Moze Project

8/16/2019 Moze Project

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KYAMBOGO UNIVERSITY

Faculty of Engineering

Department of Mechanical and Production Engineering

Designing an Automobile Body So! "o# Kyambogo Uni$e#sity

A project proposal submitted to the faculty of engineering in partial fulfilment of the requirement

for the award of degree in bachelor of engineering in automotive and power engineering of

Kyambogo niversity

!"

!#A$%E M&'E'

()**+,-*APD*./

'upervisor

Mr0 Ka1ebe 'e1ajja 2obert

,3(4

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DE56A2A%7&$

%he information contained in this proposal has never e8isted anywhere and therefore 7

declare it as original

Student Date

99999999999900 99999999900

!#A$%E M&'E'

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APP2&/A6

%his is to certify that this project will be done under my supervision and whatever that is

contained in it will be done by the student named above: it is therefore fit to be handed over to

the e8amination board of Kyambogo niversity0

Su!e#$iso# Date

9999999999999990 9999999999

KAKE!E ''EKA;;A 2&!E2%

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DED75A%7&$

7 dedicate this proposal to my dear parents for all spiritual and financial support towards

attaining the objectives of this project0 7n a special way: 7 also dedicate this proposal to Eng0

Ka1ebe 'se1ajja 2obert for the guidance and encouragement towards accomplishing this

research proposal0

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%able of 5ontents

DE56A2A%7&$00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 i

APP2&/A60000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 ii

DED75A%7&$000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000iii

6ist of tables0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 vii

6ist of figures00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 viii

0 A5K$ED.ME$%00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 i8

A!'%2A5%00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000008

5hapter one000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(

7$%2&D5%7&$0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(

(03 !A5K .2&$D &F %

,0,

,0+ 'pray Painting00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 -

,0+ .eneral Design .uidelines and !est Management Practices for0000000000000000000000000000000000000(3

$ew 5onstruction of Auto !ody 'hops00000000000000000000000000000000000000000000000000000000000000000000000000000000000(3

,0+0 ( $ew 5onstruction 5ompared to 2eusing !uildings or 2etrofitting an E8isting Auto!ody 'hop00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 (3

,0+0, &ffice and customer accessible areas000000000000000000000000000000000000000000000000000000000000000000000000((

,0+0) Paint spray booth designs000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000((

,0+0+


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,0+04 /entilation000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 (,

,0+0> .eneral e8haust ventilation000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(,

,0+0- 6ocal e8haust ventilation systems000000000000000000000000000000000000000000000000000000000000000000000000000000(,

,0+0C Floor drains and water pollution control000000000000000000000000000000000000000000000000000000000000000000000 (,

,0+0(3 'ite 6ayout000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000()

,0+0(( Par1ing000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 ()

,0+0(, /ehicle storage00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 ()

,0+0() !uilding access00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 (+

,0(+ Fire safety and access000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(+

,0+0(= Fencing and security measures0000000000000000000000000000000000000000000000000000000000000000000000000000000(+

,0= !est Management Practices000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(=

,0=0( 6ow/olatile &rganic 5ompound /&5B paint000000000000000000000000000000000000000000000000000000000000(=

,0=0, 'pray gun cleaning0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(=

,0=0)

,0=0C 'anding waste00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 (-

,0=0(3 #astewater and storm drains0000000000000000000000000000000000000000000000000000000000000000000000000000000000 (-

,04 .eneral environmental regulation and compliance00000000000000000000000000000000000000000000000000000000000(-

,040( #aterborne coatings and paints00000000000000000000000000000000000000000000000000000000000000000000000000000000(C

,040, 7nventory control practices00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000(C

,040) Personal protection equipment0000000000000000000000000000000000000000000000000000000000000000000000000000000000,3

,040+ 2ecord1eeping00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000,3

,0> Planning for an autobody wor1shop00000000000000000000000000000000000000000000000000000000000000000000000000000000,,

,0>0( %he Key to Profits in autobody wor1shop000000000000000000000000000000000000000000000000000000000000000000,,

,0>0, Planning for the structural layout of an auto body shop000000000000000000000000000000000000000000000,)

,0- 'hop !usiness .oals0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 ,+

,0-0( $umber of vehicles processed per wee10000000000000000000000000000000000000000000000000000000000000000000,+

,0-0, %ype of wor1 desired00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000,+

,0-0) Present and Future Employees000000000000000000000000000000000000000000000000000000000000000000000000000000000,+

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,0-0+ #or1


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6ist of tables

%able (? research methods and description0000000000000000000000000000000000000000000000000000000000000000000000000000000 ))

%able ,? 7ncome and proposed e8penditure for the research project000000000000000000000000000000000000000000)+

%able )? schedule plan for all activities of the research project000000000000000000000000000000000000000000000000000)=

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6ist of figures

Figure (? A downdraft spray booth00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000C

Figure ,? A semidowndraft spray booth000000000000000000000000000000000000000000000000000000000000000000000000000000000000000C

Figure )? A cross draft spray booth00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 (3

Figure +? 'chematics and Photos of a Downdraft !ooths0000000000000000000000000000000000000000000000000000000000,(Figure =? Portable 7nfrared Drying 6amp000000000000000000000000000000000000000000000000000000000000000000000000000000000000,(

Figure 4? 7nterior of an auto body wor1shop0000000000000000000000000000000000000000000000000000000000000000000000000000000,,

