The verdict in three sentences
For a machining supplier with 90 CNC machines and EN 9100 certification, each point of machine availability is worth tens of thousands of euros a year, and audits demand full traceability of interventions. A vendor CMMS costs EUR 15,000 to 40,000 to set up plus EUR 50 to 100 per user per month, a custom CMMS EUR 50,000 to 90,000 excl. VAT delivered in 5 months. Custom wins when automatic machine counter feeds and audit preparation are central, with a target of 92% availability.
The problem: reactive maintenance and stressful audits
Around Berlin and Brandenburg, from Ludwigsfelde to Wildau and Dahlewitz, tier 1 and tier 2 suppliers are absorbing the A320 and A350 ramp-up and engine programmes. Maintenance often stays reactive: a spindle fails, the machine stops, the part is scrapped and delivery slips. Preventive routines exist on paper or in Excel, but they are triggered by calendar rather than actual spindle hours.
Meanwhile, EN 9100 audits require proof of equipment control: intervention history, measuring equipment calibration, technician qualifications, traced spare parts. Preparing an audit then takes 5 to 10 days of work for maintenance and quality.
| Indicator | Typical situation without managed CMMS | Target with machine-connected CMMS |
|---|---|---|
| Machine availability | 78 to 82% | 92% |
| Share of preventive maintenance | 20 to 30% | 60 to 70% |
| MTTR (mean time to repair) | 6 to 10 h | 3 to 5 h |
| Unplanned stops per month | 25 to 40 | 10 to 15 |
| EN 9100 audit preparation | 5 to 10 days | under 1 day |
| Critical spare part stockouts | 4 to 8 a year | 0 to 1 a year |
Vendor CMMS or custom: the 2026 comparison
| Criterion | Vendor CMMS | Custom CMMS by Kolonell |
|---|---|---|
| Setup | EUR 15,000 to 40,000 | EUR 50,000 to 90,000 excl. VAT |
| Recurring | EUR 50 to 100 per user per month | support EUR 800 to 1,500 per month |
| 5-year cost for 25 users | EUR 90,000 to 190,000 | EUR 98,000 to 180,000 |
| Machine counter feeds | optional connector, often limited | OPC UA, MTConnect, Fanuc, Heidenhain, Siemens |
| EN 9100 traceability | standard reports | audit file generated in one click |
| ERP and MES link | generic API | dedicated connector to your ERP |
| Fit to your routines | configuration | custom, evolving |
Over 5 years, costs converge. The difference lies in counter feeds: a CMMS that triggers preventive work on actual spindle hours, cycles or machine alarms changes availability. Vendors sometimes offer it, but rarely for a mixed fleet of recent 5-axis centres and older lathes.
Project scope and timeline
| Module | Function | Timing |
|---|---|---|
| Asset register | 90 machines, hierarchy, OEM documents | weeks 1 to 4 |
| Machine connectors | spindle hours, cycles, alarms via OPC UA gateway | weeks 5 to 10 |
| Condition-based preventive | triggered by counter thresholds | weeks 8 to 12 |
| Mobile requests and work orders | shop floor tablet, photos, signature | weeks 9 to 14 |
| Spare parts stock | minimum levels, criticality, suppliers | weeks 12 to 16 |
| Traceability and audit | history, qualifications, EN 9100 export | weeks 15 to 20 |
The pilot starts on a 10-machine cell in week 12, then rollout extends to the full fleet. Data stays hosted in Germany or the EU, often required by OEM customers and GDPR.
Mini case study
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Thomas, maintenance manager at an aerospace machining supplier in Berlin, runs 90 CNC machines operating 4,500 hours a year. Availability is 80%. Each lost machine hour costs on average EUR 95 of value added. Reaching 92% recovers 12 points, or 540 hours per machine per year if demand follows. Conservatively counting only a third of this gain on 30 bottleneck machines, the company recovers EUR 162,000 of value added a year. The project costs EUR 78,000 excl. VAT plus EUR 12,000 of annual support. Payback comes in 7 months, before the 8 days of audit preparation saved each year.
FAQ
How much does a custom CMMS for an aerospace supplier cost in 2026?
Budget EUR 50,000 to 90,000 excl. VAT depending on connected machines and interfaces, then EUR 800 to 1,500 a month of maintenance. A first version without machine connectors starts around EUR 35,000.
Can older machines be connected?
Yes, through an acquisition box reading run signals or cycle counts, for EUR 300 to 800 per machine. Recent Fanuc, Siemens or Heidenhain controls connect via OPC UA or MTConnect.
Does the CMMS meet EN 9100 requirements?
It provides the expected traceability: timestamped history, qualifications, measuring equipment checks and parts used. The audit file is exported in under an hour instead of 5 to 10 days.
How long to reach 92% availability?
The gain is gradual: 3 to 5 points in the first 6 months through condition-based preventive work, then 92% targeted at 12 to 18 months. It depends on the fleet's starting condition.
Can the CMMS talk to our ERP?
Yes, a dedicated connector syncs spare parts, purchase orders and costs. It is priced at scoping, usually EUR 5,000 to 12,000 excl. VAT.
Let's scope your project. Share your machine fleet, audit constraints and ERP for a quote between EUR 50,000 and 90,000 excl. VAT and a 5-month plan. Detailed quote within 48 h. WhatsApp +221 77 596 93 33.
Mohamed Bah
Fondateur, Kolonell
Passionate about digital and entrepreneurship in Africa, Mohamed has been helping Sénégalese businesses with their digital transformation since 2020. Founder of Kolonell, he believes every SME deserves a professional and accessible online présence.
