Archive for January, 2015

5 Steps to Busting Bottlenecks

Tuesday, January 13th, 2015

This IMPACT Collision Solutions TIP was written by industry expert DAVID LUEHR.

The Five Steps to Busting Bottlenecks.

Most of you have heard about Lean thinking, Lean manufacturing, or simply Lean. But have you heard about the Theory of Constraints? I know some of you have, but as with Lean, the concept may still be a little unclear to you. Although there are both commonalities and differences between Lean and TOC, I believe collision repairers can benefit from understanding and applying both ways of thinking to their repair businesses.

The word Lean was originally used in James Womack’s 1990 book entitled “The Machine that Changed the World.” His book described the dominance of Toyota and the effectiveness of the Toyota Production System. The goal of lean is to remove unnecessary waste from the value steam. Waste could be described as waiting, unnecessary activities, excess movement, excess inventory to name a few. This lean thinking has revolutionized many industries and still does today. Unfortunately, many collision repairers have made attempts to implement such thinking and systems in their shops with limited results at best. While there are many benefits to creating a lean culture and adopting lean methods and using its tools, few shops have figured out how to fully realize their profit potential unless they have also become familiar with the Theory of Constraints.

The Theory of Constraints was first introduced by Israeli physicist Eliyahu M. Goldratt in his 1984 book “The Goal.” This book has had a profound effect on my life since first reading it in the early nineties. I would highly encourage all of you to read this book too! Although there is a little more to it, it is basically about bottleneck management and adopting an understanding that there is always at least one resource (department, machine, person) in your business that is a limiting factor to your throughput ability (making money). This limiting factor is called a bottleneck or “constraint.” Like the neck of a bottle, there is a restriction on how much work can flow through it.

Theory of Constraints uses a systematic approach to busting bottlenecks and increasing your shop’s ability to make money.

Step 1: Identify the constraint. This step is pretty easy to identify because it is usually the resource that has the most inventory (cars) stacked in front of it waiting to be worked on. In many shops the constraint is the paint booth (or poor use of the booth), but in many advanced shops that are performing thorough disassembly and blueprinting, the hold-ups are commonly there. Also it is not uncommon for the biggest constraint to be the front office itself.

Step 2: Exploit the constraint. Exploiting the constraint involves making sure we are using the resource as effectively as possible. If the paint booth is the constraint, are you effectively using it during all the work hours in the day, or does it sit empty until 10am?

Step 3: Subordinate to the constraint. When you subordinate to the constraint, everything falls beneath it. You effectively make sure it does not get interrupted or delayed in any way. Again, if your booth is a constraint, you would want to make sure the quality of the prep work was sufficient and your colors were tinted so no additional delays would occur while the vehicle was in the booth. You should also make sure the booth is well maintained to avoid mechanical failures. Blueprint/Damage analysis departments are often a constraint, yet I am amazed at how often the people performing these operations are routinely interrupted to deal with other issues. You need to “protect” your constraint at all costs! Subordinating means making sure that everyone in the shop clearly understands that nothing comes before the constraint, it takes top priority.

Step 4: Elevate the constraint. This step simply means to make the department, or resource bigger. It could mean you need to add a tech, extend hours, buy a frame rack, or perhaps apply some Lean tools and techniques to increase the constraint’s capacity. Again, the size of your constraint dictates the size of your potential throughput!

Step 5: Repeat steps 1-4. Much like Lean, TOC is a continuous improvement process. Once one constraint is identified and resolved, begin at Step 1 again. Repeat not only the process, but also the procedures that got you through.

During my training at the AGI Goldratt Institute, I was told by a very wise TOC Instructor that the smart practitioners eventually decide where they want the constraint to be, and then they build their business around it. This keeps you from spending all your time chasing bottlenecks around your shop.

I am going to leave you with an eye-opening figure. Every dollar lost in a constraint resource due to mechanical breakdown, quality defect, or any other reason is a dollar lost forever! If you run a shop producing $100,000 a month and your constraint shuts down, it costs you roughly $600.00 an hour! You may want to protect your constraint!

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PRODUCT SPOTLIGHT – DAP Smart Bond Adhesives

Monday, January 12th, 2015

As a business owner who is looking at an ever increasing competitive market, you’re evaluating ways to go green and save time and money. You sit at your laptop, boot it up, and begin searching for adhesive products that will help production time and increase workplace moral. You then come across a product with the following features and benefits:


Naturally, you click on the link to review and study the product only to find that it is the perfect investment to help you achieve your productivity objective.

These are the features and benefits offered in the new smart bond adhesive product line. This new line of products have gone above and beyond your normal bonding adhesive agents and has addressed a key component within business bottom lines.

Subfloor, Heavy Duty, and Landscaping are the three new smart bonding adhesives that DAP has released to the market. These products are a major jump in the world of construction bonding adhesives and will be able to help companies save money, time, and energy.