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0 A5K$ED.ME$%

7ts my pleasure to e8press my genuine appreciation for different people who provided me ideas

and support in different ways0 My heartfelt special than1s ta1e the opportunity to my project

supervisor Mr0 Ka1ebe 'se1ajja 2obert for his assistance: guidance: patience and time

throughout the lifelong of the project wor10

Furthermore: 7 would li1e to than1 my friends too: for their assistance0 At last but not least my

special appreciation goes to Muyingo ;ohnbosco for his undisputable support and e8pertise0

'pecial than1s to my parents Mr0%a1irambudde $athan and Mrs0$ambuule 'ylvia for their

unfailing support throughout the course of my studies0

Above all my special gratitude goes to the most .racious: the almighty .od

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A!'%2A5%

%his proposal loo1s at the body shop that is in the Kyambogo niversity which does not meet

the standards of a body shop and results into human and environmental ris1s to address the

problem of continuous painting in an open environment has arisen environment concerns and is

ha@ardous to both human and the environment0 %he project will be directed by the following

objectives studying the e8isting body shop layouts: finding the e8isting standard parameters of

body shops: designing an automobile body shop and carrying out a cost analysis of the

developed design0 %he methodology will include observation: interviews: and des1 research0

Furthermore: the proposal includes the budget of the amount to be used during its conduction0 7t

also includes the e8pected budget and it is finali@ed with the wor1 schedule towards the

completion of the project0

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5hapter one

7$%2&D5%7&$

(03 !A5K .2&$D &F %


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7t has four laboratories where tests on materials: research and demonstrations are carried out

and these include the following?

(0 'team laboratories

,0 Fluids

)0 Materials

+0 7nternal combustion engine

Each of these laboratories and wor1shop division are assigned to a technician who ensures that

tools: equipment and machines are safe and carrying out demonstrations by students0 %he

divisions of the wor1shop are headed by the heads of sessions

%he purpose of this project is to provide design guidelines and best management practices

relating to auto body shops in Kyambogo niversity0 %his project is intended to support the

Kyambogo universitys effort to improve the environmental performance of auto body shops in

the 5ity: and in turn: eliminate to the e8tent possible: impacts currently created by auto body

operations throughout $ational 5ity by providing owners and operators of auto body shops

general design guidelines and #hen both the design guidelines are e8ercised for auto body

shops: ma8imum benefits to wor1er safety: public health and the environment can be achieved0

Auto body shop owners and operators are encouraged to review the general design guidelinespresented here for incorporation into their auto body business operations0 %hese guidelines are

intended to operate in conjunction with e8isting Municipal 5ode requirements0 2eferences for

further information on each topic are also provided0 7n some cases: specific regulatory

requirements may apply0 7n these cases: applicable regulations are also provided in the

references0

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(0( Problem statement

%he mechanical department automotive wor1shop is poorly planned and designed and its also

too small to accommodate all the processes involved in an automobile body wor1shop0 %his

therefore retards the ability to impart 1nowledge and practical s1ills required by automotive

engineers0

(0, &bjectives of the study

(0) .eneral &bjective

Designing an automobile body shop for Kyambogo niversity

(0+ 'pecific &bjectives

( %o study the e8isting body shops0

, %o find out the e8isting parameters of the body shop layouts0

) %o design an automobile body shop0

+ %o carry out cost analysis of automobile body shop0

(0= 2esearch questions

iB #hat are the different automobile body shop designs in the e8istencesG

iiB #hat are the different parameters of automobile body shopG

iiiB


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(0> ;ustification

Most of automobile body shops in ganda are open to the environment: paint fumes and paste

particles which are dangerous to human life are directly disposed off thus coming up with

measures of minimising human health ris1s and environmental pollution

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(0- 'ignificance of the report

%he research shall improve on the health life style of the operators wor1ersB0

%he research shall reduce on the environmental pollution0

%he research shall lead to increased quality output thus reali@ing more profits

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5hapter two

,03 6iterature 2eview

Automotive repair shops also offer paintwor1 repairs to scratches: scuffs and dents to vehicle

damage as well as damage caused by collisions and major accidents0 Many body shops now

offer paint less dent repair : which is done by pushing the dents out from inside a shop or garage

where the bodies of automotive vehicles are repaired0 !ody shop can as well be defined as

Automotive EngineeringB a place where the bodywor1 of motor vehicles is built or repaired0

#hile providing a valuable source of s1illed employment: auto shops can pose potential health

ris1s to wor1ers and nearby residents0 5ommon ha@ards to wor1ers and people living nearby

include inhalation of solvents from parts cleaning and painting operations: airborne particulate

matter from body wor1 and bra1es: direct contact with solvents and corrosive materials: fire and

e8plosion ha@ards from flammable materials: injury ris1s from stored automotive parts: heavy

metals e8posure: and water and soil contamination from improper storage or disposal of

ha@ardous wastes0 &f particular concern to the project was reducing emissions and wor1er

e8posures to solvents and particulate matter from painting: parts cleaning: and bra1e jobs: as

these e8posures have been associated with serious health effects and can be easily addressed

with product replacement: process changes: and personal protective equipment0 According to a

study conducted by the %o8ics se 2eduction 7nstitute at the niversity of Massachusetts

6owell: aerosol chlorinated solvents are frequently used in auto shops for bra1e cleaning: and

other solvents: such as toluene: 8ylene: and acetone: are commonly used for cleaning of paintspray guns and for Hoff labelI uses0 %hese practices 'anding and body wor1 also pose a health

ris1s to wor1ers and their families from e8posure to solvents: lead: and other metals in the

sanding dust: which can be inhaled or ingested by wor1ers and may be ta1en home on wor1

clothes to e8pose family members0

,0( !ody 'hop Processes?

