The Cost of Motor Downtime
💰 Real Downtime Cost Example
Manufacturing plant, main production line motor fails Friday night:
| Scenario | Timeline | Production Lost | Total Cost |
|---|---|---|---|
|
Standard Service (Wait until Monday) |
60 hours downtime | 60 hours @ $5,000/hr | $300,000 |
|
Emergency Service (Call us immediately) |
6 hours downtime | 6 hours @ $5,000/hr | $30,000 |
Emergency Service Cost: $4,500 (rush rewind + after-hours)
NET SAVINGS: $265,500
Emergency service isn't expensive - downtime is. The cost of emergency service is typically 1-3% of the cost of continued downtime. Call us immediately when critical equipment fails.
Our Emergency Response Process
When you call our emergency line, here's exactly what happens:
Immediate Answer (24/7)
0-5 minutes: Your call goes directly to on-call technician, not voicemail. We answer nights, weekends, holidays. Technician assesses situation and begins mobilizing resources.
Rapid Assessment
5-15 minutes: We gather critical information: motor nameplate data, failure symptoms, downtime cost, urgency level. Determine if on-site service, emergency replacement, or rush rewind needed.
Resource Mobilization
15-30 minutes: Check inventory for replacement motors. Mobilize mobile service truck. Call in additional technicians if needed. Prepare equipment and parts.
Technician Dispatch
30-120 minutes: Technician en route to your facility. Average response time: 2 hours in Denver metro, 3-4 hours northern Colorado, same-day rest of state.
On-Site Diagnosis
Arrival + 30-60 min: Test motor to confirm failure. Assess if field-repairable or needs shop service. Provide verbal quote for emergency service.
Solution Implementation
Variable timeline: Install replacement motor (2-4 hours), pickup for rush rewind (6-24 hours), or on-site temporary repair. Whatever gets you running fastest.
Back in Production
Goal: <24 hours: Critical equipment back online. Permanent solution (rewind original motor) follows if temporary fix installed. Minimize your total downtime.
Emergency Services Available
Mobile Emergency Service
Fully-equipped service trucks respond to your facility. On-site testing, diagnosis, temporary repairs, motor removal for shop service.
Response: 2 hours Denver metro
Cost: $200-400 service call + labor
Rush Rewinding
24-hour rewind service for fractional-25 HP motors. 48-hour for 25-100 HP. Priority processing, overtime labor, expedited testing.
Turnaround: 24-48 hours typical
Premium: 50-100% over standard pricing
Emergency Replacements
Large inventory of common motors in stock. Emergency sourcing from distributors nationwide. Overnight shipping coordinated.
Availability: Same-day for common sizes
Cost: Motor cost + rush delivery fees
After-Hours Repairs
Weekend and night shop access for critical repairs. Technicians called in for emergency work. No waiting until Monday.
Availability: 24/7/365
Premium: 1.5-2x regular labor rates
Rental Motor Coordination
We coordinate rental motors while yours is being repaired. Relationships with rental companies for fast delivery.
Availability: Subject to rental stock
Cost: Rental company fees (daily/weekly)
Emergency Installation
Install replacement motor immediately. Laser alignment, electrical connections, startup testing. Get you running NOW.
Timeline: 2-4 hours typical
Cost: $800-2,500 depending on complexity
When to Call Emergency Service
Call Emergency Service Immediately:
- Production Line Down: Main production motor failed, stopping entire line or process.
- Critical System Failure: HVAC motor in data center, water treatment plant, hospital, etc.
- Safety System Down: Ventilation, fire suppression, emergency backup systems.
- High Downtime Cost: Every hour down costs $1,000+ in lost production.
- Contractual Obligations: Deadline to meet, penalties for late delivery.
- Seasonal Critical Period: HVAC failure during heat wave, irrigation during growing season.
- No Backup Available: Single motor with no redundancy, can't limp along.
- Weekend/Holiday Failure: Can't wait until regular business hours resume.
- Multiple Systems Affected: One motor failure cascading to affect multiple processes.
Can Probably Wait for Regular Service:
- Non-critical equipment with backup available
- Planned shutdown period coming soon
- Failure during regular business hours with low urgency
- Equipment that can be isolated without affecting production
Not Sure If It's an Emergency? Call anyway. We'll help you assess urgency and determine best approach. No pressure - just honest advice about whether emergency service is worth the premium.
Response Times by Location
| Service Area | Typical Response Time | Availability |
|---|---|---|
| Denver Metro Core | 1-2 hours | 24/7/365 |
| Denver Metro Extended | 2-3 hours | 24/7/365 |
| Boulder/Longmont | 2-3 hours | 24/7/365 |
| Fort Collins/Loveland | 3-4 hours | 24/7/365 |
| Colorado Springs | 3-4 hours | 24/7/365 |
| Greeley/Windsor | 2-4 hours | 24/7/365 |
| Rest of Colorado | 4-8 hours (same-day) | 24/7/365 |
| Surrounding States | 8-24 hours | Case-by-case basis |
Emergency Service Pricing
Emergency service costs more than standard service - but far less than continued downtime:
Emergency Service Call Fees:
| Time Period | Service Call Fee | Labor Rate Multiplier |
|---|---|---|
| Regular Hours (M-F, 7AM-5PM) | $150-250 | 1.0x (standard rate) |
| After Hours (M-F, 5PM-11PM) | $250-400 | 1.5x standard rate |
| Late Night (11PM-7AM) | $400-600 | 2.0x standard rate |
| Weekends (Sat-Sun) | $300-500 | 1.5-2.0x standard rate |
| Holidays | $500-800 | 2.0-2.5x standard rate |
Rush Rewind Pricing Premium:
- 24-Hour Rush: 100% premium (2x normal rewind cost)
- 48-Hour Rush: 75% premium (1.75x normal cost)
- 72-Hour Rush: 50% premium (1.5x normal cost)
- 1-Week Priority: 25% premium (1.25x normal cost)
Example: Standard 50 HP rewind = $2,000 | 24-hour rush = $4,000 | But saves $120,000+ in downtime at $5,000/hr facility.
What's Included:
- Immediate response and mobilization
- After-hours shop access
- Overtime labor for technicians
- Priority processing ahead of standard jobs
- Rush parts sourcing and delivery
- Expedited testing and quality checks
- After-hours pickup and delivery
What to Have Ready When You Call
Speed up emergency response by having this information available:
Critical Motor Information
- Motor nameplate data (HP, voltage, RPM, frame)
- Manufacturer and model number
- What the motor drives (pump, compressor, fan, etc.)
- Application (critical? backup available?)
- How it failed (symptoms, what happened)
- Photos of nameplate and motor if possible
Business Information
- Your facility location and address
- Contact name and direct phone number
- Downtime cost per hour (rough estimate)
- How quickly you need it fixed
- Budget approval limits (who can authorize emergency work)
- Site access requirements (security, after-hours entry)
Prevent Emergency Situations
Best way to avoid emergency service costs is preventive maintenance:
Critical Equipment Should Have:
- Spare Motor: Keep spare on shelf for critical single-point-of-failure equipment
- Annual Testing: Catch problems before they become failures
- Vibration Monitoring: Bearing problems give 2-8 weeks warning if monitored
- Thermal Imaging: Electrical problems show up as hot spots before failure
- Backup Plan: Know who to call, have our number saved, pre-approved emergency budget
Preventive Maintenance Program: For $300-600/year per motor, quarterly testing identifies problems early. Average ROI: 5:1 from prevented failures. Learn more about motor maintenance programs →