Maintenace and Repair – Better results with TCO and TPM

In industries such as fleet management and leasing, the concept of TCO (Total Cost of Ownership) is well established.
How does this approach fit into the industry?

Horia Todoran: The TCO approach is primarily about keeping the share of an equipment in the total life cycle costs of a machine as low as possible. Within production plants in Romania, we are currently facing the challenge of modernizing and upgrading the hydraulic systems, especially in terms of energy efficiency. This is not easy with hydraulics, as it is decentralized, and many individual systems need to be upgraded.

In this context, the holistic TCO approach can be particularly advantageous. It takes various aspects into account, with a higher focus on the operational activities, such as standardization, such as reducing the number of component variants or digital monitoring of the machine status in order to better organize maintenance cycles. This is where Industry 4.0 can help. It enables automation, condition monitoring and predictive maintenance.

Staufen follows a similar approach with TPM. Where do the two concepts overlap?

Arpad Boros: TPM is a structured lean approach that systematically reduces waste within maintenance processes. It fits perfectly with the TCO concept because it also takes a holistic approach. Essentially, it is about transferring responsibility for routine maintenance to employees on the shop floor and thus reducing the workload.

Traditional maintenance teams are experienced in repairing things when they break. This can be described as firefighting. However, the goal of TPM is to prevent fires from starting. We achieve this by employees continuously monitoring the manufacturing. Industry 4.0 technologies are also a useful support here, as they simplify monitoring through digital processes.

What are the benefits of combining TCO and TPM for industrial companies?

Horia Todoran: The two concepts fit together like hardware and software. The TCO approach is ideal for creating clarity and transparency regarding operation costs of a machine or system. Using standardized components, repairs and a low number of variances automatically leads to less inventory and lower maintenance costs. TCO also fulfils the same task in production processes: by looking at the total costs, unnecessarily complex procedures can be identified. With regard to maintenance, it is also about integrating the operators into the tasks. With tailor-made solutions, monitoring tasks can be simplified or automated.

TPM has a strong impact on the processes within
companies and leads to a series of changes in planning, production, and maintenance. What are the most difficult steps for companies?

Arpad Boros: In my experience, the most difficult step is to explain to the management that the TPM approach is not a fast cost-cutting program. The results only come with a certain delay – but then, they are sustainable. Among other things, operators must be trained and coached so that they can take responsibility for their machines. Another important prerequisite is communication between all stakeholders who play a role throughout the life cycle. They must sit at the same table, otherwise the process will not work.

In modern industries, new machinery investments can be significant, especially in heavy industry. What measures do companies need to take to ensure that new investments are future-proof?

Horia Todoran: Investments are about making progress through technological innovations – with a view to sustainability and preserving livelihoods, among other things. As a specialist in drive and control technology, we are always offering our customers new technologies and innovations. We focus on the impact of these new technologies. Although they may incur higher acquisition costs. If you look at the TCO over ten years – including power, maintenance, and other operating costs – it often becomes clear that a more expensive initial investment is more cost-effective in the long term compared to cheaper, conventional machines.

Can companies pursue this TCO/TPM vision alone or do they need an experienced partner for a smooth and effective implementation?

Working with an experienced partner has many advantages, including a fresh perspective on established processes and organizational structures. In my experience, companies often fail to recognize the significant waste and potential within their own operations. The firefighting operations of maintenance teams are simply accepted; after all, they are part of everyday life. An external perspective can help to identify your own blind spots.