An auto body shop is a business where customers can ta1e their vehicles for repairs0 %his can

include very small repairs such as a dent or window replacement up to and including a full body

ma1eover with welding and painting0 %as1s performed in a body shop include receiving:

cleaning: repairing: refinishing: and painting of damaged automotive vehicles e8amining

damaged vehicles and estimating cost of repair pulling out dents filling depressions with body

fillers refinishing and repainting auto body parts removing and replacing hood: fender: core

support: door shell: etc0 removing upholstery: accessories: electrical and hydraulic equipment to

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https://en.wikipedia.org/wiki/Paintless_dent_repairhttps://en.wikipedia.org/wiki/Paintless_dent_repair


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gain access to auto body and fender replacing windshields and repairing windshield crac1s

completing minor estimates of damaged area straightening out and*or realigning vehicle

frames0 A wor1er in a body shop often dismantles vehicles removes and replaces air bag

systems and sensors applies decals recharges air conditioning systems arranges disposal of

waste paints: solvents00 Although all of the above processes are common to body shop

operations: this project will focus on the fire ha@ards associated with body shops operations0

,0(


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From a liability standpoint: there are also many trip and fall ha@ards in a body shop0 %hese

include but are not limited to e8tension cords and hoses for air tools 1eep in minde8tension

cords are for temporary use onlyB0 Also in some body shops there are HeyeletsI cemented into

the concrete to hold a car chained in place to straighten frames etc0 %hese are usually hidden

and should be well identified to prevent tripping0

,0+ 'pray Painting

%he easiest way to control the ha@ards of spray painting is to 1eep them small0 %he best way to

do this is to use a spray booth specially designed for the operation0 'pray booths must be steel

frame construction with steel walls with a minimum thic1ness of (0(+ mm or be of an equivalent

noncombustible construction0 %he interior finish of the booth is required to be a smooth and

continuous noncombustible surface0 &ther construction considerations include the floor: which

must be noncombustible: the si@e of the booth and the allowance for lighting which is normally

through special glass panels from the e8terior of the booth0 E8cept where separated from the

spray area by a vapour tight separation with no openings: all electrical equipment within the

spray area: including lighting fi8tures: shall be of an e8plosion*vapour proof type : designed for

that use and installed according to the manufacturers recommendations: local codes: standards

and bylaws0 'pray painting creates two types of ha@ards90 the buildup of overspray and the

accumulation of flammable vapours0 %o control these ha@ards: spray booths are also required to

be equipped with an overspray collection system to prevent overspray from accumulating on the

e8haust fan and in the ductwor10 5ontrol of the vapours is provided by the use of e8haust fan

motors which are normally located outside the ductwor1 and booth as they are not permitted to

be subject to the buildup of overspray residue0 Fan blades which are located in the ducts must

be of a nonferrous material to prevent spar1ing0 7nterloc1s must be provided between spraying

equipment and ventilation systems to prevent operation of the spraying equipment when the

ventilation system is shut down or the circulating pump of a water wash system is not operating0

%here are several types of overspray*ventilation systems is use0 Most use either a dry filter style

or a water wash style: including downdraft booths0 %he following diagram indicates the different

methods of providing ventilation and designates them as?

• Downdraft

• 'emi Downdraft: or

• 5ross Draft

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%he difference is determined by the method that the air is drawn into and e8hausts from the

booth0 Drying &perations are permitted inside the spray booths providing the interior surfaces of

the spray booth are 1ept clean of overspray0 Portable dryers are also permitted providing they

are electric infrared and are removed during spray painting operations0 7nterloc1s must be

provided to prevent spraying and drying operations from ta1ing place at the same time0 %hese

interloc1s also provide a minimum three minute purging time after spraying to remove vapours:

maintain a safe atmosphere within the enclosure during drying and ensure drying equipment will

shut off when the ventilation system is shut down0

Figure 1: A downdraft spray booth

Figure 2: A semi-downdraft spray booth

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Figure 3: A cross draft spray booth

,0+ .eneral Design .uidelines and !est Management Practices for

$ew 5onstruction of Auto !ody 'hops

Design guidelines and !MPs are most effective when jointly coordinated0 Design guidelines

provide the physical facility to support effective and efficient protection of health safety and the

environment while welle8ecuted !MPs provide the mechanism to achieve and maintain

protection of health safety and the environment during the operation of the auto body shop0 7t is

arguable that an auto body shop that is a high performance and stateoftheart facility without

!MPs will underperform an auto body shop without a high performance facility: but with well

established !MPs0 %his project introduces a series of design guidelines and !MPs related to

auto body shops0 7t is recommended that for new construction of auto body shops these design

guidelines and !MPs be jointly implemented0

,0+0 ( $ew 5onstruction 5ompared to 2eusing !uildings or 2etrofitting an E8isting Auto !ody

'hop

%he design guidelines proposed in this brochure are intended for new construction of auto body

shops but do not e8clude their application to the reuse of an e8isting building for an auto body

shop or the retrofitting of an e8isting auto body shop0 7t should be noted that reusing a building

or retrofitting an e8isting auto body shop may add more challenges: but overall is considered a

more sustainable option when factoring in the life cycle costs of the materials both in the

deconstruction and construction of a new facility0 %he !MPs proposed in this brochure areapplicable to both new and e8isting auto body shops0

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,0+0, &ffice and customer accessible areas

