Minor non-conformity Vs Major non-conformity
Before diving in, it helps to understand what is at stake. Non-conformities found during a BS 10125 audit fall into two categories.
Minor non-conformity
Affords no risk to the repair activity when dealt with within a suitable period.
Major non-conformity
Affects the technical aspects of vehicle damage repair activity so that there is a risk that repair work may not be carried out correctly or safety may be compromised.
The five areas below include both types of non-conformity, and the distinction between them matters.
1. Repair process records: the most common finding of all
With 200 non-conformities recorded against Clause 5.4, this is the single biggest area of failure across the data set. Auditors regularly flag missing or inaccurate repair information, incomplete task control records, and gaps in documentation around adhesives, bonding agents, and system reinstatement.
If it is not recorded, an assessor cannot see it. Build the habit of thorough, complete record-keeping.
2. Repair preparation
Make sure you have right resources are in place Clause 4.1 produced 13 minor non-conformities at initial audit stage, making repair preparation the most frequent minor finding for workshops going through certification for the first time.
Making sure you have the right resources, competencies and supply partners in place to ensure a repair is completed and right first time. Good repair preparation equals reduced rework costs.
3. Currently competent person: Most common major non conformity at initial audit
Clause 4.4.3 is the most common source of major non-conformities for workshops seeking certification for the first time. BS 10125 requires some critical repair tasks to be completed only by currently competent persons. Ensure staff are trained and qualified to recognised industry standards
4. Adherence to repair methods: the most serious finding by volume
With 51 major non-conformities, Clause 4.5.1.2 carries more serious findings than any other in the data set. Auditors have found cases where technicians have not followed prescribed repair methods, including incorrect torque settings, bolts not renewed where specified, and instances where repair methods were not accessed at all during the job.
Ensuring your team consistently refers to and follows the correct repair methods for every repair, regardless of the job type, is a requirement of the standard. It is also the foundation of a safe and trustworthy workshop.
5. Repair task control: the gap between doing and proving
Clause 4.8 covers how repairs are Controlled from start to finish. Think about the last repair that ran across multiple technicians and days, can you verify who completed each task and repair has been completed as intended. Ensure your repair task control process is accurately and effectively documented.
One more area to watch: subcontracting
If your workshop subcontracts any part of the repair process to external providers, your audit will include a review of those arrangements too. BS 10125 requires that subcontracted work meets the same standards as work carried out in-house, and that you have documented agreements in place to evidence this. It is an area that catches workshops off guard, particularly those that subcontract specialist work on an informal basis. Review your subcontracting arrangements before your assessment and make sure they are documented, agreed, where required auditable evidence of current competency.
What this tells you about your own workshop
Across 1,573 non-conformities, the pattern is the same. All are avoidable and contribute to conducting safe and effective repairs.
