TRAINING ANIMATION GUILD GL ONE STOP
POWERPOINT GLASURIT ONE STOP
PROCESS COMPARISON MWP TRADITIONAL VS. GL ONE STOP
GLASURIT ONE STOP EQUIPMENT LIST GL ONE STOP ONION PRINCIPLE
Provides technicians with a thorough explanation of Glasurit One Stop with regard to the concept, set-up, targets, benefits and procedure for working at the Glasurit One Stop.
MOVIE - GLASURIT ONE STOP
CONCEPT
IDEA OF GLASURIT ONE STOP
The concept of Glasurit One Stop involves creating a repair shop within a repair shop. Glasurit One Stop provides a fully equipped work bay for repairing defined small damage with professional, optimized, quick and highly efficient repair processes. If a pending repair meets the criteria, the bodyshop receptionist assigns it to Glasurit One Stop. If not, it is assigned to the standard process. A shortcut from the reception area to Glasurit One Stop (direct and close cooperation) even supports and speeds up the repairs (key-to-key time).
OBJECTIVES OF GLASURIT ONE STOP
Achieving the highest possible margin and competitive offers for the increasing share of small damage repairs. Under real conditions, the repair effort and in turn, the repair costs are reduced. The benefits can be passed on to the customer through reduced invoice amounts. This is particularly in the interest of commissioning parties such as damage management organizations and insurance companies, and can also be attractive for private car owners. Highly efficient repair processes and close cooperation between the reception area and the technician (key to key) significantly reduce repair times.
A further target comprises the expansion of spraying capacities. Compared to a new spray booth, Glasurit One Stop achieves this goal with lower investments.
BENEFITS OF GLASURIT ONE STOP
Glasurit One Stop provides an attractive working environment for productive employees. It is a fully equipped, tidy, bright and ventilated space.
Example of Glasurit One Stop
All of the necessary tools, equipment and materials are available and accessible on the spot, which is also more convenient for the technician.
The technician takes responsibility for the entire repair process. This boosts motivation and dedication to the job and enhances results.
The entire repair is carried out at a single location by a single employee. In general, all parts are repaired on the car without any assembly efforts. Furthermore, there are no additional interfaces that cause waiting times and effort required to move the car. This means that the car is repaired in a continuous process with superior productivity. (Please refer to process chart in figures 2 and 3)
In the end, the repair effort and time (key to key) are significantly reduced. The repair times are reduced to a degree that will lower your rental car costs.
This clearly improves the margin situation and competitiveness.
DAMAGE PORTFOLIO
To perform repairs efficiently at Glasurit One Stop, the repairs have to meet certain criteria.
KNOCK-OUT CRITERIA:
-
More than 2-3 parts*
- Horizontal parts
- Wet on wet
- Single, separate parts
- Multi-layer systems (3-stage and multi-stage systems)
- Large vans
- Welding /grinding (sparks in filter)
- Technical and structural damage
- Repair requiring more than eight hours
- Mat clear coats
Only panels that stay on the car.
*Depending on the panel sizes and available drying equipment
NO MORE THAN 2-3 PARTS
When painting more than two to three parts, the drying equipment has to be moved several times, which takes too much time. Such jobs can be performed more quickly in the spray booth.
NO HORIZONTAL PARTS
The ventilation in Glasurit One Stop is not as linear as it is in a spray booth. In Glasurit One Stop there is a higher risk of dust pollution when spraypainting horizontally. In addition, in many cases, the drying equipment in Glasurit One Stop does not completely
NO WET-ON-WET APPLICATION
The longer flash off times for wet-on-wet jobs mean they can be realized more quickly in a spray booth.
NO SINGLE, SEPARATE PARTS
Single, separate parts are easy to place in a spray booth. On top of this, it is possible to combine this type of job with a repair job for a different car. Drying can also be a challenge at Glasurit One Stop e.g. bumpers and parts that need to be painted both inside and outside.
NO MULTI-LAYER SYSTEMS (3-STAGE AND MULTI-STAGE SYSTEMS)
Such systems require more and longer flash off times. These jobs should preferably be performed in a spray booth with the option of increasing the temperature.
NO LARGE VANS
The size of the panels is bigger and it is necessary to move the drying equipment several times.
NO WELDING /GRINDING (SPARKS IN FILTER)
These operations cause sparks to fly, which could make the paint stop filters catch fire.
NO TECHNICAL OR STRUCTURAL DAMAGE
Glasurit One Stop does not offer all of the tools required for this kind of job. A great deal of disassembling of parts and welding and grinding is necessary to repair this kind of damage.
HOW TO RUN GLASURIT ONE STOP
Shop-in shop-principle. Only repairs enter the shop that can be repaired efficiently. The estimator/receptionist only schedules jobs for Glasurit One Stop that can be repaired efficiently there. The steering is conducted based on the previously described damage portfolio and the application of the knock-out criteria. Direct communication and ongoing exchange between the receptionist and the technician at Glasurit One Stop is a prerequisite. Customer demands and information about what to repair and how to undertake the repair have to be exchanged and clarified. Only repairs are performed that the customer has requested and for which the customer has approved payment. This means that the receptionist and the technician must have a good cooperation.
A dedicated technician works at Glasurit One Stop and runs the repair from start to end. This requires a certain level of flexibility and different skills:
- Preparation skills (masking, body filler application, spray application, sanding)
- Topcoat application (incl. blend-in techniques, Spot Repair)
And no less important
- Flexibility
- Creativity on the job
SETUP OF GLASURIT ONE STOP
The setup best suited for Glasurit One Stop is defined based on a workflow analysis, including an anticipated damage portfolio and the current layout in the bodyshop. One of the three sample setups can serve as a starting point. They can then be adapted or modified to suit the individual situation of the bodyshop.