&ffices and customer areas should have sufficient barriers e0g0: walls: doorwaysB from the auto

body wor1place areas and separate ventilation systems to minimi@e potential e8posures by

office wor1ers and customers to ha@ardous materials and equipment that may pose a health or

safety ris10 Daylight measures with lighting controls and thermostats to control


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• 'ince this has the potential to be used more frequently than the storage room: a

separate room for mi8ing is recommended0


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,0+0C Floor drains and water pollution control

(B %he use of floor drains should be minimi@ed in favour of low volume or nonliquid floor

cleaning methods0

,B #here floor drains are needed: floor drains should have separators and holding areas in

order to capture potentially ha@ardous wastes and allow the facility to properly dispose of

the waste: if necessary: before it is discharged0

)B Floor drains cannot connect to any storm water system and cannot connect to any

sanitary sewer systems near any spray booth areas: ha@ardous material storage areas

e0g0: mi8ing roomsB: or ha@ardous waste storage areas: in order to remove the

possibility of e8cess paint or other ha@ardous liquids from discharging in to a storm water

or sanitary sewer system0 Floors should be sealed with epo8y or suitable sealant toimprove spill cleanups

+B A wastewater recycling system is an e8cellent design measure that improves

environmental and economic benefits by supplying recycled water to car washing

operations and other operations instead of using 5ity water0

,0+0(3 'ite 6ayout

iB Auto body shops should be located at least =33 feet away from schools or residential

areas0

iiB %he area in front of the bay doors should not allow more than four cars to be queued in

front of bay doors0

iiiB Auto loading*unloading areas should be located behind buildings to assist in traffic and

par1ing circulation0

,0+0(( Par1ing

• Par1ing should be provided at an appropriate allocation amount with easily accessible

par1ing for customers and employees0

• All par1ing for employees should be located behind buildings0

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• 7t is best if driveways and entrances are wide enough to prevent truc1s from reversing

into public rightsofways and allow manoeuvring on the property for better traffic

circulation0

,0+0(, /ehicle storage

(0 A time limit on vehicle storage should be enforced to ensure that vehicles awaiting repair

are not 1ept onsite for e8tended periods: which helps control the amount of space

dedicated to vehicle storage0

,0 A minimum amount of storage should be provided to require facilities to create dedicated

area for storage and not rely on using onsite par1ing areas or storing vehicles on the

street0 A ma8imum storage area avoids large and hardtomaintain storage areas0

)0 /ehicles awaiting repair should be stored in the storage area: not in par1ing or otheropen areas0

,0+0() !uilding access

!uildings should be oriented in such a way that customers can enter the facility without crossing

or interfering with repaired vehicles0

Employees should have the same building access but from the rear of the building when

possible0

,0(+ Fire safety and access

All auto body shops should have a minimum of two access locations suitable for the access of

fire fighting vehicles0


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Ma8imum amount of each material stored or used in each area

2ange of container si@es

6ocations of emergency isolation and mitigation valves and devices

Product conveying piping containing liquids or gases: other than utilityowned fuel gas

lines and lowpressure fuel gas lines

&n and off positions of valves for valves that are of the selfindicating type

'torage plan showing the intended storage arrangement: including the location and

dimensions of aisles

%he location and type of emergency equipment

,0+0(= Fencing and security measures

All vehicle storage areas should be screened in order to regulate the appearance and avoid

unsightly par1ing lots of vehicles awaiting repair0

Fencing or screening should be solid and decorative and no more than eight feet in height:

e8cept at the front property line: where it should be no more than si8 feet in height0

'creening vehicle storage areas is a simple and easy way to regulate the appearance and avoid

unsightly par1ing lots of vehicles awaiting repair0 Mandating a type and height of fencing or

screening ensures that the fencing acts as a screen from the surrounding neighbourhood:

without becoming a visual distraction0

,0= !est Management Practices

,0=0( 6ow/olatile &rganic 5ompound /&5B paint

6ow /&5 paint products should be used0

%he use of low /&5 content paints reduces the amount of /&5s that may be released

into the air during spraying0

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,0=0, 'pray gun cleaning

• %he 5ity of $ational 5ity promotes the use of aqueous cleaners for paint spray gun

cleaning applications0


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,0=0+ 'olvent recycling

(0 %he 5ity of $ational 5ity promotes the use of aqueous cleaners for paint spray gun

cleaning applications0


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)B 5ontainers should be in good condition and compatible with the material they are

holding0 Each container should remain closed e8cept when adding or subtracting

wastes0 5ontainers should be clearly labelled with the following?

+B %he date ha@ardous wastes began accumulating in that container

=B %he lettering: HB %he ha@ardous properties of the waste to8ic: ignitable: corrosive: reactiveB

-B %he name and address of the generator

CB 2eusable cloth rags and towels should be used at permitted facilities to reduce trashvolume and possibly increased ha@ardous waste generation0 sed rags or towels

that are contaminated with automotive fluids or gasoline may be considered

ha@ardous materials0

(3B %o the e8tent practical: reusable cloth rags and towels should be used and laundered

at an appropriate laundry facility0 2ags and towels that are to be disposed should be

stored in an appropriate: mar1ed container and disposed of at an approved permitted

facility that can handle these materials0

,0=0> Pollution prevention

Pollution prevention refers to activities that reduce the amount of pollution generated by a

process such as the handling: use and disposal of ha@ardous materials0 Pollution prevention

should include the most basic steps first: such as?

