Written by Investing in custom machinery is not just about filling a production gap — it’s about building a long-term performance system that runs reliably for years, not just weeks.
And the earlier you prepare, the more successful (and scalable) your automation journey will be.
Here’s how to think like top-tier manufacturers — and how to pick a partner who can deliver machines that actually live up to their specs.
📋 Step 1: Prepare Before Contacting Any Supplier
🎯 Start with a Total Productive Maintenance (TPM) mindset.
Before you reach out to any builder, prepare the following data:
| What to Prepare | Why It Matters |
|---|---|
| 🧮 Target OEE & Technical Availability | Machines must support the real output you expect — not just run. |
| 🅰️ Machine Classification (AA/A/B/C) | Helps define expectations: Class A = high uptime, low failures. |
| 🔄 Changeover Times (SMED) | Impacts design flexibility, tooling, and operator workflow. |
| 🔗 Lifecycle Management Goals | Enables better maintenance, spare part and upgrade planning. |
| 📊 TPM Tools at Specification Stage | Use Early Equipment Management tools: FMEA, P-M Analysis, etc. |
| 📦 Product Specs & Volumes | Determines structure, motion control, and feeding logic. |
| 📏 Part Dimensions & Tolerances | Directly affects accuracy, tooling, and part clamping. |
| ⏱️ Desired Cycle Time | Guides sizing of actuators, motors, and PLC scan speeds. |
| ⚙️ Existing Utilities (Air, Power, etc.) | Helps optimize power needs and interface with your infrastructure. |
| 💾 Data Collection Needs | Enables SQL, MES, or SCADA integration planning. |
🛠️ Step 2: Choose a Truly Reliable Partner
Anyone can weld steel and attach a motor — but few understand what makes a machine reliable over years of real production.
✅ 1. TPM-Aware Engineering Design
- Understands OEE losses and how to eliminate them
- Designs for Class A TPM machine standards
- Plans for easy maintenance, cleaning, and root cause visibility
✅ 2. Lifecycle Thinking, Not Just Delivery
A strong partner will support your machine through its entire lifespan:
- Spare part strategy and critical stock
- Remote diagnostics and alarms
- Upgrade paths and modularity for future-proofing
Don’t ask: “How long will it run?”
Ask: “How long will it run well, and how will I know when it won’t?”
✅ 3. Intelligent Control Systems
- PLC/HMI hardware that fits your standards
- MES and SQL-ready architecture
- Multi-level access control
- Built-in alarm/fault analysis & remote access
- Backup and restore options for disaster recovery
🤖 Bonus: Think Net Capacity, Not Brochure Numbers
Machines don’t work in theory — they work in messy, imperfect real-world shifts.
Net Capacity = Technical Availability × Performance × Quality
Any builder who doesn’t speak this language is not thinking about your long-term output.
🧰 Checklist: How to Spot a Reliable Custom Machinery Partner
| ✅ Green Flags | ❌ Red Flags |
|---|---|
| Real past project case studies | Vague promises, no documentation |
| Talks about TPM, SMED, MTTR | Only talks about speed and price |
| Supports lifecycle and upgrades | “Just buy, we’ll figure it out” |
| Plans for changeovers and cleaning | Blames operators for downtimes |
| Offers remote diagnostics & SQL logs | Requires manual data tracking |
🏁 Real-World Reliability: A 5-Million-Cycle Case
In a world where some components boast 100,000 cycles,
Tork Mekatronik builds machines that deliver 200,000+ cycles every month.
We recently delivered a machine to a major OEM that achieved:
- 🔁 Over 200,000 cycles/month
- 🧮 5+ million total cycles
- ⚠️ Zero mechanical failures
- ✅ Zero TCR (Total Customer Returns) — not a single defective part reached the customer
And it’s still running — maintenance-free and fully traceable via SQL logging and HMI diagnostics.
This is what engineering for reliability truly means.
🔗 Explore Our Solutions
Explore how we apply these principles in real production environments:
💬 Don’t settle for theoretical reliability.
Build something that lasts. Build with Tork Mekatronik.