This document discusses value-oriented maintenance and improvement of overall equipment effectiveness (OEE) and cost efficiency. It describes ConMoto Consulting Group's experience optimizing production sites through their MaintenanceScoreTest assessment and modular improvement system. Their approach identifies maintenance weaknesses, compares processes to maintenance excellence standards, and implements customized improvements to maximize value creation through optimal maintenance processes.

1. VALUE ORIENTED
MAINTENANCE
IMPROVEMENT OF O.E.E.
AND COST EFFICIENCYOver 20 years of experience
More than 125 sustainably
optimised production sites/
plants in the last seven years
Successful team of consultants
led by experienced industry
managers with a significant
track record in the sectors
• Automotive/mechanical
engineering
• Aviation
• Chemicals
• Food & beverages
• Life science/
pharmaceuticals
• Oil/gas
• Pulp & paper/wood
• Railways
• Semi-conductors/
electronics
• Steel/metal
• Textiles/spinning/dyeing
• Utilities
Proven implementation
momentum across 4 continents
with striking results
We create advantage

2. 2
Years of experience in on-site implementation for our customers on 4 continents
In successful companies today, production has to be organi-
sed so as to be not only efficient, but also flexible and adap-
table. In order to meet these requirements, the searching
gaze of many corporate managers is now increasingly di-
rected upon maintenance activities. Rightly so, since Value
oriented Maintenance and asset management is definitive
for economic efficiency and flexibility in producing goods.
Depending on the industry and asset intensity, at peak
more than 60% of production costs are influenced directly
and indirectly by the quality of maintenance activities.
A comprehensive study1
shows that many companies, even
those in "model industries", are still a long way from first-class
maintenance and asset management. This failure to attain
increased efficiency is staggering. The result, however, at
the same time illustrates the fact that production has a future
even at high-wage locations if the opportunities inherent in
Value oriented Maintenance are consistently utilised.
Concretisation of the variables for the sustainable opti-
misation of maintenance systems is effected using the
MaintenanceScoreTest©
developed by ConMoto and
repeatedly perfected in the course of multiple projects.
Using this five-day assessment, maintenance-specific pro-
cesses, structures and Key Performance Indicators (KPIs)
are systematically analysed and evaluated according to
twelve main criteria. Concerted development within an
inter-disciplinary team made up of managerial staff and
operatives results in a holistic view of strengths and weak-
nesses in terms of maintenance and asset management.
The company-specific efficiency profile thus established
is compared with an ideal situation which is described as
one of Maintenance Excellence. This comparison leads
directly to tangible variables for improvements which can
be reliably evaluated by means of basic data and compa-
rative figures.
Consequently, the identified potentials for the targeted im-
provement of the Overall Equipment Effectiveness (O.E.E.),
the enhancement of process stability, the lowering of
maintenance costs and the reduction of capital required
for spare parts and investments are specified.
The modular system available conjunct to the analysis
facilitates a result-oriented implementation of the measu-
res for improvement in the production plants along with a
comprehensive change management. It can be individu-
ally adapted to the respective company. In addition to the
six core variables "Maintenance strategy", "Contractor
management", "Time management/capacity planning
and scheduling", "Spare parts management", "Operator
involvement" and "KPIs and costing", needs-orientated,
supporting variables are available. By means of these
best practices and tools, proven time and again across
diverse industries, a customised improvement of main-
tenance activities is advanced. The objective is the im-
plementation of optimal maintenance processes, which
are efficient and robust, which minimise risks and which
promote the mobilisation and involvement of staff at all
levels of the hierarchy.
En route to Maintenance Excellence, "troubleshooting"
is superseded by a targeted increase of corporate value
creation. As a first step, it is pertinent to manage the given
total system so that a cost minimum is reached taking into
account direct and indirect costs of maintenance (costs
arising from production downtime). As a second step,
sustainable life cycle asset management is to be imple-
mented, deploying the requisite innovation momentum.
Only in such a manner can maintenance be enduringly
developed so as to constitute an accepted expert partner
with an objectively measurable value-add, and thus a sus-
tainable increase in competitiveness attained.
ConMoto Value oriented Maintenance and Asset Innovation
1) Cf. ConMoto study "Value oriented Maintenance – The Strategic Dimension of the Spanner"
2) In order to improve the classification of the maturity of maintenance systems, ConMoto developed the Maintenance Excellence graduated model.
This is based upon best practice experiences derived from successful projects with more than 500 industrial companies.
Project sites

