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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.
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.
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.
ELITE LEAN Assessment Analysis
Access Requirements
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Bodyshop Management System
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Estimating System in Use
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Floor Plans (including external areas)
Operational Data
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Repair Orders (paint/non-paint)
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Total Labour Hours Invoiced
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Key-to-Key Time and Touch Time
Financial
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Total Turnover (Body & Paint)
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JCNI backlog
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Turnover Breakdown: Labour, Parts, Paint, Sublet, etc.
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Costs Breakdown: Parts, Paint, Consumables, External Services
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Wages: Productive and Administrative Staff
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Process Requirements
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Lean Management Document Request List
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MSO Company Processes and SOPs
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Insurance Contracts Overview & Process
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Part Supplier Process (including restrictions)
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Document Flow from Head Office
Operational Analysis
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Layout Efficiency and Workflow
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Staff Numbers, Positions
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Org Chart
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Job Descriptions
Elite Lean Program Structure
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.
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.
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
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.
ELITE LEAN Fundamentals
Approach
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Understand client objectives
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Define: Define key processes and goals (e.g., increasing spare parts sales or reducing repair cycle time).
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Measure: Collect data on current performance (e.g., lead times, defect rates).
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Analyze: Identify root causes of inefficiencies or defects.
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Improve: Implement targeted solutions.
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Control: Ensure changes are sustained over time.
Outcome
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Increased productivity
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Consistency in processes.
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Reduced defects in repairs.
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Enhanced customer trust.
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Increased body shop throughput, profit, and overall sales
Sternauto Group (Germany)
100%
INCREASE IN THROUGHPUT
“Within the first week after achieving our milestones we could double our output from approx. 14 to 28 jobs per week”
Sternauto Group (Germany)
100%
INCREASE IN THROUGHPUT
“Within the first week after achieving our milestones we could double our output from approx. 14 to 28 jobs per week”
Sternauto Group (Germany)
100%
INCREASE IN THROUGHPUT
“Within the first week after achieving our milestones we could double our output from approx. 14 to 28 jobs per week”