If your auto body repair shop is full and cars are not leaving, you have a production problem. Cars sit idle waiting on a single clip while technicians stop working to pull in new vehicles.
The Core Problem: Broken Sequencing
The real problem is starting repairs without full accuracy of parts.
- Supplement chaos:
- The cost of “bouncing”:
- Dead stalls:
A jammed auto body shop creates the illusion of revenue. If cars are not moving, there is no cash flow.
Two Practical Ways to Improve Right Now
To fix the flow, you must change how vehicles enter the body shop. Take these actions immediately.
1. Enforce the “100% Teardown” Rule
Don’t
- Don’t order parts from visual estimates or photo-based apps.
- Don’t assume hidden parts are undamaged.
Do
- Do a complete and full teardown before final parts ordering.
- Do remove bumpers, liners, and headlamps to confirm damage.
- Do verify every clip, bracket, and fastener before body work.
2. Gatekeep Your Stalls (“Kit-Complete” Policy)
Don’t
- Don’t pull cars into stalls early to “secure” hours.
- Don’t allow incomplete or unverified parts into production stalls.
Do
- Do assign a car to a stall only after all parts are physically verified.
- Do mirror-match every new part to the old part.
- Do keep the keys in the office if the parts are not 100% correct.
One technician finishing one car beats juggling three stalled cars.
Isolate exceptions:
Parts delays will still happen. If they do, remove the car from the production stall immediately and replace it with a kit-complete job (which means every required part for that repair is on hand, verified, and ready before work begins). Track the delayed car separately so it does not block revenue or technician time.
The Bottom Line
Build plans to finish cars without interruption. Expect exceptions. When they happen, remove the car from production and reset the plan.
Plan repairs to completion. Anticipate delays. But stay disciplined.