3. 3
Spectacular results – This is what our customers say about us
Objectively measurable project results in diverse industry sectors3
Clariant
Dr. Timm Plitt
Head of Maintenance, Werk Gendorf
"ConMoto addressed our concerns appropriately, and sub-
stantially furthered our development by providing advisory
and expert inputs. We were particularly convinced by the
momentum of implementation evinced by ConMoto."
Eberspächer Abgastechnik
Sidney Dingert
Head of Maintenance, Neunkirchen
"With the help of ConMoto, we succeeded in systematically
developing our maintenance in terms of its effectiveness and
efficiency so as to make it future-proof. We were thus able to
apply the ConMoto best practice methods and experiences to
the specific concerns of our plants in a structured manner."
Mondi
Peter Putz
Technical Director, Kraft Paper
"What ConMoto has enabled us to learn over the last one-
and-a-half years in our five Kraft Paper plants is impressive.
This is the basis for the further development of our facili-
ties over the next five years."
Siltronic
Dr. Dieter Gilles
Plant Manager, Wacker AG, Burghausen
"ConMoto definitively assisted us in optimising our main-
tenance and production activities in a targeted manner. Of
particular note is the integration of content-specific new
ideas, which were concertedly implemented in our wafer
production facility at Burghausen."
3) Maint. cost rate = Maintenance cost rate (totall maintenance costs ÷ indexed asset replacement value)
O.E.E. = Overall Equipment Effectiveness
CAPEX = CAPital EXpenditure
EBIT-effect = Improvement of the operating result (earnings before interest and taxes)
4) Including building suppliers, energy suppliers, tool manufacturers
Process industry
(>50 optimised production plants)
High-precision engineering
(>25 optimised production plants)
Automotive/mechanical engineering
(>25 optimised production plants)
Miscellaneous4
(>25 optimised production plants)

4. ConMoto best practices and tools to address your challenges
Do you have heterogeneous implementation levels in your production sites/plants? We are
experts in the sustainable implementation of measures for improvement and the establishment of a
self-supporting development for your maintenance and asset management.
Do you consider "learning" to be a strategic exercise that purports to counter demography
and the shortage of skilled professionals? We offer you tailored approaches to training and a
stabilising shop floor management programme as the basis for sustainability and competitiveness.
Are volatility management and variabilisation of maintenance services issues that are debated
by your company's Executive Board? We assess the need to effect maintenance activities
contingent upon the equipment availability that you require, and prepare scenarios for reduced,
average and full utilisation.
Do you wish to promote a targeted, product-specific development of your maintenance
programme on the basis of differentiated portfolio analyses? We show you best practice
decision-making processes to make your maintenance programme focused and professional and,
thus, to manage and safeguard competitive advantages.
Do you wonder when the optimal time for re-investment is? We evaluate the value-add of your
existing cost-intensive assets and the interplay with your maintenance programme. This involves
developing opportunities to systematically extend the life cycle of your machine and facility pool.
Do you plan to make significant investments in the global market, and are you on the brink
of "leaping into new worlds"? We have rich global experience in the establishment of future-
proof processes and structures for your maintenance and asset management programme in
new locations.
Do compliance and the adherence to legal stipulations assume top priority in your company?
We support you in developing and implementing integrated HSEQ (Health, Safety, Environment and
Quality) management.
Your personal contact person
Nils Blechschmidt
Senior Partner
ConMoto Consulting Group GmbH
Managing Director
ConMoto Strategie und Realisierung
Tel.: +49 (0)89 780 66-114
Fax: +49 (0)89 780 66-101
Email: blechschmidt@conmoto.de
Nils Blechschmidt has been a management consultant since 1995 at ConMoto Consulting Group GmbH
and since 2002 he is a Senior Partner and shareholder of the company. He is responsible for the field of
"Value oriented Maintenance and Asset Innovation". As an expert in this area and with well-founded know-
ledge of various sectors, such as the aerospace industry, engineering and plant construction, the car
and component supplier industry, process industry (chemicals, steel, semi-conductors, pharmaceuticals,
food), plastics processing industry and transport technology, he gives numerous lectures. Before his time
at ConMoto, Nils Blechschmidt was employed as the Technical Head of an aircraft maintenance business
for seven years. He completed his education as a Dipl.-Ing. (graduate engineer) in aerospace technology
at the University of the Bundeswehr in Munich and gained his MBA at Henley Management College (UK).
Our company
We have been supporting companies for more than 20 years to secure and improve their competi-
tiveness and sustainability. Around 80 consultants, distributed across our offices in Munich, Stuttgart,
Vienna, St. Gallen, Bratislava and Shanghai, work competently and with commitment to realise the
best possible benefits for our clients.
We create advantage!
This is the guiding approach of our implementation-oriented consultancy.
ConMoto Consulting Group
GmbH, Munich
Boschetsrieder Str. 69
81379 Munich
Germany
Tel.: +49 (0)89 780 66-0
Fax: +49 (0)89 780 66-100/-101
ConMoto Consulting Group
GmbH, Stuttgart
Gerokstr. 11
70184 Stuttgart
Germany
Tel.: +49 (0)711 767 79-0
Fax: +49 (0)711 767 79-205
ConMoto Consulting Group
Ges.m.b.H, Vienna
Schottenring 16
1010 Vienna
Austria
Tel.: +43 (0)1 585 0 274-0
Fax: +43 (0)1 585 0 274-11
ConMoto Consulting Group
GmbH, St. Gallen
Notkerstr. 10
9000 St. Gallen
Switzerland
Tel.: +41 (0)71 244 08 71
Fax: +41 (0)71 243 18 81
ConMoto Consulting Group
GmbH, Shanghai
Unit 1606, Time Square
93 Huai Hai Zhong Rd.
200021 Shanghai
People’s Republic of China
Tel.: +86 (0)21 614 152-75
Fax: +86 (0)21 614 152-76
Email: info@conmoto.de
Web: www.conmoto.de
www.conmoto-consulting.com