A number of variations and combinations are possible.
GLASURIT ONE STOP EXAMPLE 1
Well-suited for Spot Repairs
Well-suited for Spot Repairs
- Only air extraction. No extra clean air coming in.
- Basic equipment
- Ceiling and front open
- Well-suited for Spot Repair
- Smooth floor to accommodate wheels of drying equipment, trolleys, etc.
- No central dust extraction
- No Air and Electricity socket
- No extra cabinets for tools and equipment
- No lift
GLASURIT ONE STOP EXAMPLE 2
Well-suited for Spot Repair and up to one panel repair
Well-suited for Spot Repair and up to one panel repair
- Diagonal air movement
- In-coming air filtered out of the bodyshop
- Well-equipped
- Well-suited for Spot Repair partial repairs up to one vertical panel
- Mobile drying system
- Smooth floor to accommodate wheels of drying equipment, trolleys, etc.
- Central dust extraction
- Central energy box
- Extra cabinets for tools and equipment
- Lift on the floor
GLASURIT ONE STOP EXAMPLE 3
Well-suited for Spot Repair and up to two panel repairs
Well-suited for Spot Repair and up to two panel repairs
- Vertical air movement
- In-coming air filtered from outside
- Fully equipped
- Well-suited for cosmetic repair of up to 2-3 vertical panels
- Drying system on rail
- Grate floor. Not suited for trolleys but always clean.
- Central dust extraction
- Central energy box
- Extra cabinets for tools and equipment
- Lift integrated in the floor
GLASURIT ONE STOP PROCESS
At Glasurit One Stop, the Spot Repair and Fast Repair techniques are applied with the help of IR drying technologies and UV-primer filler. Please consult the relevant Training Modules:
- UV PRIMER FILLER
- SPOT REPAIR PROCESS WITH 90 LINE
- SPOT REPAIR PROCESS WITH 100 LINE
- FAST REPAIR
Some specifics to be considered for Glasurit One Stop are presented below.
HOW TO PLACE THE CAR
The placement of the car in Glasurit One Stop is an important factor for the efficiency of the repair. Place the damaged area as close as possible to the air extraction. Placement in this area
- speeds up the flash off times
- reduces pollution due to dust particles
Furthermore, use the car lift for the convenience of the technician and to avoid a possible swirl-up of dust from the floor.
Car improperly placed on lift Car properly placed on lift
If the car is to be brought into Glasurit One Stop from a cold environment (in winter) it is advisable to heat the repair area before starting with the repair. A special drying program can be saved in the IR-drying system.
MASKING/DISASSEMBLY
All required masking materials, including tools, are available in Glasurit One Stop in practical dispensers and at locations conducive to an ergonomic work process.
As general rule, at Glasurit One Stop the panels are repaired on the car. Mounted parts such as blinkers or door handles may be disassembled to achieve repair results that meet the customer's requirements. In other cases, use creative masking techniques that are less time-consuming.
Use character lines on the panel to reduce the repair area.
Mask the car only once. Cover the entire car with masking foil to protect it from sanding dust and spray dust. Afterwards, slice out the damaged area and mask the surrounding area with masking paper and masking tape. Special masking materials such as masking foam and sensor covers may speed up the process.
Use the onion principle for filler masking. The onion principle means that you start with a large layer and follow it with a smaller layer.
ONION PRINCIPLE FOR THE MASKING PROCESS
Onion principle for the masking process
CLEANING PROCESS
We recommend that you do not put the car through a car wash prior to refinishing.
Limit cleaning to the repair area. The cleaning agents listed in the table below are most effective for this purpose.
1st step: Pre- cleaning with solventborne cleaner.
2nd step: Post- cleaning with waterborne cleaner.
Fill the cleaning agent into a pump spray bottle and spray it on the repair surface.
Then wipe the area with a clean cloth.
Pump spray bottle
PREPARATION
Keep the repair area small. Otherwise, you can easily extend the repair to other parts or you will not have enough space left to refinish needed fade-out zones.
To achieve the goal, use sanding equipment for smaller areas (small sanding blocks or an orbital sander with smaller diameter, 75 to 80 mm diameter). In addition, start with the sanding grid needed for the repair.
Small sanding block 
Orbital sander 75-80 mm diameter
Use character lines on the panel to reduce the repair size.
IR USAGE
At Glasurit One Stop it is important to use IR drying programs with lower intensity. This is because all of the work is carried out on the fully equipped car. If the intensity is too high, there is a risk of burning different sensitive substrates such as mirror caps and plastics.
Often a universal program with lower temperatures is available that can be used for all layers.
IRT HYPERION: GLASURIT ONE STOP
Example of drying programs for the Glasurit One Stop: It features a special pre-heat program for warming up repair areas and a universal drying program with lower max. temperature to protect temperature sensitive substrates from damage.
|
ALWAYS ALLOW 2-4 MIN FLASH OFF BEFORE USING IRT |
TIME | RAISE | MAX |
| 1) PRE-HEAT |
2 min. 0 min. |
20° min 0° min |
20° 0° |
| 2) GLASURIT ONE STOP |
6 min 9 min |
15° min 15° min |
65° 65° |
|
NORMAL FILM BUILD = DRY TABLE HIGHER FILM BUILD = LONGER FLASH OFF TIMES |
FINISHING
Apply standard finishing processes to remove dust particles and to polish fade-out zones. The effort required for finishing may be reduced by following the recommended application tips.
Ensure that the products are sufficiently cured and cooled before you start the finishing activities. These measures ensure good repair results and prevent the need to take corrective measures.
