skill Map<br>▪ Training Schedule to Improve Technician Skill<br>▪ Evidence of Training Conducted (Theory Test Scores, Actual Training Photos)
Monitoring and Management of In-Process Repeat Repair (from Final Inspection)
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▪ Record of In-Process Repeat Repair from Final Inspection on monthly basis, with target and proper visualization
Pre-Production Management
Confirmation of Areas to be Repaired
Customer and Insurance Repair Approval Confirmation
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▪ Check 10 post-estimation Repair Orders. If the damaged area on the vehicle is inspected and the customers' requests confirmed
Vehicle Preparation
Both Repair and Non-Repair Areas are Easy to Identify by Technicians
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▪ Repair area marked clearly with a masking tape or chalk (or any other indicators)
Production Repair Process
All BP Process (Common)
Availability of Body Repair Manual
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▪ Body Repair Manual Available and Accessible to Technicians
Possession / Use of Required Equipment for each BP Repair Process
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▪ [Body Alignment] Frame Aligner, Tracking Gauge, Safety Wire<br>▪ [Panel Replacement] Air Saw, MAG Welder, Spot Weld Cutter<br>▪ [Panel Repair] Washer Welder, Single Action Sander, Straight Edge (30cm and 60cm)<br>▪ [Putty & Primer Surfacer] Dual Action Sander, Infrared Dryer<br>▪ [Final Inspection] Wheel Aligner, Headlamp Optical Axis Adjusting Device
Installation of Seat Covers, Floor Mats and Other Courtesy Items
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▪ Check all vehicles for seat cover and floor mat<br> > For Light Repairs, seat cover is to be installed in driver’s seat.<br> > For Medium and Heavy Repairs, seat cover is to be installed in passenger’s seat and back seat (depending on necessity).
Parts Removal
Presence of Unnecessary Items in the Stall
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▪ No rubbish or tools, equipment, or parts not needed for the current job process in the stall
Panel Replacement
Usage of Body Sealant, Undercoat and Rustproofing Wax on Location specified in Body Repair Manual
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▪ Availability of Body Sealant, Undercoat and Rustproofing Wax<br>▪ Actual checking of usage of materials based on Body Repair Manual
Production Repair Process
Putty Shaping
Performance of Putty Dry Sanding
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▪ Actual checking of performance of putty dry sanding
Colour Matching
Paint Containers 4S
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▪ All paint, solvent and waterborne paint are covered to prevent evaporation
Clean Mixing Scale without Old Paint
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▪ No paint / stain at the stored mixing scale
Topcoating
Paint Booth Walls and Filters 4S Condition
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▪ No dirt clearly attaches to finger when the walls in the paint booth are touched<br>▪ Secondary (roof) intake filters: filter without obvious sagging while the booth is operating<br>▪ Exhaust filters: Optimal pressure is maintained in the booth through periodic filter replacement
Availability of More than 1,000 Lux Lighting in Paint Booth
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▪ Using the lux meter, measure the illumination inside the Paint Booth, should be more than 1000 lux
Spray Gun 4S Condition
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▪ Clean Topcoating spray guns and nozzles without adhered paint
Usage of Paint Strainer
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▪ Availability of Paint Strainer
Availability of Oil-water Separator for Air Compressor
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▪ Availability of Oil-Water Separator<br>▪ Check the functionality of Oil-Water Separator
Polishing
Buffing Pad 4S Condition
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▪ No old compound adhered to the buffing pad
Availability of Final Inspection Check Sheet
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▪ Availability of Final Inspection Check Sheet with Judgment Criteria
Availability of More than 1,000 Lux Lighting in Inspection Bay
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▪ Using the lux meter, measure the illumination inside the Final Inspection Bay, should be more than 1000 lux
Shower Test for Glass and Windshield Repairs
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▪ Availability of Tools and Area for Shower Test<br>▪ Check the Actual Performance of Shower Test
Post-Production Management
Explanation of Repair Work Details
Customer Repair Approval Confirmation
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▪ Check 10 copies of documents that are given to customers at delivery as confirmation of job completion, should have customer’s signature
Customer Feedback
Recording and Sharing of Customer Complaints to Concerned Group
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▪ Scheme for recording customer complaints<br>▪ Details of the complaints are confirmed, and feedback given to workshop staff
