The Business Case for Preventive Maintenance
Most facilities run motors until they fail, then scramble with emergency repairs. This "run to failure" strategy seems cheaper but costs far more due to unplanned downtime, emergency service premiums, and secondary damage.
💰 Real ROI Example: Manufacturing Plant
| Metric | Before PM Program | After PM Program | Savings |
|---|---|---|---|
| Motor Fleet Size | 50 motors | 50 motors | - |
| Failures Per Year | 10 failures | 2 failures | 8 fewer failures |
| Average Failure Cost | $15,000 | $15,000 | - |
| Annual Failure Costs | $150,000 | $30,000 | $120,000 |
| PM Program Cost | $0 | $25,000/year | -$25,000 |
| NET SAVINGS | - | - | $95,000/year |
ROI: 4.8:1 - For every $1 spent on preventive maintenance, saved $4.80 in prevented failures.
Benefits Beyond Cost Savings:
- Planned Downtime: Schedule repairs during maintenance windows, not production runs.
- Extended Motor Life: Well-maintained motors last 50-100% longer than neglected ones.
- Energy Savings: Properly maintained motors run 5-10% more efficiently.
- Improved Reliability: Fewer unexpected shutdowns, more consistent production.
- Safety: Reduce risk of catastrophic failures, fires, injuries from flying parts.
- Warranty Compliance: Many warranties require documented preventive maintenance.
- Better Planning: Trend data shows which motors need budgeting for replacement.
- Lower Insurance: Some insurers offer premium reductions for documented PM programs.
Preventive Maintenance Programs
We offer three tiers of preventive maintenance - choose based on equipment criticality and budget:
Basic Program
Semi-Annual Inspections (2x/year)
- Visual inspection
- Insulation resistance test (megger)
- Vibration screening
- Temperature check (IR gun)
- Connection tightness check
- Lubrication service
- Basic condition report
- Recommended actions
Best For: Non-critical motors, backup equipment, low-cost applications
Standard Program
Quarterly Inspections (4x/year)
- Complete visual inspection
- Insulation resistance trending
- Vibration analysis (FFT)
- Thermal imaging
- Current balance check
- Bearing condition monitoring
- Alignment verification
- Lubrication schedule management
- Detailed trending reports
- Predictive failure alerts
- Annual comprehensive test
Best For: Critical production motors, 24/7 operations, motors >25 HP
Premium Program
Monthly Monitoring + Quarterly Testing
- Monthly vibration monitoring
- Monthly thermal imaging
- Quarterly comprehensive testing
- Oil analysis (if applicable)
- Motor current signature analysis
- Power quality monitoring
- Efficiency measurement
- 24/7 online monitoring option
- Automatic failure prediction
- Priority emergency service
- Dedicated account manager
- Custom reporting dashboard
Best For: Mission-critical equipment, high downtime cost, motors >100 HP
Comprehensive Inspection Checklist
Every preventive maintenance visit includes systematic inspection of all motor systems:
🔍 Visual & Mechanical
- Motor mounting tightness
- Foundation condition
- Shaft condition
- Coupling condition/alignment
- Fan/fan cover condition
- Drain plugs sealed
- Nameplate readable
- Paint/corrosion
- Ventilation openings clear
- Guards in place
⚡ Electrical Systems
- Insulation resistance (megger)
- Voltage balance (all phases)
- Current balance (all phases)
- Power factor
- Terminal tightness
- Wire condition
- Conduit connections
- Ground connection
- Junction box condition
- Control circuit operation
🔧 Bearing Systems
- Bearing temperature
- Bearing noise
- Vibration analysis
- Lubrication level/condition
- Grease condition (if applicable)
- Seal condition
- Drain/purge operation
- Bearing frequencies (FFT)
- Early defect detection
- Lubrication schedule adherence
🌡️ Thermal Monitoring
- Winding temperature
- Bearing housing temperature
- Frame temperature
- Terminal box hot spots
- Connection temperatures
- Thermal patterns
- Cooling system effectiveness
- Temperature trending
- Thermal imaging report
📊 Performance Testing
- Load current vs. nameplate
- Speed verification
- Efficiency estimation
- Power consumption
- Starting characteristics
- Operating temperature
- Process performance
- Baseline comparison
- Degradation trending
📋 Documentation
- Inspection report
- Test results trending
- Thermal images
- Vibration spectra
- Recommended actions
- Priority ranking
- Cost estimates
- Maintenance history
- Next service due date
- Digital records database
Predictive Maintenance Technologies
We use advanced diagnostic tools to predict failures before they happen:
Vibration Analysis
Detects bearing defects, unbalance, misalignment, looseness 2-8 weeks before failure. FFT analysis identifies specific problems. Trending shows degradation rate.
