Shop Floor Layout

Shop Floor Layout

Sample Floor Layout in a Small Collision Facility

Even smaller shops can take advantage of good planning and modern equipment. In this example, the shop has the equipment and capabilities of performing small, light repairs to big, heavy repairs. No matter which stall or area a car is placed, it is never blocking another vehicle or stopping workflow. Any vehicle can be accessed or moved at any time. This shop also uses a speed lane system for small repairs (one to four panels). High-production shops using this model can process 12 to 15 cars per day.

  1. Estimating and teardown bay: Separated from the main shop to not impede production
  2. Detail bay: Fully isolated from the main shop to prevent chemical contamination in the work area
  3. Drive lane: Open lane, which allows parts, carts and vehicles to be moved to any stall at any time
  4. Frame rack and hoist stall: Positioned directly in front of overhead doors, so any non-drivable vehicle can be towed directly into the stall
  5. Mechanical room: Fully framed off, isolated room, which keeps all electrical and mechanical areas free of dust and debris
  6. Side-load system: Wheels are placed on a track and dolly system, enabling vehicles to be fully masked before being loaded into paint areas; this eliminates downtime traditionally spent masking cars inside the paint booth
  7. Prep stations with a speed lane: Any vehicle needing primer is loaded into the right-hand bay of the prep station. The left side is used for speed lane repairs, where any vehicle with four panels or less is painted in the prep station.
  8. Staging area: Vehicles are fully sanded and masked for painting
  9. Paint booth: A premium downdraft paint booth ensures higher-quality paint jobs and maximizes efficiency
  10. Paint mix room: Centrally located between the paint booth and the speed lane prep with doors opened to either side, minimizing steps from one to the other

Sample Floor Layout in a Large Collision Facility

The following design offers most of the features we recommend for a large collision facility layout. This layout shows only the production area of the shop — all estimating, tear down and detailing is performed in another section of the building. Shops with this model can process 18 to 25 cars per day.

  1. Drive lane: Open lane, allowing parts, carts and vehicles to be moved to any stall at any time
  2. Hoist stall: Positioned directly in line with the drive lane, so any non-drivable vehicle can be towed directly into the stall
  3. Quick repair area: Vehicles which need very small repairs, typically only one to three panels, are worked on in this area. The vehicles are open to either drive lane, so they can be positioned in the first booth that comes available
  4. Detail area: Located as far away from the paint area as possible to prevent chemical contamination in the paint area
  5. Heavy-hit stalls: Grouped together so they can share specialty tools, such as welders and measuring equipment
  6. Medium-hit stalls: Vehicles with multiple panel damage and light structural damage
  7. Paint area
    1. A. Paint booth: A premium downdraft paint booth ensures higher-quality paint jobs and maximizes efficiency
    2. B. Hybrid prep station: Any vehicle needing primer is primed here, then side-loaded to 7A for painting; this area also doubles as an overflow for the speed lane
    3. C. Speed lane: Any vehicle with four panels or less is painted in the prep station
  8. Side-load system: Wheels are placed on a track and dolly system, enabling vehicles to be fully masked before being loaded into paint areas; this eliminates downtime
  9. Staging area: Vehicles are fully sanded and masked for painting
  10. Paint mix room: Centrally located between both speed lanes and the paint booth with doors opened to either side, minimizing steps from one to the other

 

Autobody Shop