• 7mproving inventory control

reducing the amount of products in storage

• sing firstin: firstout for paint and material

• 7nventorying storage areas regularly

• Keeping containers closed and inspecting for lea1

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• sing good house1eeping practices

,0=0- 'torm water Pollution Prevention Plan '#PPPB

A 'torm water Pollution Prevention Plan '#PPPB should be implemented for each auto body

shop0 A '#PPP provides a systematic approach to preventing contamination of the storm water system0 '#PPP requirements can be found in 5hapter (+0,, of the $ational 5ity Municipal

5ode0

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,0=0C 'anding waste

(B 'anding waste: especially with wet sanding: may contain to8ic metals that can

contaminate surface waters0

,B %his waste should not be washed to gutters: streets: or storm drains whether or not it is

ha@ardous waste0

)B #ith wet sanding: minimal water would be used and then collected before entering the

sanitary sewer when possible0 Also the wash water should be collected in a clarifier

before discharging to the sanitary sewer0

+B %he clarifier should be inspected and serviced regularly0

=B A vacuum sanding unit can also minimi@e the uncontrolled discharge of sanding waste

during dry sanding operations0

,0=0(3 #astewater and storm drains

7n general?

• #aste water from wash areas should flow A#A" from storm drains0

• 5ars should be washed in a bermed and covered wash area0

• A contained wash pad should be installed prior to the sanitary sewer0 7f a permanent

wash pad cannot be installed: a portable wash pad should be used with a pumping

system to the sanitary sewer drain0

• A closed loop water recycling system should be installed to reduce water use and trap

contaminants0

,04 .eneral environmental regulation and compliance

All businesses should determine applicable regulatory requirements: appropriate compliance

options and permitting requirements0

An 7ntegrated Maintenance and &perational Plan 7M&P% should also be considered0 %his plan

would outline the types of equipment and maintenance procedures used at the facilities and

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integrate environmental and occupational sectors0 %he plan would be maintained and provided

upon request: but not required for submittal to the 5ity0

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,040( #aterborne coatings and paints

• #aterborne coatings and paints are considered less to8ic and have lower /&5 levels

compared to solventborne products0 7t is possible to use fewer products with waterborne

coatings and paints when compared to solventbased products0 %his can lead to an

immediate cost savings0

• #aterborne products may have a shelf life between ,+ and 43 months0 7n some cases:

waterborne products may have an advantage over solventborne products: such as with

the use of waterborne primer where solvent primer would react with e8isting substrate

materials or coatings0

• %here is a concern about added drying times with waterborne coatings0 %his can be

easily addressed with the proper air movement in a spray booth0 Depending on the

booth cycles per day: there are different methods to improve air movement in a booth:

which will improve drying times0

,040, 7nventory control practices

An inventory control practice reduces costs and potential ha@ards: such as a spill or fire0

(0 7t is essential to minimi@e inventory and purchase only what is needed0 %he firstin: first

out principle is also important to ensure that the older materials are used first0

,0 All materials should to be stored to maintain proper temperature: humidity and to reduce

material degradation0

)0 7nventory limits should not e8ceed emergency response capacity0

+0 7t is recommended that shops minimi@e the use of similar solvents and use waste

e8change programs0

=0 E8cess or wasteB materials that are not needed at one auto body shop can be of value

to another auto body shop which may have a use for that material0 7f a networ1 of auto

body shops can be identified and created: a waste e8change program can be developed

to e8change e8cess materials0 %his can help transfer valuable materials to facilities that

may need these materials rather than disposing of the e8cess materials as a waste0 7n

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addition: the networ1 could include local or regional vocational or technical schools that

would benefit from e8cess materials that would have otherwise been wasted0

,040) Personal protection equipment

As mentioned earlier?

• Auto body shops should have an 77P and 2PP to ensure health and safety in the

wor1place0 %hese programs address such measures as wor1er evaluation: selection

appropriate airpurifying or suppliedair respirators: fittesting: training and maintenance0

• %his includes wearing goggles or face shields when operating sanding or grinding

equipment: installing dust collectors on sanders and grinders and installing splash

guards on grinders that use coolants0

• Also it is essential to have safety guards on any mechanical equipment as well as

always wearing the appropriate clothing e0g0: no loose clothingB0

• Employers need to enforce these practices with employees and provide periodic training

that is culturally respective and effective0

,040+ 2ecord1eeping

2ecord1eeping can play an important role in evaluating an auto body shops operating

practices0 2ecords should be maintained for the following?

iB


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Figure 4: Schematics and Photos of a owndraft !ooths

Figure ": Portab#e $nfrared rying %amp

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,0> Planning for an autobody wor1shop

7f you are planning an addition to a current facility or building a new facility: this handboo1 is for

you0 7t is designed to help you plan?

%he right amount of space for your shop

%he best way to lay it out

%he right equipment0

,0>0( %he Key to Profits in autobody wor1shop

#hether you are adding on to your e8isting facility or building a new facility: using a well

designed layout helps you get the most out of your space0 A good plan can stop production

bottlenec1s and other problems before they occur0 A well designed plan for every department

will ensure ma8imum productivity and profitability0 5onsider tal1ing to your employees: they may

1now of problem areas and bottlenec1s you were not aware of0 "our jobber and Paint 5ompany

may be of assistance as they visit many shops and see many different ideas and concepts0

'ome equipment suppliers also offer layout and design services of suggested equipment layout

and wor1flows0 /isiting other body shops will also allow you to see good ideas: and Hgood ideasI

that didnt wor1 out0 %his wor1boo1 is designed as guide to help you with ideas and guidelines

for designing a productive and profitable body shop0

Figure &: $nterior of an auto body wor'shop

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,0>0, Planning for the structural layout of an auto body shop

