Master emergency breakdown response with our comprehensive on-road triage system. Make critical rebuild vs replace decisions quickly, minimize downtime, and get your vehicles back in service faster with proven protocols and decision trees.
Rapid assessment and decision-making protocols for on-road breakdowns
On-road triage is a systematic approach to assessing and responding to vehicle breakdowns in real-time, enabling rapid decision-making between temporary repairs, component rebuilds, or complete replacements.
This playbook provides your drivers and technicians with clear protocols for evaluating breakdown severity, determining repair feasibility, and making cost-effective decisions that minimize downtime while ensuring safety and compliance. For comprehensive safety protocols, refer to our roadside safety checklist to ensure all emergency procedures are followed correctly.
| Severity Level | Response Time | Primary Action |
|---|---|---|
| Critical Safety | Immediate | Tow to facility |
| Major System Failure | < 2 hours | Mobile repair unit |
| Minor Component | < 4 hours | Roadside repair |
| Non-Critical | Scheduled | Continue to destination |
| Preventive | Next PM | Monitor & schedule |
Structured approach to handle on-road breakdowns efficiently and safely
Ensure your team has the proper emergency kit components readily available for immediate response.
Use our detailed rebuild vs replace matrix to make informed decisions quickly.
Follow proper lockout/tagout procedures when performing critical system repairs.
Systematic approach to making cost-effective repair decisions
Evaluate if the vehicle can be safely repaired on-site or requires towing to a facility.
Compare repair costs against replacement value and consider downtime impact.
Assess repair time vs replacement availability and operational urgency.
Implement the most cost-effective solution based on comprehensive analysis.
Fleets implementing structured on-road triage playbooks report significant improvements in response times and cost savings.
Reduction in average downtime
Decrease in towing costs
Improvement in first-call resolution
Reduction in secondary failures
"Implementing the on-road triage playbook transformed our breakdown response. We've reduced average repair time by 60% and saved over $200,000 annually in unnecessary towing and emergency repair costs."
Fleet Operations Director, TransLogistics Inc
Get answers to the most frequently asked questions about implementing on-road triage protocols
Essential equipment includes: diagnostic scanner, basic hand tools, emergency triangles and flares, communication device, first aid kit, temporary repair materials (tape, wire, clamps), common fluids (oil, coolant, brake fluid), spare fuses and bulbs, tire repair kit, and a comprehensive triage checklist. Advanced kits may include portable jump starters and air compressors.
Effective training includes classroom instruction on triage protocols, hands-on practice with diagnostic tools, scenario-based exercises for common breakdowns, safety procedures and hazard assessment, communication protocols with dispatch and maintenance, documentation requirements, and decision-making frameworks. Regular refresher training and updates on new procedures ensure consistency. Don't forget to include after-hours response procedures in your training program.
Choose rebuild when: repair cost is less than 50% of replacement cost, vehicle has low overall mileage, core components are in good condition, parts are readily available, downtime is acceptable, and warranty considerations favor rebuild. Choose replacement when safety is compromised, multiple systems are failing, repair exceeds 70% of replacement cost, or the vehicle has exceeded its useful life. Always check the latest service bulletins for manufacturer recommendations on specific components.
Documentation should include: date, time, and location of breakdown, initial symptoms and driver observations, diagnostic codes and test results, photos of damage or failed components, safety assessment findings, repair vs replace decision rationale, parts and labor estimates, actual repairs performed, and post-repair test results. Use digital forms for real-time data capture and transmission.
Key liability considerations include: ensuring repairs meet DOT safety standards, documenting all temporary repairs and limitations, obtaining proper authorization before proceeding, following manufacturer specifications, using qualified personnel for critical systems, maintaining appropriate insurance coverage, and scheduling follow-up inspections for temporary fixes. Never compromise safety to expedite repairs.
Enhance your rebuild vs replace decision-making with these essential resources
Industry-standard repair times for accurate scheduling and cost estimation.
View GuideDiscover comprehensive repair guides and resources for efficient fleet maintenance
Transform your breakdown response with proven triage protocols that minimize downtime, reduce costs, and keep your fleet moving.
Average response time under 2 hours
DOT-compliant repair protocols
40% reduction in emergency costs