Repair Blueprint and Damage Analysis SOP

Standard operating procedure for collision repair planners to perform full disassembly, identify hidden damage, document findings, and lock a repair plan before body repair begins.

Steps

• The estimator verifies the repair order and blueprint scope
  The estimator confirms the repair order number matches the vehicle VIN, the blueprint revision date is current within 30 days, the customer authorization signature is present, and the estimate scope matches the requested repair objective; escalate any discrepancy before disassembly begins.
• The appraiser inspects and documents the vehicle condition
  The appraiser photographs all four sides and the undercarriage, measures visible damage using OEM measurement points, records dimensions to ±0.5 mm tolerance, and classifies damage severity as minor, moderate, or severe before disassembly begins.
• The technician disconnects power sources and secures the vehicle
  The technician disconnects the battery, verifies all power sources are isolated, installs wheel chocks, and confirms the vehicle cannot move before disassembly starts.
• The technician performs full disassembly to expose hidden damage
  The technician removes affected components one at a time, labels and stores fasteners in trays, and preserves removed parts for reassembly reference until all repair-relevant areas are exposed.
• The planner inspects structural, mechanical, electrical, and cosmetic damage
  The planner compares each exposed area to OEM repair specifications, scan results, and measured deviations, then records every visible and hidden damage item with the affected component and repair implication.
• The estimator documents parts, labor, and sublet requirements
  The estimator enters all required parts, labor operations, materials, and sublet items into the estimate management system, attaches supporting photos, and notes any line-item changes discovered during blueprinting.
• The planner resolves estimate deviations and escalates exceptions
  The planner compares findings against the approved estimate, documents any deviation outside tolerance, and escalates hidden damage, safety concerns, or OEM deviations for approval before repair work proceeds.
• The manager locks the repair plan and releases the vehicle to repair
  The manager confirms all required approvals are complete, verifies the repair plan is locked in the estimate system, and releases the vehicle to body repair only after documentation is finalized.