2009 Bodyshop Planning INT
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Transcript of 2009 Bodyshop Planning INT
Successfully designinga new bodyshop.
Basic management know-how.
Spies Hecker – simply closer.
Building a new bodyshop or converting an
existing one demands a considerable input
of capital. It is also a risky business as
it always means a long-term commitment.
The design phase therefore requires close
examination and a full understanding of
what is involved and must never be under-
taken in a hurry.
This brochure focuses on the design of a
new car paintshop or combined bodyshop/
paintshop. When extending or converting
existing premises, every situation will
always be different, so general advice is of
little use. Nevertheless, you may find useful
suggestions in this brochure.
Commercial vehicle paintshops and other
large-scale painting installations usually
have specific requirements of their own that
necessitate consultation with experts from
the outset.
Selecting the site.
Choosing the right site is the most impor-
tant decision after opting to build a new
paintshop an/or bodyshop in the first
place.
1. Criteria – market analysis:• Size of catchment area
• Size of population
• Vehicle density
• Registration figures
• Maintenance and repair needs per vehicle
• Existing competitors and their services
• Local market trends
2.Criteria – site analysis:• Traffic access: Can the customer reach the workshop quickly and conveniently?
Car customers are willing to accept a 15 to 30-minute trip for servicing, commercial vehicle customers 1 hour.
How well is the site served with motorways, major roads and public transport?
• Visibility: Is the workshop identifiable from all unobstructed directions?
• Traffic flow: traffic congestion, commuter route?
• Neighbourhood /surroundings:Where is the workshop located? Proximity to residential areas, dealerships /
dealership parks, commercial parks or crowd-pullers like supermarkets or home improvement /DIY stores, etc.
• Development plan /building obligations:What building regulations affect the site? Buildings permitted,
type of construction, building height, façade design, possible vehicle access, site boundaries, etc.
• Proximity to places of residence /employment
• Climatic conditions: prevailing wind direction
(so that annoyance to neighbours can be ruled out from the outset)
• Ground: geology, load-bearing capacity, water table, contamination from previous uses
• Environmental obligations: landscaping, surface water, plans to modify the site and compensatory measures, etc.
• Laws, rules and regulations: at local, regional and national levels
• The factor of time: Demolition necessary, site ready for immediate development?
• Costs: site, building, tax rate, ancillary costs or requirements, environment, etc.
3.Criteria – business strategy:• Defining the customer profile:
– Private customers
– Dealerships
– Industrial enterprises (contracted coating work)
– Insurers
• Future use strategy:
– Repairs, refinish, car trade, parts sales
– Business activities: cars, trucks, industrial coatings
– Concentration on a single marque, franchise, independent workshop
• Deciding on the growth target: Increasing share of the market, possibility of extending the workshop?
• Future business activity: On what scale can the services be extended to other areas that promise
high yield in the future, such as bodywork, parts sales, industrial coating, etc.?
• Use of equipment and technology in future workshop: E.g. VOC legislation demands the use of
advanced spray booth, application and paint technologies.
• Co-investors: Are there companies that will help to finance construction (e.g. workshop plus office premises)?
How to plan a new bodyshop.
The following steps are recommended:
1. Noting down your own ideas with drawings.
2. Consulting a Spies Hecker planning specialist.
3. Finalising the plans with the architect,
equipment manufacturer, public authorities, etc.
The first step in deciding on the site is to
analyse the location. The future bodyshop
should, naturally, have as many customers
as possible with easy access in its vicinity.
The quality of the site is crucial to the suc-
cess or failure of the business as correc-
tion is not usually possible at a later date.
Of course, the choice of site is closely tied
to the type of shop and the envisaged
business strategy.
Market analysis.
Ascertaining the existing market potential
is necessary to determine the size of the
business and the volume of sales in the
coming years. The market analysis entails a
sensible combination of local data, statis-
tics, empirical values and forecast trends.
The market should be analysed whenever
medium-size to large workshops are being
planned.
Starting points foroptimum design.
2.Desired refinish facility asa starting point.
In this case, the calculation is performed the
other way around. Starting with the painting
area (number of spray booths), it is possible
to calculate the number of required pre-
paration stations and hence the possible
throughput of vehicles.
This procedure is mainly applied by smaller
businesses that have a clear idea of their
future business size.
There are two starting points for optimum
bodyshop design.
1. Market analysis asa starting point.
Businesses that conduct a market analysis
beforehand refer to the anticipated poten-
tial of vehicles requiring refinishing and
design the bodyshop accordingly.
The results of the market analysis will help:
1. Determine vehicle throughput and
sales targets
2. Define the painting area
(number of spray booths, etc.)
3. Define the number of staff required
• Number of workstations in the
panel repair area
• Number of workstations in the
preparation area
• Number of workstations in the
paintshop
• Number of workstations in the
finish area
• Number of workstations in
administration
By drawing up a flow chart, you organise
trouble-free vehicle throughput from order
acceptance through to delivery.
Workflow.
Vehicle reception
Panel repair
Preparation
Painting
Finish
Valeting
Here is an example of a workflow plan
for paintshop and combined bodyshop/
paintshop.
Determining the amount of requiredfloorspace in the paintshop.
The minimum size of the paintshop depends
on the expected sales, painting capacity,
number of employees, and the booth facility.
The key variables given in the following table
are rough values derived from experience.
