Elite Lean Management

A modular, data-driven program designed to optimise every aspect of your body shop’s performance — increasing throughput, reducing waste, and embedding a culture of continuous improvement.

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Throughput

Maximise throughput while reducing waste.

Alignment

Align lean principles with real business goals.

Efficiency

Drive efficiency by restructuring operations with focus on quality and speed.

WHY ELITE LEAN?

The Elite Lean Management Program empowers collision repair businesses to achieve measurable performance improvements through a systematic, stage-by-stage rollout. Rooted in Lean Six Sigma principles and tailored to the automotive industry, this program delivers lasting results that scale, from single-site independents to multi-location MSO groups.

ASSESSMENT

ELITE LEAN Assessment Analysis

Access Requirements

Bodyshop Management System
Estimating System in Use
Floor Plans (including external areas)

Operational Data

Repair Orders (paint/non-paint)
Total Labour Hours Invoiced
Key-to-Key Time and Touch Time

Financial

Total Turnover (Body & Paint)
JCNI backlog
Turnover Breakdown: Labour, Parts, Paint, Sublet, etc.
Costs Breakdown: Parts, Paint, Consumables, External Services
Wages: Productive and Administrative Staff

Process Requirements

Lean Management Document Request List
MSO Company Processes and SOPs
Insurance Contracts Overview & Process
Part Supplier Process (including restrictions)
Document Flow from Head Office

Operational Analysis

Layout Efficiency and Workflow
Staff Numbers, Positions
Org Chart
Job Descriptions

PROGRAM

Elite Lean Program Structure

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Training & Consultancy

Our hands-on workshops and on-site coaching bring Lean principles to life, equipping teams with practical tools such as 5S and Kaizen while embedding lasting behavioural change. By working directly alongside technicians and managers, we ensure new habits take root — building confidence, structure, and a culture of continuous improvement that sustains long after the program is complete.

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Process Design & Equipment

We reconfigure shop layouts to achieve optimal material and information flow, ensuring every process moves with precision and purpose. Our consultants recommend and implement targeted equipment upgrades that boost productivity, safety, and consistency. By introducing the latest global technologies, we help body shops modernise operations, reduce waste, and maintain a competitive edge in an evolving industry.

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Change Management & Communication

Plan and execute stakeholder engagement strategies
Ensure clear, consistent messaging as new processes are presented
Teach and assist with Quick Reference Guides (QRGs)—SOPs condensed into easy-to-use one-page guides—to reinforce new workflows and Kazan improvement planning
Monitor adoption and address resistance through coaching and feedback loops

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Business Planning

We develop strategic plans that align directly with your operational goals, creating a clear roadmap for measurable growth. Our team builds detailed financial models that balance investment with return, ensuring every decision drives value. By increasing profit margins and job throughput through smarter parts management and process efficiencies, we help your business achieve sustainable, data-backed profitability.

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FUNDAMENTALS

ELITE LEAN Fundamentals

Approach

Understand client objectives
Define: Define key processes and goals (e.g., increasing spare parts sales or reducing repair cycle time).
Measure: Collect data on current performance (e.g., lead times, defect rates).
Analyze: Identify root causes of inefficiencies or defects.
Improve: Implement targeted solutions.
Control: Ensure changes are sustained over time.