Category Archives: News

Process optimization and IT integration – The success formula for the digitization of maintenance

Depending on the industry, maintenance does affect up to 70 percent of direct and indirect production costs. Therefore, an efficient maintenance organisation is a decisive cost lever. It also contributes to the sustainable success of any plant-intensive production. The performance of maintenance is mainly determined by two factors: on one hand, the efficiency of the maintenance processes and its methodology. On the other hand, their integration into the IT infrastructure. Both ensure the reduction of losses and waste to minimum. 

Process optimization facilitatehuman/human as well as human/machine cooperation at the highest effective and resource-friendly level. Without functional best-practice processes, even the most contemporary IT systems cannot provide any significant added value for maintenance. Then again, even the best processes can only achieve limited efficiency gains without integrated IT systems. Consequently, process optimization and IT integration must go hand in hand with the digitization of maintenance. Only their combination sustainably exploits the full optimization potentials. ConMoto’s project figures speak for themselves: 

  • Increase in overall plant efficiency (O.E.E.) by 5 to 20 percent depending on the industry, 
  • Reduction of the maintenance cost rate by 7 to 28 percent, 
  • Reduction of spare parts stocks by 15 to 55 percent.

Effective integration of process optimization and IT integration in maintenance creates competitive advantages 

The added value generated by IT systems becomes more significant with each newly developed technology. A maintenance system that exchanges data directly with a process control system saves and shortens communication paths. Algorithms for precision maintenance predicting future failures from condition data and plant histories can operate more accurately and faster than any engineer. Augmented or virtual reality technologies such as data glasses and digital twins allow maintenance personnel to access information quicker and more extensively than ever before. Meanwhile, the effective integration of processes and IT has become a decisive competitive advantage in maintenance – no matter on which stage of the digitization process your company currently is. 

Creating competitive advantages by the effective integration of process optimization and IT in maintenance
Creating competitive advantages by the effective integration of process optimization and IT in maintenance

The core of digital maintenance is a computerized maintenance management system (CMMS). 70 to 80 percent of the companies with a maintenance volume of more than one million euros per year already use a CMMS. Stillmost of them are not actively put to their intended use. The active use of CMMS systems facilitates the administration of databases with relevant information on the systematic management of maintenance processes. They enable the planning of maintenance activities, record and then evaluate them. Thus, the total costs can be broken down in detail, which contributes decisively to the further development and planning of maintenance. The selection of suitable software as well as the corresponding integration of the best practice maintenance processes and methodology are important success factors. 

In a further step of digitalization, many companies are currently engaged in mobile maintenancethe support of maintenance processes by employee-operated mobile devices. Regardless of their location, maintenance personnel may enter and request CMMS data in real time. The initial issue to be dealt with is always choosing the right software – in the field of mobile maintenance as well as in all other steps of digitalization such as predictive maintenance, augmented reality, digital twin, IoT and artificial intelligence. In the meantime, there are many companies on the market that offer maintenance software and the necessary hardware such as, for example, tablets and AR glasses. Ultimately, it is important to align the overall system of processes and IT systems with the specific requirements of your maintenance organization. 

Selection of software and hardware according to best practice criteria 

ConMoto has implemented maintenance systems and methodology at more than 250 production sites, continued the development of existing IT systems or supported our clients in selecting and implementing new IT solutions. We advise you neutrally and manufacturer-independent regarding the right software and hardware respectively – within the scope of a structured and qualified decision-making processThe selection procedure is based on best practice aspects, which includes all functionalities important for maintenance. In the final step, the customer and ConMoto consultants carry out an individual prioritization in order reflect the specific requirements of the company perfectly. The result is a ranking of the different vendors accompanied by the ideal choice of the most suitable IT solutions and interaction. 

Profit from the benefits of our pioneering role in process optimization and digitization of maintenance. 

ConMoto named Top Employer in the small and medium-sized company sector for the third year in a row

ConMoto Award Top Employer 2020
ConMoto receives the Top Employer 2020 Award

For the third time after 2018 and 2019, has awarded ConMoto as “Top Employer in Small and Medium-Sized Companies”. The seal of approval aims to draw attention to the advantages of medium-sized employers. It serves as an orientation for employees in finding interesting employers.

This special award is not based on surveys. Those often have low participation rates and are therefore not particularly insightful. Instead, the users’ access and reading behavior on is evaluated based on more than 60,000 job ads within a year.

The evaluation criteria are:

  • The number of users that a company achieves on average per job ad and company profile,
  • The percentage of users who actually read the content, i.e. stay on the page for a corresponding period of time, and
  • The proportion of readers who engage in an application-related action, for example by clicking on “Apply Now” or on the company’s website link.

Based on these three categories, a popularity index is created for each employer. ConMoto is once again one of the best rated companies this year. We are very proud of the award “Top Employer in Small and Medium-Sized Companies 2020”.

