When a Simple Scratch Becomes a Complex Repair
How Kaizen helps repair planners catch critical requirements
The Scenario Setup
Customer presents with a scratched front bumper. Looks like a simple sand and paint repair. Here's what your repair planner needs to verify first...
The Damage
Minor scratch on front bumper cover
The Complete Story
Web of connected requirements
This Information is Scattered Across:
Service manuals
Technical bulletins
Position statements
Equipment specifications
The Typical Approach:
"Sand, prime, and paint the scratch. Quick repair, happy customer."
What's Hidden:
- • Optional equipment limits repairability
- • Damage location affects repair vs replace
- • Temperature and material restrictions
- • ADAS calibrations required
Miss one document, miss a critical requirement.
1. Equipment Verification
First question: What sensors does this vehicle have?
Decoded Equipment:
- → Adaptive cruise control
- → Blind spot monitoring
- → Forward collision warning
- → Parking sensors in cover
2. Damage Location Assessment
Finding:
Scratch near lower grille area, within radar projection zone
OEM Position:
No substrate repair in sensor zones
3. Refinish & Post-Repair Requirements
Special Materials:
- • Radar-transparent basecoat required
- • Maximum mil thickness restrictions
- • Metallic color considerations
Calibrations Required:
- • Pre-scan diagnostic
- • Static radar calibration
- • Dynamic cruise calibration
- • Post-scan verification
Documentation Trail
Every requirement linked to OEM procedures, position statements, and technical bulletins - giving planners complete backup for every decision.
Original Thought:
"Minor scratch repair"
Kaizen-Assisted Analysis:
- • Cannot repair - must R&R bumper cover
- • Radar-transparent refinish materials required
- • Pre-scan diagnostic required
- • Multiple post-repair calibrations
- • Post-scan verification
- • Test drive with diagnostic verification
"With Kaizen assisting your repair planner, the complete requirements are identified upfront."
Key Shop Benefits
Better research leads to better repair plans and better outcomes for your shop
Stop Revenue Leakage
Capture missed billable operations and reduce costly supplements that eat into your margins
Cut Front Office Time
Complete repair plans in minutes, not hours. Free up staff for revenue-generating work
Reduce Supplement Rates
Get it right the first time. Fewer supplements mean faster cycle times and happier customers
Document Every Decision
Complete OEM audit trail protects your shop from liability and supports every line item
Ensure Safe Repairs
Never miss critical procedures. Sleep better knowing every repair meets OEM standards
More Hidden Complexity Examples
Every repair has hidden requirements. Here are more common scenarios where Kaizen helps.
Windshield Replacement
Damage:
Cracked windshield requiring replacement
Hidden Requirements:
Rain sensor recalibration
Lane departure warning camera recalibration
Heated windshield wiring verification
Acoustic glass requirements
Adhesive cure time based on temperature
Result: 5+ calibrations, 24hr cure time
Side Mirror Damage
Damage:
Passenger mirror housing cracked
Hidden Requirements:
Blind spot monitoring sensor alignment
Memory mirror reprogramming
Heated mirror element testing
Camera recalibration for surround view
Paint blend into door required
Result: Complex electronics, multi-step calibration
EV Battery Shield Impact
Damage:
Minor impact to battery shield from road debris
Hidden Requirements:
High voltage system deactivation
Certified technician requirement
Special lifting procedures
Battery cooling system inspection
Thermal imaging verification
OEM-only replacement parts
Result: Specialized training, safety protocols critical
This Is Today's Reality
Modern vehicles pack sensors everywhere: radar behind bumpers, cameras in mirrors and windshields, ultrasonic sensors in every panel. Each with repair restrictions. All requiring different calibrations.
Your repair planner needs to verify all of this. Kaizen makes that research faster and more thorough.