Companies who buy in mass that are tired of spending money on Tubes, and are tired of the time invested in the process to use the equipment are primary targets for this product line. Below is the listed features and benefits of the DAPS product lines:

Subfloor adhesive

DAP® SMARTBOND® high-strength polyurethane adhesive brings heavy-duty strength and reliability to your job. This unique dynamic formula applies as a foam and then transforms to an adhesive gel for fast cure and a high strength permanent bond to dimensional and treated lumber, plywood, OSB and high performance enhanced OSB.

The product exceeds ASTM D-3498 shear strength tests for wet, frozen and dry lumber. DAP® SMARTBOND® can be applied up to 25% FASTER than a 10 oz. cartridge adhesive. It only takes about 20 SECONDS to start using a new can of DAP® SMARTBOND® compared to MORE THAN TWO MINUTES to change a traditional 28 oz. cartridge adhesive. You’ll experience less gunning, less change-out, and less fatigue with DAP® SMARTBOND®.

Just one 20 oz. can of DAP® SMARTBOND® Subfloor adhesive delivers about 400 linear feet at 1/2” bead compared to one 28 oz. cartridge of construction adhesive which only yields 38 linear feet at the recommended 3/8” bead. With 8X the adhesive coverage in one can, that’s less weight to carry around on the job & less to truck from site to site.

DAP® SMARTBOND® High Yield Subfloor Adhesive is available in two different job-site solutions designed with the professional in mind. The SMARTBOND® Pro-Grade Applicator Gun offers faster application, precise bead control and maximum adhesive yield. Use our DAP® SMARTBOND® Cleaner to keep the gun free of excess adhesive. The easy-to-use SMARTBOND® Straw-Grade aerosol canister offers all-in-one convenience and a tab to seal the straw between uses.

Heavy-duty adhesive

DAP® SMARTBOND® is a high-strength polyurethane adhesive that brings heavy-duty strength and reliability to your job. Its unique dynamic formula applies as a foam and then transforms to an adhesive gel. SMARTBOND® cures fast and develops an incredibly strong, durable, and permanent bond to wood, plywood, drywall, foam, concrete, brick, stone, steel, aluminum, PVC, fiberglass, painted surfaces and composite materials.

DAP® SMARTBOND® can be applied up to 25% FASTER than a 10 oz. cartridge adhesive. It only takes about 20 SECONDS to start using a new can of SMARTBOND® compared to MORE THAN TWO MINUTES to change a traditional 10 oz. cartridge adhesive. SMARTBOND® gets your job done faster, letting you move on to the next job quicker.

Just one 12 oz can of DAP® SMARTBOND® Heavy Duty adhesive delivers about 240 linear feet at 1/2” bead compared to one 10 oz cartridge of construction adhesive which only yields 30 linear feet at a 1/4” bead. With 8X the adhesive coverage in one can, that’s less weight to carry around on the job & less to truck from site to site.

Landscaping adhesive

DAP® SMARTBOND® applies as a foam and then transforms to an adhesive gel. SMARTBOND® cures fast and develops an incredibly strong, permanent bond to all common hardscape materials, including landscape blocks, brick, natural and synthetic stone, wood, treated wood, and concrete. SMARTBOND® Landscape adhesive is the perfect choice for installing retaining or garden walls and around water features to achieve permanent structural strength and reliability.

DAP® SMARTBOND® can be applied up to 25% FASTER than a 10 oz. cartridge adhesive. It only takes about 20 SECONDS to start using a new can of SMARTBOND® compared to MORE THAN TWO MINUTES to change out a traditional 10 oz. cartridge adhesive. Easier to use than regular cartridge adhesives and speeds up laying blockwork and stone.

Just one 10 oz. can of DAP® SMARTBOND® Landscape adhesive delivers about 240 linear feet at 1/2” bead compared to one 10 oz. cartridge of construction adhesive which only yields 30 linear feet at a 1/4″ bead. With 8X the adhesive coverage in one can, that’s less weight to carry around on the job & less to truck from site to site.

So looking at the incredible features offered in this line of adhesives I have to share the thought that went through my head: “It seems too good to be true right?” Pondering that realization, I decided to do some more research on the product line to specifically locate the issues with the smart bond product line.

According to customer reviews as well as sales testimonies, the two biggest issues revolved around ease of use and the fact that 8 times the amount of tubes was a touch inflated. Other than those two cons the smartbond adhesive promoted scored on average a 4 out of 5 stars in customer reviews. But even with the success they had with their clientele, I still had questions. Below is a list of the FAQ’s from DAP’s website:

Does one can of DAP® SmartBond® Construction Adhesive really give you 8X more coverage than traditional adhesives?