Two ConMoto horses win at the equestrian tournament in Harsum

Ferike Bormann on ConMoto Crazy Chara wins the M-class showjumping
Ferike Bormann on ConMoto Crazy Chara wins the M-class showjumping

Just like the economy, equestrian sport is getting back on track. After tournaments were not possible for a long time, a showjumping competition took place in Harsum on the Pentecost weekend. There, two horses bearing ConMoto in their name were very successful. Franz Bormann won the S-class showjumping on ConMoto Qufocolo Crazy Stud by points. It was the 101st victory of his career in an S-class competition. He also received a golden bow on the stallion for 1st place in a class M jumping competition.

His daughter Ferike Bormann won an M-class showjumping competition in Harsum on the Hanoverian mare ConMoto Crazy Chara by points. Even though the tournament was still held without an audience, it is a positive signal that show jumping is back on track as well. The sporting performances in Harsum were excellent. ConMoto congratulates Ferike and Franz Bormann – we are delighted to see them and their horses succeed with our support.

19 successful cost reduction projects within the last seven months

ConMoto ensures the competitiveness of clients in different industries

Especially when the economic situation is difficult, potential analyses are a proven method and the basis for reducing costs and increasing productivity. The comprehensive ConMoto potential analysis is based on standard modules that are individually adapted to our clients’ requirements. Each analysis includes the main elements of finance and performance as well as the corporate functions production, logistics/supply chain and order management. Other key issues and cross-sectional topics such as product development, purchasing, digitization of production or infrastructure are added depending on the respective assignment.

At a glance: Average results of 19 ConMoto potential analyses
At a glance: Average results of 19 ConMoto potential analyses

Over the past seven months, ConMoto has carried out 19 such analysis projects in a wide range of industries: twelve in the automotive sector and six others, for example, in medical technology or plant engineering. The potential analysis is useful for companies of different sizes. At the recently assessed plants, the number of employees ranged from 176 to 2,466 and annual turnover between 28 and 593 million euros. The estimated savings potentials amounted to an average of 17.1 percent of the production costs – this figure alone shows convincingly what is feasible with a structured approach.

Productivity up, costs down

Cost savings are offset by increases in productivity. The analyses revealed productivity potentials of 34.6 percent in manufacturing and 39.5 percent in logistics on average. In the indirect areas, the average of possible cost reductions was 24.8 percent. The performance values identified feasible increases of the overall equipment effectiveness at an average of 25.6 percent. Lead times could be reduced by an average of 38.3 percent.

The actual potential analysis takes between one and two weeks, depending on the size of your company and the scope of the specific tasks. It concludes with the definition of measures (initial target concepts, a tactical implementation plan) and a blue-sky workshop. Currently, we are supporting our clients in implementation projects regarding the realization of these potentials. The ConMoto consultants work with a transparent hardness level system to check the cost impact and tools for close progress monitoring.

Rüdiger Feigl new member of ConMoto’s Management Team

ConMoto_ Ruediger Feigl
Dipl.-Ing. (FH) Rüdiger Feigl

Rüdiger Feigl recently joined the management team at ConMoto. The mechanical engineer has more than 20 years of consulting experience as a partner in both renowned large consulting companies and boutique firms. Prior to working as a consultant, he gained eight years of industry experience in various functions within the automotive supply industry worldwide.

Before joining ConMoto, Rüdiger Feigl worked as a partner in leading lean management consulting firms where he was responsible for the operational excellence competence center. His consulting focus is the development of functional strategies as well as their design. Mr. Feigl is specialized specifically on the implementation of efficiency and effectiveness programs in development, production and supply chain management at manufacturing companies, mostly from the automotive industry. He is an expert in lean transformation, agile management, restructuring and supplier risk management.

At ConMoto, Rüdiger Feigl is responsible for the consulting fields of production system, investment planning and restructuring.

ConMoto’s virtual anniversary

ConMoto's virtual anniversary
ConMoto’s signature gray overalls at your aid! (article in FOCUS magazine, 43/1993)

On April 1st, 1990 Dr.-Ing. Ralf Feierabend founded ConMoto. Even though celebrating together is not easy in times of social distancing, we at ConMoto did exactly this: within the scope of a team meeting with 90 participants in twelve countries including from Asia as well as the Americas, we held our virtual anniversary party.

We shared memories from 30 years of company history: pictures, stories and talks. All ConMotos embraced the welcome pastime during a time that has all of us working in separated locations. Still, we do work as a team and continue to provide our services to our clients with all reasonable care.

Difficult times demand adequate solutions. And just as we were successful throughout three decades, we are going to master the crisis as well: together. First and foremost, we wish you good health – and positive moments for your company, too.