5hoosing an Architect and .eneral 5ontractor0 Planning an efficient body shop calls for

teamwor10 #hen youre loo1ing for an architect or contractor: loo1 for the ones that already

have e8perience in body shop design and

5onstruction0 %he right architect will be able to listen to you and give you the best design for

your needs0 "our architect should 1now all about the local codes and regulations that could

affect you0 2emember that potential customers see the outside of your building first: so it should

loo1 just as attractive as any professional building0 Discuss your total space needs with your

architect0 %hat means not only the space you need today: but the additional space required as

your business grows0 Planning the building for additional growth will save you money on future

additions later0 "ou should also tal1 to all the equipment suppliers youre considering and have

your architect tal1 to them also0 %heir representative can help you more if they are involved in

the early stages of the planning process0 %hese suppliers can help you chose the proper

equipment and plan for the best use of your space0 #hen you chose a contactor 1eep a few

things in mind?

(0 Ma1e sure the contractor has a good reputation0 5hec1 his references: and as1 about

his ability to complete a job right: and on time0

,0 Ma1e sure the contractor has a performance bond and payment bond0 A performance

bond guarantees the job will be completed at the agreed upon price: whether the

contractor finishes it himself or not0 A payment bond is your insurance that the contractor

can pay his subcontractors during construction0

)0 7f the contractor uses subcontractors during construction: ma1e sure he will coordinate

them: not you0 Along with your architect it will help to get your contractor involved during

the design stage0 %hey have e8perience that can help you9so use it0 Keep them both

involved from the beginning0

26


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,0- 'hop !usiness .oals

Knowing your business goals will help you design the right space0

,0-0( $umber of vehicles processed per wee10

%his is really important for choosing pulling systems: spray booths: etc0 Accelerated curing

equipment such as 'mart 5ure from .lobal Finishing 'olutions can finish from (3 to (+ cars per

- hour shift: while nonheated models may produce as few a , to ) per shift0 Knowing what

production level you wish to achieve is critical in ma1ing the right choice0

,0-0, %ype of wor1 desired0

5ycle times are e8tremely important to body shops in direct repair programs0 5onversely

restoration shops are not as concerned with quic1 turnaround0 'hops repairing medium or

heavy duty truc1s will require different facility and equipment considerations0 Again your

answers will guide you and your suppliers to a properly designed facility0

,0-0) Present and Future Employees0

%he number of employees you have wor1ing will have a lot to do with your production and

space requirements0

,0-0+ #or1


40/51

,0-04 6ighting

$atural lighting is the best and build designs use s1ylights and windows to bring natural light

inside0 $orthern facing openings provide more even light throughout the day0 !ecause natural

light varies you still need artificial lighting0 "ou can boost lighting just by painting the walls white

or some other reflective light colour0 "ou need colour corrected lighting in some critical areas0

%he refinish department: including the paint mi8 room: spray booth: prep stations and limited

finishing wor1stations0 "our detail area should have colour corrected lighting as well as a

delivery area if you have one0 Artificial lighting can cause a condition call HmetamerismI0 %his

condition may cause the paint in the area you just repaired: loo1 as though it doesnt match the

rest of the car0 Ma1e sure you have adequate lighting in all areas of your facility0

%he !uilding E8terior An attractive building brings in customers and gives them their first

impression about your operation0 Even if someone is only driving by and doesnt need your

services just then: chances are they will remember you and come bac1 when their car does

need wor1G 5areful 6andscaping: a professional loo1ing building e8terior: a nice sign and easy

par1ing all ma1e a big difference in attracting customers0

28


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,0C Major 'hop Departments

,0C0( Estimating*'ales

%his is usually the first: and often the only area of your shop the customer will see0 Place your

estimating area in a protected: climate controlled location0 %his area should be very well lighted

and include a lift to allow a complete vehicle inspection0 Floor drains should be available if

possible to allow for easy cleanup and rain and snow coming off the vehicles in inclement

weather0 pper and lower level lighting is highly recommended0 A reel mounted trouble light will

aid on internal inspections0 0 A larger number of customers getting estimates are female0 Ma1e sure your estimate

area is attractive to female customers0

-0 Female customers may bring young children with them when they come in0 5onsider a

television and D/D*video cassette player or a play area in the waiting area for these

customers0

,0C0, !ody 'traightening and Metal 2epair

"ou should locate this department on the other side of the refinishing department: or at least put

a partition between the two0 2educing dust and contaminates from reaching the refinish area

will reduce the preparation wor1 required to achieve HcleanI paint jobs0 %he equipment list on

will help you determine the space required in the metal shop0 %ypical metal stalls are (, feet

wide 8 ,+ feet deep0 Again this may vary on the type of wor1 you perform0 7ncrease the width of

a stall lying along a wall to (= feet to allow for ample room to wor1 on both sides of the vehicle0

Most pulling systems require a stall (+ feet wide 8 ,= feet deep0 %his also can vary depending

29


42/51

on the equipment you select0 'tudies show that inground or portable lifts can have a significant

increase in a technicians productivity0 'taging cars with the damaged area facing the isle will

allow the production

Manager easier visibility to the wor1 in progress0 7n floor pulling systems will decrease yourshops cycle time as technicians dont have to wait to use a frame rac1 or bench0 %hese systems

allow for correction of light damage to be completed in the technicians stall without having to

move the vehicle0

Many shops dont consider the way wor1 should flow through their facility0 Proper flow will help

increase productivity more than anything else you can do0 A lineal flow straight lineB is ideal: but

this also ta1es up the most space0 A circular flow also wor1s well in a collision facility: and

reduces the amount of space required0 %he one thing you want to do: is to design a facility that

requires the least amount of moving cars as possible0

%he number of stalls a technician requires to be productive can create heated arguments0 %he

