In 2006 we converted our production operation into a “lean production facility," a single piece flow process based on the Toyota Production System. In 2009, we began to teach this methodology to others in order to continue with our own education as well as to better our industry.

In the lean process, this “flow” is configured as a “pull system” wherein work is delivered when required by the customer and then sequentially back up-stream through the entire process.

"Lean production is not just a collection of good tools like 'repair blueprinting' or 'team work'.  It is a major cultural change that demands all the commitment and energy an organization has in order to be successful."

Great rewards are to be had in employee, vendor, and customer satisfaction.  However, there can be significant barriers to its implementation in the collision repair industry.  The biggest problem is the intellectual capacity of and behavioral change required of management.  Many in our industry do not understand the true nature of this transformation.

Trying “lean” a little at a time is not a good option and will result in lots of stress and possible failure.  That being said, our industry has some very hard working and creative people at many levels and they will make this work when they put their mind to it.

MAB in the news . . . .

Additional resources

If you feel you fit the profile and would like to speak with us further, we recommend that you explore some of these resources first.

The Toyota Way:
by Jeffrey Liker
Publisher: McGraw-Hill
ISBN-10: 0071392319
ISBN-13: 978-0071392310

The Toyota Way Fieldbook:
by Jeffrey Liker, David MeierBook
Publisher: McGraw-Hill
ISBN-10: 0071448934
ISBN-13: 978-0071448932

The Machine That Changed the World:
by James P. Womack
Publisher: Harper Perennial (November 1991)
ISBN-10: 0060974176
ISBN-13: 978-0060974176


An Introduction to the Toyota Production System
2014 Sustainability Summit Breakout (PDF)
Publish date: April 9, 2014

Manage Materials the Lean Way
Publish date: April, 2013

Press Release
DuPont Performance Coatings Partners with Marshall Auto Body for Future Lean Curriculum Development

by: Andrew Johnson
Publish date: July, 2010

FenderBender : Lean Starts in the Front Office
by: Andrew Johnson
Publish date: July, 2010

Lean Collision Repair Shops: the big picture
by: John Ryswick
Publish date: June 3, 2009

The 'Lean Look' at Marshall Auto Body
Search Autoparts
By: John Yoswick
Publish date: June 3, 2009


Contact: Aaron Marshall

Lean involves keeping the product (vehicle) busy, not the people. By completing each step in the process error free, an uninterrupted "flow" is maintained.

Above we show the transformation process and the current state. Because this system is based on continuous improvement, this can only be a snap shot of an ongoing journey.

Sustainability Champion

Wisconsin Sustainable Business Council
Tell Your Sustainability Story »

March 21, 2014
the Wisconsin Sustainable Business Council
by Marcus Cederstrom

It’s time again to feature a Green Masters Program Sustainability Champion! We love highlighting all of the great work that Green Masters Program participants are doing to drive sustainable business practices forward.

So, without further ado, the Green Masters Program Sustainability Champion: Marshall Auto Body!

Marshall Auto Body

Marshall Auto Body is based in Waukesha, Wisconsin, and specializes in as they say, “managing the time, quality, and cost of auto body collision repair.” Eight years ago, the company implemented a lean manufacturing system that helps them to find and eliminate waste, surface problems, and even increase utilization and throughput. Along with their work in eliminating waste, the company monitors their energy usage and makes that available online through their e-gauge. Marshall has partnered with H&H Group Holdings (another Green Maters Participant) to install solar panels at their facility. Their monitoring system allows them to plan for and minimize peak demand for energy consumption. Marshall Auto Body hopes to be carbon neutral by 2016.


Seminar : July 31, 2014
3:30 PM - 5:00 PM
NACE Expo & Conference
Advanced Production Techniques

This session assumes you understand lean concepts and basic production principles and offers actionable ideas to further reduce cycle time.

Aaron Marshall co-owner of Marshall Auto Body. Aaron is widely known for his innovative lean repair processes, which are featured in the ICAR - Lean curriculum. Aaron, a pilot, travels to Axalta shops and offers practical lean implementation assistance.  Aaron has a degrees in International Business from University of Denver.