Volker Staack new member of ConMoto’s Executive Board

Dipl.-Kfm. Volker Staack
Dipl.-Kfm. Volker Staack

Dipl.-Kfm. Volker Staack just joined ConMoto’s Executive Board. He possesses more than 17 years of professional experience, both as a partner at renowned top consultancies and smaller companies. For eight years, Mr. Staack had lived and worked in the U.S., for six years in European countries besides Germany. Overall, Mr. Staack is a highly skilled industry professional of more than 12 years experience, especially in the electrical industry.

Prior to joining ConMoto, Volker Staack was a Partner at a globally leading consultancy in the U.S. and a specialized “boutique” consultancy in Germany. He oversaw the Global Innovation Practice and globally implemented consulting projects within the industry sectors machinery and plant construction, automotive and aerospace – often by order of private equity investors. His consulting portfolio includes purchasing and procurement, development and innovation as well as product cost management and product range management. He is an expert for organization development and change, agile management, restructuring and supplier risk management.

At ConMoto, Volker Staack in responsible for the consulting areas procurement, development and product cost management.


Nils Blechschmidt talks maintenance 4.0 at the Global ManuChem Strategies

Nils Blechschmidt talks maintenance 4.0 at the Global ManuChem Strategies+++ UPDATE: Unfortunately, the conference has been postponed due to the current corona virus outbreak – we will keep you informed as soon as a new date has been announced. +++

Manufacturing experts and top management representatives of the chemistry, pharmaceutical and process industries will attend the conference Global ManuChem Strategies in Berlin from March 15th to 17th, 2020. The event focusses on all aspects of the optimization of production processes. A main emphasis is the digitization of production.

The key note of Nils Blechschmidt, senior partner and member of the management board of ConMoto, addresses the challenges of industry 4.0 as well. He is speaking about maintenance 4.0 and asset innovation

on Monday, March 16th, 2020 at 3:30 PM.

Inter alia, Blechschmidt is going to discuss aspects of smart maintenance as well as data generation and analysis. Additionally, he will introduce a new ConMoto project study covering maintenance, asset innovation and life cycle costing.

Annual Handelsblatt conference: Potenzials for the steel industry

Nils Blechschmidt auf der „Zukunft Stahl“
Nils Blechschmidt at the “Zukunft Stahl”

Nils Blechschmidt, Senior Partner and Member of the management team, presented his keynote “Value-oriented maintenance and Maintenance 4.0” at the annual Handelsblatt conference “Zukunft Stahl”. In Düsseldorf, he spoke about the strategic importance of maintenance for the steel industry in front of an audience of 170 managers.

Blechschmidt reflected especially on how automation and digitization change maintenance processes. He explained how the future-oriented implementation of Maintenance 4.0 concepts enables steel-producing companies to increase their productivity. The world’s leading maintenance expert estimated the possible decrease of the total cost of ownership during the whole lifecycle of a plant at -20 to -30 percent, whereas the return on net asset (RONA) may be increased by 20 to 32 percent. The RONA is a clear indicator of the efficiency and profitability of a company’s plants.

Dr. Marc Heinisch, Senior Partner and Chief Sales Officer at ConMoto, summarizes the results of their talks with many steel industry decision makers: “Besides scalable technologies, the change to decarbonization and green steel requires a lot of change management and implementation strength for the innovative, efficient production of high-tech steels.”

ConMoto Academy & Training holds LEAN trainings for LÄPPLE Group

ConMoto Academy & Training holds LEAN trainings for LÄPPLE Group
A LEAN workshop Lego brick

“We love technology” describes what LÄPPLE Group stands for – including its companies LÄPPLE AUTOMOTIVE, FIBRO and FIBRO LÄPPLE TECHNOLOGY (FLT) as well as LÄPPLE AUS- UND WEITERBILDUNG, its training branch. LÄPPLE’s 2,700 employees produce chassis modules, standard components and rotary tables. They also devise automation solutions. Looking back at 100 years of corporate history already, the family company positions itself worldwide successfully with its products and solutions.

In order to reach its growth and revenue goals in the future as well and remain true to its high quality standards, the group is striving to integrate the methods and tools of LEAN management into its company culture. Therefore, the management introduced the project “LEAN LÄPPLE” throughout the group and its companies. ConMoto Academy & Training has developed the trainings and provides them for both executives and employees.

After the trainings, ConMoto is going to perform a comprehensive rollout and educate the LEAN management team as well. In particular, one company product is an integral part of the trainings. “LEAN LÄPPLE” introduces a process of continuous improvement, therefore establishing a lean and learning organization in all divisions. LEAN culture is making use of the skills and capabilities of all employees to implement a waste-free value creation chain – including customers and suppliers as well. Together, we are set out to make “LEAN LÄPPLE” the basic principle of the production and management systems as well as an integral part of an applied company culture.