1ey to running a profitable collision shop is to restore the car to preaccident condition in the

least amount of time possible0 As you 1now you dont get paid until the car is delivered bac1 to

your customer: in the mean time you have to pay salaries: parts: utilities: building payments etc0

Most technicians will ta1e as many stalls as you allow them too: but they can still only wor1 on (

car at a time0 7 recommend that even for your most productive technicians allow no more than ,

stalls per man0 Most often 7 use (0= stalls per technician0

An aluminium repair area is a dedicated area for repair aluminium panels0 %his is a dedicated

are with special tools to be used only on aluminium0 Aluminium dust is an e8treme e8plosion

ha@ard and requires a water bath dust collection system0 'pecials welders: preheaters and

other tools are required for this area0

,0C0) !ody Prep and Prime0

$ew paint system and equipment technology has made sanding and priming easier and more

productive0 E8amples include? prep stations: dust collection systems and infrared curing

systems0 Most equipment

Manufactures have prep stations available in downdraft and semi downdraft models0 %he

downdraft models require a pit be built into the floor: but provide for the best curtain of air

around the car0 Most prep stations allow the operator to choose if the unit is recirculating the

30


43/51

shop air or e8hausting the air from the shop to the outside0 Many jurisdictions have changed the

codes on equipment used for painting and priming operations0 %he codes require that areas

where finishing operations will be performed: a 6imited Finishing #or1station be used0 Most

6imited Finishing #or1stations have prep station plenums attached to an air replacement unit0

#hen spray operations ta1e place the operator must place the unit in the e8haust mode0 %he

6imited Finishing #or1station will then bring in outside air to replace the air being e8hausted out

of the building the same as a heated spray booth0 Most jurisdictions limit the amount of spraying

%hat can be performed on a 6imited Finishing #or1station0 7t is therefore very important you

purchase the proper equipment for your use0

Dust collection systems can be portable or a centrali@ed unit0 A portable unit is moved to each

vehicle: while a centrali@ed unit has a collector in one area with collection drops located

throughout the shop0 Dust collection systems will help 1eep your facility clean reducing cleaning

costs0 Another benefit is the cars require less preparation wor1 before going to the refinish

department0 'tudies show a dust collection system can reduce sandpaper usage by ,=J as it

ma1es the paper run cooler reducing clogging0

7nfrared curing systems reduce filler: primer and paint curing times0 sing short wave lighting

these systems heat the vehicle substrate: allowing the material to cure from the inside out0

7nfrared curing units can reduce primer cure time to ) to = minutes: allowing the technician to

finish the repairs quic1er0 Many of the new systems have adjustable time and temperaturecontrols: and a distance sensor to reduce operator error0 7nfrared curing systems are available

in portable: rail suspended systems and curing arches0

,0C0+ Painting and 5uring

Many collision shop managers and owners feel the paint department is their largest bottlenec10

5areful consideration should be given to the equipment purchased for your paint department0

Most of the equipment: paint booths: prep stations: and limited finishing wor1stations are high

tic1et items0 Do to the installation requirements of paint shop equipment it is e8pensive and

difficult to move0 "ou should give careful consideration as to the right equipment and location of

this equipment to ma8imi@e productivity0 5ombination spray*cure booths provide a safe wor1ing

environment and ma1e it easier to productivity produce highquality paint jobs0 Painting and

curing create fumes that must be collected and removed from your shop0 A properly designed

spray booth provides a safe amount of air movement to reduce the potential for dangerous

fumes to collect0 se of

31


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45/51

+0 Furniture for customer waiting area0

,0C0> Parts*'toc1 2oom

6i1e every shop: yours will need space for storing supplies: new and used parts and the parts

removed from jobs in process0 %o reduce cycle times and ma8imi@e productivity: repairs should

not begin until all the required parts are received and chec1ed for accuracy0 %his requires an

inventory system to easily trac1 what parts are on hand and what is still required for each job0

&ne of the simplest methods of handling your parts inventory is to store all parts related to a

specific job on a Hparts cartI made for this tas10 %he parts can be easily moved from the parts

room to the proper vehicle0 7f you chose this system youll need floor space to store all of your

carts0

A stoc1 area is required to store sandpaper: mas1ing paper: plastic repair materials: etc0 in a

secure area0 'ome collision shops use the space above the office to store these bul1y items0 7f

thats what you want to do: ma1e sure your architect designs a way to get to that area safely

and easily0

A parts department*stoc1room should be located near the production managers office to allow

him easy access to see what items are on hand and the items required for a particular job0 %he

si@e of this department will depend on your business0 'ome high production collision shops

have their parts delivered once the supplier has all the parts and the vehicle is scheduled0 %his

is an e8cellent way to reduce the si@e of the parts storage area0 $o matter what si@e your shopis: plan on an outside parts delivery door0 %hat way parts do not need to be brought through

your office or shop when they are delivered0 Again: this area should be 1ept clean and clutter

free0

,0C0- Equipment 'election

&nce you 1now the type of wor1 you want to do: and the amount of production required: its time

to pic1 the equipment youll need to do it0 !efore you decide on or order any major piece of

equipment: sit down with the manufactures*distributors representative and go over your needs0