These may vary according to the operating
procedure or business strategy.
The details of throughput / capacity assume
the application of Spies Hecker products and
adherence to the prescribed flash-off and
drying instructions and the surface area
processed in an average medium-size job
(3-4 parts/job).
Size of workstation.
There are, of course, empirical values for the
optimum size of the individual workstations.
The most important ones are contained in
the following table.
Businesssize
Small 5-6 units 3-4 1 2-3 1 combi booth 300-400 m2
Small 1 combi boothto medium 11-13 units 6-8 2-4 5-7 & 500-700 m2
1 separate oven
Medium 2 combi boothsto large 16-19 units 9-12 3-6 8-11 & 700-900 m2
1 separate oven
2 combi boothsLarge 22-26 units 12-16 4-8 11-15 & 1,000-1,200 m2
2 separate ovens
Maximumthroughput capacity(per working day= 7.5 hours)*1
Number ofworkstationsin preparationzone
Number ofemployees(excluding officeand admin.)*2
Spray boothFloor space(excluding officeand restrooms)
Rules of thumb:
Preparation:
2 workstations per productive employee,
3-4 preparation areas per booth unit
Finish zone:
should be equal to 25-50% of
the preparation area
*1 The average rate of capacity utilisation is 70-80% (annually).
*2 For staff holidays, further training and sick leave, 20-30% more staff has to be assumed, depending on business size and structure.This means 2-3 extra staff per 10 employees.
Number ofvehiclestations infinish zone
Workstation Width x length (average)
Panel repair 3.5-4.0 x 7.0 mDepends on equipment selected
Body parts store with rack system Depends on size of business
Straightening and measuring station 5.0 x 7.0 m (minimum size)
Paintshop Width x length x height (average)
Spray booth Standard 4.0 x 7.0 x 3.0 / 3.5 m
Enlarged 4.0 / 4.5 x 8.0 x 3.0 / 3.5 m
Oven 1 vehicle station 3.0 x 7.0 / 8.0 x 3.0 m
2 vehicle stations 5.0 x 7.0 / 8.0 x 3.0 m
Equipment room Depends on equipment
Preparation area 3.5 x 6.0 m
Finish area 3.5 x 6.0 m
Mixing room Depends on the number of mixing machines /units to be accommodated
Paint preparation room Depends on the equipment / units to be accommodated
Paint store Depends on the substances being stored and(complying with regulations on on the legislation in the country in questioncombustible liquids)
Waste collection station Depends on the equipment / collection boxesto be accommodated
Customer zone, offices, staff rooms Depends on the client’s wishes
The vehicles undergoing refinishing should
pass through the paintshop without having
to manoeuvre or queue outside the spray
booth.
The room sequence chart, defining the
arrangement of the rooms and the necessary
connections, is therefore indispensable to
the design of a new paintshop.
Individual assistance for your company.
To this end, you can access special advice
from Spies Hecker. Under Colors Unlimited
International, Spies Hecker offers further
modules that support you in the design of your
own customised bodyshop. Should you be
interested, contact your Spies Hecker adviser.
These examples give you a rough impression
of how designs can vary. As each bodyshop
design is based on a number of different
conditions and priorities, it must also be
tailored to the special needs of the business.
Examples of floor plans.
• It is advisable to drive the dried vehicle
out of the rear of the oven so that it can
be reassembled in the immediately
adjacent finish area (separation of dirty
from clean areas).
• If possible, a permanent place should
be allocated for spot repairs so that not
all refinishing work has to take place in
the booth. At the same time, such spot
repair zones make it possible to carry out
small jobs faster.
Like the finish area, the spot repair zone
should be located in a clean area. It should
also be possible to drive cars in and out
quickly.
• The staff rooms should be located close
to the workshop area.
• There should be sufficient parking and
storage space outside the building.
Illustrated on the following pages are three
bodyshop plans. They differ in size because
of their different booth configurations.
• Bodyshop with one combi booth
• Bodyshop with one combi booth and
one separate oven
• Bodyshop with two combi booths and
two separate ovens
During planning, the following points
should be borne in mind:
• As little unproductive space as possible,
i.e. standing space; as little space for
manoeuvring as possible.
• The estimating area should be close to
the offices.
• Preparation areas – ideally, there should
be a vehicle lane in the middle with the
workstations on the left and right of it,
each workstation should be equipped
so that the vehicle does not have to be
moved again until it is painted.
Detailed floor plan.
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3. Bodyshop with two combi booths and two separate ovens.
28 m
Officereception,7 x 7.5 m
46 m
Restrooms
3.5 ton w/f lift
Cu
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Mix
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room
Finish
Sto
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1.5
x 3
.5 m
Panel repair
Equi
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Paintingpreparation
3.5 m 3.5 m
2. Bodyshop with one combi booth and one separate oven.
1. Bodyshop with one combi booth.
4 m
Equipment roomFinish
Foreman’s office,6.5 x 3.5 m
Combi booth
PreparationMixing room
Store
Restrooms,7.2 x 2.5 m
14 m
25 m
4 m
Finish
Rec
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.5 x
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20 m
30 m
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3.5
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Spies Hecker GmbHHorbeller Strasse 1750858 Köln, GermanyTel.: +49 2234 6019-3630Fax: +49 2234 6019-3880www.spieshecker.com