Yes. It’s not just us saying it. DAP® used an accredited third-party product testing lab, the NAHB Research Center (now named Home Innovation Research Labs) to test the coverage of DAP® SmartBond. One 20 oz. can of DAP® SMARTBOND® Subfloor Adhesive (straw or gun-grade) equals the coverage of eight 28 oz. subfloor cartridge construction adhesives. One 12 oz. can of DAP® SMARTBOND® Heavy Duty or Landscape Adhesive equals the coverage of eight 10 oz. cartridges of construction adhesive.

How does DAP® SmartBond® Construction Adhesive make my job go faster?

The NAHB Research Center (Home Innovation Research Labs) verified through an intensive time and motion study of subfloor application that it takes about two minutes to swap out a fresh cartridge of construction adhesive, cut the nozzle, pierce the seal, pre-pump the gun and get back to work. With DAP® SMARTBOND®, getting back to work only takes about 20 seconds. A typical 2,400 sq. ft. new house will use up to 50 cartridges of traditional adhesive. That’s almost two hours spent swapping tubes compared to less than one minute with five cans of SMARTBOND® on the same size house.

Why does DAP® SmartBond® “collapse” as it is sprayed?

DAP® SMARTBOND® is a moisture cure polyurethane adhesive. To cure, it draws water from the air. When applied as a foam, there’s a huge amount of surface area to quickly pull in moisture. Then, DAP® SMARTBOND® is engineered to transform and “collapse.” Unlike other foam adhesives, the unique collapsing action of DAP® SMARTBOND® quickly turns the foam into a thick, viscous gel that doesn’t blow away in a stiff wind or from the turbulence of a plywood panel being dropped on top of it.

How does DAP® SmartBond® work compared to traditional construction adhesives?

While all construction adhesives generally perform the job which they are labeled for, DAP® SMARTBOND® is the fastest, easiest and highest yielding product you can use. Some adhesives don’t develop their full strength for up to a week, while SMARTBOND® gains structural strength in about an hour and is fully cured in just 24 hours. Especially on big jobs, getting 8X the coverage with SMARTBOND® is a huge benefit to getting the job done faster, easier and more efficiently saving you time and money. Other construction adhesives use a caulk gun applicator for a paste-like adhesive that, depending on the formula, cures through water evaporation, solvent-release or by pulling moisture from the air. DAP® SMARTBOND® is a dynamic polyurethane adhesive that dispenses easily from an aerosol can as a foam and transforms by collapsing into a high-strength, fast-curing viscous gel. The foam lets you see exactly where you applied it and allows you to be sure you used the ideal amount of adhesive. Also, the foam allows it to cure faster and more evenly, thereby developing fast strength.

In what temperature range can DAP® SmartBond® be used?

While we recommend the cans be stored above 60°F, DAP® SMARTBOND® will still gun out in temperatures as cold as 23°F. On those hot days, you can use it up to 105°F.

In what types of weather conditions can DAP® SmartBond® Construction Adhesives be used?

DAP® SMARTBOND® Construction Adhesives can be applied in cold and freezing conditions and in temperatures ranging from 23°F to 105°F. They can be used for both interior and exterior applications. While we do recommend that surfaces be dry and free of dirt for best results, DAP® SMARTBOND® can be applied to damp surfaces that are free from standing water and frost.

Can DAP® SmartBond® be used for vertical applications?

DAP® SMARTBOND® will adhere to vertical surfaces, but due to the unique collapsing foam action, gravity may cause DAP® SMARTBOND® to slump. On smaller application like a backsplash, trim or baseboards, DAP® SMARTBOND® should work just fine. Some bracing or fastener use may be required. On a larger application like a panel or drywall sheets, we recommend using DAP® Beats the Nail® Construction Adhesives.

How do I clean up DAP® SmartBond® Adhesives?

DAP® SMARTBOND® is a polyurethane adhesive. While polyurethane is very strong and durable, it is also sticky while curing. Acetone or other solvents can be used for cleanup. Once DAP® SMARTBOND® adhesive is cured, it must be mechanically removed and cannot be removed from clothing. DO NOT use acetone or other solvents to remove product from skin. For skin contact, first wipe off excess uncured adhesive off with a paper towel immediately. Then wash remaining uncured foam immediately with soap and water. Any remaining uncured residue can be removed with petroleum jelly or baby oil. For cured adhesive, soak in warm soapy water, and then apply petroleum jelly. Cured product will wear off in time.

Is DAP® SmartBond® re-usable?

Yes it is, for up to 30 days when properly stored as directed. To save unused straw-grade DAP® SMARTBOND® products for future use, simply insert the safety tab pin into the end of the straw when you’re done using it, and the can is reusable for up to 30 days.

So in the end this product is the perfect solution to the company looking to positively affect their bottom line. It can also be used on flooring and rafters for RV’s (Not plastic). So overall from research, customer reviews, and sales testimonies I have to give this product line 4 sticky adhesive stars out of 5 for business efficiencies. But don’t take my word for it, take a look at it yourself.

Contributed by Justin White.

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