7t is in your best interest: as well as the suppliers best interest to ma1e sure you have the right

equipment for the type of wor1: and required production you need0 7n most cases you can chose

from several manufactures0 Each manufacture may have several models with optional

equipment and upgrades to choose from0 2emember that choosing the right equipment early:

during the planning stage aids you in several ways0 First: your architect can do a better job

laying out your shop if he 1nows e8actly what

33


46/51

7s going into it0 'econd: your equipment suppliers should want to wor1 with you: your contactor:

and possibly each other to coordinate delivery and installation with your building0 Finally: a good

portion of your equipment purchases will be for e8pensive: hightic1et items li1e spray booth or

body straightening*measuring equipment0 An important consideration when choosing equipment

is the company representing the manufacture0


47/51

5hapter three

)03 Methodology

)0( 7ntroduction

%he research methodology requires gathering relevant data from the specified documents andcompiling databases and arrive at analysing the material and historical reconstruction of the

design of automobile body shop0

)0, 2esearch design

%he research shall use quantities and qualitative design0 %he former will enhance the

understanding of the meaning of the numbers while the letter will give precise and testable

interpretation to qualitative ideas in the design of automobile body shop0

)0) Data types and sources

Primary data shall be captured from the already e8isting design of body shops while secondary

data from literature: internet: published reports: journals and newspapers0 'econdary data will

be reviewed alongside primary data and any other information gathered from other sources will

be used to fill the gap when ma1ing conclusion in the study0

)0+ Data collection tools and techniques

)0+0( 7nterviews

Face to face interviews will be conducted with the automobile body shop panel beaters:

sprayers and preparatory0

)0+0, &bservation

Assessing the design of the panels: recommended methods of repairs from which the design

will be done0 %his will be done by assessing the construction: operation: faults: diagnostic tools

and failure remedies in the automobile body shops0

)0+0) 6ibrary research*des1 research

2eview of the e8isting literature in the library will be done including reviewing information from

the other case studies: abstracts: reviews and boo1s and journals in the library relating to

design of the automobile body shop0 %his will provide detailed study to come up with correct

analysis: presentations and conclusions0

35


48/51

No Ob&e'ti$e Metod Des'#i!tion

iB %o study e8isting body shop layout &bservation 7nterviews

Des1 research

%he research will visit the

various automobile body

shops to observe their

operation in relation to

human and environment

safety0

iiB %o find out the standard

parameters of the e8isting body

shop

Des1 research

&bservation

%he researcher shall use

internet: library: catalogs

then observe the e8istin

body shops0

iiiB %o design an automobile body shop Des1 search

observation

%he researcher shall use

internet: library:catalogs

design the automobile bo

shop0

ivB %o carry out cost analysis0 Data validating %he researcher shall use

data analysis and verifica

such as pay bac1 period

the project: economic

feasibilities of the project

Table () #esea#' metods and des'#i!tion

36


49/51

5hapter Four

+0( !udget

Item Amount

Parents contribution0 (33:333

Personal contribution (33:333

ELPE$D7%2E

%ransport (33:333

'tationary >3:333

5ommunication (3:333

Subtotal (*+,+++

Miscellaneous (-:333

Table -) In'ome and !#o!osed e.!enditu#e "o# te #esea#' !#o&e't

37


50/51

5hapter five

+0, #or1 schedule

A/TIVITIES O0 A/ADEMI/ YEAR

-+(12-+(3 AUG SE4T O/T NOV DE/ 5AN 0EB MAR A4

Problem identification*%itle search

Project tittle approval

6iterature 2eview

Proposal #riting

project proposal presentation

Data collection

Data Processing

Design drawings

5osting of Project

2eport writing

Project Presentation

Project 'ubmissionTable 6) s'edule !lan "o# all a'ti$ities o" te #esea#' !#o&e't

38


51/51

2EFE2E$5E'

(0 (ce#hoesduffycom0 2etrieved (( May: ,3(4: from

http?**www0mcelhoesduffy0com*resource*Media*Auto%rades*Fact 'heet !ody

'hops2!0pdf

,0 )o##isione*uipmente+pertscom 0 2etrieved () May: ,3(4: from

http?**www0collisionequipmente8perts0com*sitebuildercontent*sitebuilderfiles*collisionsho

pplannn ghandboo10pdf0

)0 http?**www0mcelhoesduffy0com*resource*Media*Auto%rades*FactJ,3'heetJ,3

J,3!odyJ,3'hops2!0pdf
http://www.mcelhoesduffy.com/resource/Media/Auto_Trades/Fact%20Sheet%20-%20Body%20Shops_RB.pdfhttp://www.mcelhoesduffy.com/resource/Media/Auto_Trades/Fact%20Sheet%20-%20Body%20Shops_RB.pdfhttp://www.collisionequipmentexperts.com/sitebuildercontent/sitebuilderfiles/collisionshopplannnhttp://www.collisionequipmentexperts.com/sitebuildercontent/sitebuilderfiles/collisionshopplannnhttp://www.mcelhoesduffy.com/resource/Media/Auto_Trades/Fact%20Sheet%20-%20Body%20Shops_RB.pdfhttp://www.mcelhoesduffy.com/resource/Media/Auto_Trades/Fact%20Sheet%20-%20Body%20Shops_RB.pdfhttp://www.collisionequipmentexperts.com/sitebuildercontent/sitebuilderfiles/collisionshopplannnhttp://www.collisionequipmentexperts.com/sitebuildercontent/sitebuilderfiles/collisionshopplannn

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