Repair Planning Comes of Age — and Brings a Wave of Change in its Wake 

The evolution from traditional estimating to comprehensive repair planning has been underway for over 15 years, and it’s fundamentally transforming the collision repair industry. Many repair shops recognized the necessity for this shift early on and have adapted their business models to accommodate the complexities of modern vehicles. For numerous professionals in the field, repair planning and blueprinting processes are already integral components of their operations. 

This transformation began with the adoption of vehicle blueprinting, a practice in which collision repair centers used one or two writers to handle files from start to finish for a group of collision repair technicians. But as vehicles became increasingly complex, repair centers realized the importance of expanding their office staff to thoroughly assess damage up front. This led to the development and implementation of standard operating procedures focused on vehicle teardown, damage identification, and meticulous documentation. 

Navigating the cultural shift

For many repair centers, the significant cultural shift that accompanied these changes posed one of the most substantial challenges. As in any industry, altering established practices was met with resistance. However, the majority of the industry has successfully navigated this transition, resulting in a new operational model in which repair centers maintain a closer ratio of office to production staff that often approaches or exceeds 1:1. These changes have enabled repair centers to excel in repair planning, uncovering hidden damages early in the process. 

As repair planning has evolved, what was once a straightforward teardown to identify hidden damage, necessary clips, and mirror-matching parts has transformed into a comprehensive examination of shop processes. Successful shop processes now begin with the initial identification of damage and a thorough review of OEM repair procedures. Over the years, the industry has expanded to include pre-measuring vehicles, electrical diagnostics, and calibrations as integral components of repair planning. 

The importance of materials

One aspect of repair that is particularly important is the use of proper materials as specified by manufacturers. Companies like 3M collaborate directly with OEMs to develop adhesives that meet the stringent requirements for post-repair vehicle performance. These materials cannot be substituted with alternatives the manufacturer hasn’t endorsed, and repair centers must have them readily available. Without proper repair planning, delays in acquiring these materials can be as detrimental as any part delay. Products that once counted merely as shop supplies have become essential components required for vehicle repair. 

How ADAS factors into refinishing

Changes in the repair planning process have been extended to the paint department as well. For years, painters engaged in repair planning up front, starting with identifying paint codes - with some repair centers premixing colors to identify single-use toners. Repair planning in paint has further evolved alongside the rise of advanced driver assistance systems, as repair centers and painters have become increasingly aware of what can and cannot be repaired and refinished. Many OEMs have issued position statements indicating that bumper covers on vehicles equipped with ADAS can undergo only cosmetic repairs. These statements can make it challenging to properly repair a bumper cover while ensuring the ADAS systems function correctly. 

Painters must also identify other critical factors. In some instances, radar-safe formulas cannot be tinted, potentially leading to improper color matching and necessitating blending into adjacent panels. Some vehicles prohibit blending within specific sections of the bumper cover, and painters must be aware of this up front to avoid rework within the repair center. A notable example comes from Nissan, which requires approved paint lines for bumper covers. If a repair center does not carry the specified paint line, it must order approved paint from distribution to refinish the vehicle and calibrate it to its original crashworthiness. 

Shift to repair planning is a critical pivot in the industry

The ongoing shift from estimating to repair planning continues to evolve and drive OEM-approved repairs. This process is instrumental in educating insurance companies and the entire industry about the significance of repair planning. A well-executed repair plan contributes to creating a subrogation-proof file for insurance companies and results in superior repairs for consumers. The industry’s cultural shift has also empowered technicians to take pride in executing proper repairs while establishing new standards for vehicle restoration. 

The transition from estimating to repair planning represents a critical pivot in the collision repair industry. It underscores the importance of meticulous planning, adherence to OEM guidelines, and the use of approved materials. As the industry continues to evolve, repair centers will be better equipped to deliver high-quality repairs, ensuring vehicles are restored to their original condition and enhancing customer satisfaction and loyalty.