What this checklist covers
The Collision Repair Process Checklist is a 15-point scorecard for accident vehicle intake, damage documentation, repair method selection, structural repair, parts, paint process, and delivery readiness. Each criterion is scored from 1 to 5 on what the auditor sees on the day, and every gap goes into an action plan with an owner and a close date.
AutoSmart tip: Collision repair compliance is non-negotiable from a safety perspective — a vehicle returned to the road with out-of-tolerance structural dimensions, unapproved weld positions, or uncalibrated ADAS systems is a safety liability regardless of how good it looks cosmetically. The repair file is your evidence that the repair was done correctly; if it cannot be produced, the repair cannot be verified. Treat every collision repair file as a legal document from the moment intake photographs are taken.
The checks
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Accident intake and damage documentation
- Is a comprehensive photographic record of all damage taken at vehicle intake — covering every affected panel, tyre, wheel, underside, and glass — before any dismantling or cleaning?
- Is the customer's account of the accident (direction of impact, speed, secondary impacts) recorded at intake, as this information may affect repair scope and insurance claim validity?
- Is a structural integrity preliminary assessment performed at intake to determine whether the vehicle is safe to move and whether there is any risk of hidden structural compromise affecting dismantling safety?
- Is a written estimate produced for the repairing insurer or the customer (as appropriate) with the repair scope clearly defined before any work authorisation is sought?
Repair method and structural repair
- Is the OEM's repair information accessed for every structural repair, confirming approved repair sections, prohibited repair zones, and required weld specifications for the specific model and repair area?
- Is structural measurement taken using a dedicated vehicle measuring system before and after structural repair — confirming the vehicle is within OEM dimensional tolerance before proceeding to panel fitting?
- Are cut lines for section replacement placed at OEM-approved positions — not at convenient access points — with deviation from OEM cut positions requiring documented technical justification?
- Are welded joints performed using the weld type specified by the OEM (MIG, resistance spot, MIG plug) with the correct weld parameters for the steel grade involved?
Parts and paint process
- Are replacement parts for collision repairs genuine OEM parts (or insurer-approved matching quality alternatives where policy permits), with parts specification confirmed against the vehicle's original configuration?
- Is the paint system applied according to the paint manufacturer's specification — with the correct primer system, application coats, and bake schedule — not abbreviated under time pressure?
- Is corrosion protection applied to all internal cavities and weld flanges exposed during the repair, consistent with the OEM's corrosion protection requirements for the vehicle?
Final inspection and delivery readiness
- Is a pre-delivery road test conducted for every collision repair to confirm ride, handling, steering, braking, and powertrain behaviour are consistent with the pre-accident condition?
- Is a diagnostic scan performed after collision repair to identify any stored fault codes in chassis, ADAS, airbag, or other electronic systems that should be cleared or investigated before delivery?
- Is ADAS calibration completed for all systems requiring it — forward collision warning, lane keep assist, blind spot detection, parking sensors — before the vehicle is delivered, with calibration reports retained in the repair file?
- Is the complete collision repair file — intake photographs, estimate, OEM repair method reference, structural measurements, weld records, parts invoices, calibration reports — retained and retrievable for warranty, insurance, or legal reference?
How to run it
How the scoring works
Before the visit, fill in the dealer or centre, the auditor, the date and the audit cycle. Then score each of the 15 checks from 1 to 5 on what you see on the day, not on what the site aims for, and add them up out of 75.
- 1Not in place
- 2Attempted
- 3Defined
- 4Managed
- 5Fully sustained
- Green60–75 · 80–100%Compliant. Keep the standard.
- Amber38–59 · 50–79%Improvement needed: a structured action plan within 30 days.
- Red0–37 · Below 50%Priority intervention, escalated to regional management.
Then close every gap
Each gap goes into the action plan tracker and moves through four stages until the auditor closes it.
- 1PendingOwner and close date set
- 2In progressWork under way, evidence gathered
- 3CompletedEvidence submitted for review
- 4ApprovedVerified and closed by the auditor
