BODYSHOP RISK ASSESSMENT
Support Team: SAFETY MANAGER: DATE:
ACTIVITY HAZARDS RISK
FACTOR
High/Med/
Low
EXISTING OR PLANNED CONTROLS THOSE AT
RISK
IF NOT
CONTROLLED,
NOTE
ACTION REQUIRED
Figure 15.14 Risk assessment form
528 Repair of Vehicle Bodies
bodyshop. Remember, if in doubt, don’t do it no
matter what the reward.
Further reading
One thing that any person working in a bodyshop
must always bear in mind is that ignorance is
no excuse in the eyes of the law. That is, it
is, whether you are the newest apprentice or the
oldest manager, you have a legal requirement
to comply with the relevant regulations. Most
prosecutions by the Heath and Safety Executive
(HSE) are under the 1974 Health and Safety at
Work Act; this is because it is a catch-all.
However, it is important to keep up to date
with the latest regulations. The HSE publishes
books on all the regulations, obviously not all of
them are relevant to the bodyshop, current ones,
other than those already mentioned, which have
relevance to the bodyshop of a general nature
are:
• Health and Safety in Engineering Workshops
(2002) ISBN 0 7176 1717 3
• Safety Representatives and Safety Committees
(1996) ISBN 0 7176 1220 1
• Risk Management (1995) ISBN 0 7176 0905 7
• Safe Use of Work Equipment (1999) ISBN
0 7176 1626 6
• The Law on VDUs (2003) 0 7176 2582 6
• Work with Display Screens (2002) 0 7176 2582 6
• Management of Health and Safety at Work
(2002) 0 7176 2488
• Personal Protective Equipment at Work
(2000) 0 7176 0415 2
The HSE website can be found at
www.hse.gov.uk. On the HSE website can be
found lists of all the latest publications and
news items on current developments as well as
other relevant information.
15.7 Quality Management for the
bodyshop: BS EN
ISO 9001–2000
The motor industry is under increasing pressure from
its customers to show that it is able to guarantee a
high standard for its repairs. Increasingly, customers
are expecting their suppliers to have formal and
verifiable quality management systems as a guarantee
that work will be completed with an acceptable
level of assurance of quality. This expectation applies
as much to smaller firms as it does to large.
Some of Britain’s largest organizations now
include BS EN ISO 9001–2002, or other acceptable
quality management systems, as a contractual
requirement for their suppliers. Many other organizations
give preferential treatment to suppliers who
show a visible commitment to quality by pursuing
this British Standard, BS EN ISO 9001–2000.
An increasing number of companies in the body
repair industry are now seeking registration to
BS EN ISO 9001–2000, the national standard for
quality management systems. Registration is being
sought by vehicle manufacturers and suppliers of
parts and equipment, by car dealers, by garages
offering service and repair and by body repair shops.
The assurance of quality is needed to eliminate
failures and complaints and their associated costs as
far as possible. By operating a management system
according to the defined criteria of a standard such
as BS EN ISO 9001–2000, you have confidence
that you have taken all reasonable steps to guarantee
quality to your customer, and you provide
evidence of your commitment to do so. Quality
assurance systems provide the mechanism for
ensuring that a business satisfies the needs of its
customers. BS refers to British Standards Institute,
other countries may just use the term ISO 9001.
15.7.1 Requirements of BS EN 9001–2000
BS EN 9001–2000 identifies basic disciplines, procedures
and criteria to ensure that products and services
meet the customer’s requirements. It is the
British Standards Institution’s (BSI) assurance of
quality and can be applied to all industries. All
accredited companies are permitted to display the
easily recognizable BSI symbol.
The main requirement of BS EN ISO 9001–2000
is the procedures manual. All companies have to
prepare a manual which meets the 18 working
procedures required by BSI in order to conform:
1 Management responsibilities
2 Quality systems
3 Contract review
4 Document control
5 Purchasing
Bodyshop planning 529
6 Purchaser supplied products
7 Product identification and traceability
8 Process control (workshop procedures for body
repair, welding and painting)
9 Inspection and testing
10 Inspection, measuring and test equipment (to
include spray booths, welding equipment, body
jigs, measuring equipment)
11 Inspections and test status
12 Control of non-conforming products
13 Corrective action
14 Handling, storage, packing and delivery
15 Quality records
16 Internal quality audits
17 Training
18 Statistical techniques.
Service departments and bodyshops must establish:
(a) What repairs each customer wants on the
vehicle
(b) a procedure for the ordering of necessary parts
(c) A check that all tools are calibrated for use by
trained and authorized staff
(d) The production of a workshop manual covering
repairs and welding techniques used in
the bodyshop
(e) The production of a quality systems manual
which will include all 18 procedures.
In order to enable this system to work, documented
records must be kept at all stages of the repair from
the car being booked in for repair until it is returned
to the customer.
15.7.2 Benefits of BS EN ISO 9001–2000
For bodyshops
1 BSI certification.
2 The use of the BSI logo on publicity material.
3 Customers accept BSI certification as proof of
quality commitment.
4 Customers become less likely to look for a
special assessment of work done.
5 Quality performance will improve customer
satisfaction.
6 The company will have the confidence of
knowing that its quality system has been externally
assessed and approved.
7 Staff will work better in an organized working
situation.
15.7.3 The bodyshop’s action plan
1 Accept the opportunity to move towards BSI
approval.
2 Provide the environment in which the participants
can work together towards the required standard.
3 Provide the expertise and equipment needed to
work through all the necessary stages to produce
a documented quality system which will include
a quality manual, supporting procedures, working
instructions and other associated documents.
4 Provide quality training as required by the
participants.
5 Provide support throughout the whole procedure.
To achieve the action plan a company can:
1 Undertake the development work itself and conduct
an internal quality improvement project.
2 Collaborate with other local businesses and
work together to achieve the standard with
external support.
3 Pursue BS EN ISO 9001–2000 using external
consultancy support.
If it is decided to develop and implement a formal
quality system in the company, a controlled, logical
action plan should be followed. There is always a
tendency to make a system too elaborate; the aim
should be to develop a system which consistently
gives the degree of assurance your business requires.
A suggested plan of action for the development,
implementation and certification of any quality
management system is as follows:
1 Establish the company’s commitment to quality
and the achievement of BS EN ISO 9001–2000
standards.
2 Review the existing arrangements for quality
management, and identify a company quality
development plan with a controlled implementation
schedule with target dates for the completion
of essential stages.
3 Define and document the system.
4 Apply for assessment and certification to the
British Standards Institution.
5 Implement and monitor the system over a
period of at least three months.
6 Maintain certification by reviewing the system
at predetermined intervals, conducting system
audits, and maintaining a disciplined approach
to quality assurance.
530 Repair of Vehicle Bodies