Warning Time: 2-8 weeks
Thermal Imaging
Infrared cameras detect electrical problems (loose connections, phase imbalance, overloads) and mechanical issues (bearing overheating, cooling problems).
Warning Time: 1-4 weeks
Insulation Trending
Track insulation resistance over time. Declining megohm readings indicate moisture, contamination, or aging. Catch winding problems months early.
Warning Time: 2-6 months
Current Signature Analysis
Analyze motor current waveform to detect rotor bar problems, eccentricity, load variations. Non-invasive testing while motor runs.
Warning Time: 1-3 months
Oil Analysis
For sleeve bearing motors: lab analysis of bearing oil detects metal particles, viscosity breakdown, contamination. Predicts bearing wear.
Warning Time: 3-6 months
Power Quality Monitoring
Track voltage imbalance, harmonics, sags, swells. Power problems cause motor failures - catch supply issues before they damage motors.
Warning Time: Immediate
Recommended Maintenance Schedule
Maintenance frequency depends on motor criticality, operating conditions, and environment:
| Task | Non-Critical | Standard | Critical/Severe Duty |
|---|---|---|---|
| Visual Inspection | Semi-annual | Quarterly | Monthly |
| Vibration Monitoring | Semi-annual | Quarterly | Monthly |
| Thermal Imaging | Annual | Quarterly | Monthly |
| Insulation Testing | Annual | Quarterly | Quarterly |
| Bearing Lubrication | Annual | Semi-annual | Quarterly |
| Alignment Check | Bi-annual | Annual | Semi-annual |
| Comprehensive Testing | Bi-annual | Annual | Semi-annual |
| Load/Efficiency Test | Every 3 years | Every 2 years | Annual |
Motor Criticality Classification:
Critical Motors
Require most frequent monitoring:
- Single point of failure (no backup)
- Downtime cost >$5,000/hour
- Safety/environmental systems
- 24/7 continuous operation
- Motors >100 HP
- Severe duty applications
- Contract/penalty implications
Non-Critical Motors
Can use less frequent monitoring:
- Backup/redundant equipment
- Low downtime cost
- Intermittent duty
- Easy to replace quickly
- Small motors (<10 HP)
- Non-essential applications
- Spare available on shelf
📊 Case Study: Food Processing Plant
Challenge: Food processor experiencing 6-8 unexpected motor failures per year. Each failure meant 4-12 hours downtime, spoiled product, and emergency service costs.
Solution: Implemented Standard PM Program for 35 critical motors. Quarterly inspections with vibration analysis, thermal imaging, and electrical testing.
Year 1 Results:
| Metric | Before PM | After PM | Improvement |
|---|---|---|---|
| Unexpected Failures | 7 failures | 1 failure | 86% reduction |
| Downtime Hours | 42 hours | 4 hours | 90% reduction |
| Lost Production Cost | $168,000 | $16,000 | $152,000 saved |
| Emergency Repair Costs | $35,000 | $5,000 | $30,000 saved |
| PM Program Cost | $0 | $21,000 | -$21,000 |
| NET SAVINGS | - | - | $161,000 |
What We Found During PM:
- 3 motors: Bearing defects detected 6 weeks early via vibration - replaced during scheduled maintenance
- 2 motors: Phase imbalance from loose connections - tightened, prevented winding damage
- 1 motor: Declining insulation resistance from moisture ingress - dried and sealed
- 4 motors: Misalignment >0.010" - realigned, extended bearing life
- All motors: Lubrication optimized based on vibration feedback
ROI: 7.7:1
Client recovered PM program cost in first 6 weeks. All savings after that pure profit.
Getting Started with PM
How to Implement a PM Program:
- Step 1: Motor Inventory: We help identify and catalog all motors in your facility.
- Step 2: Criticality Assessment: Classify motors by importance (critical/standard/non-critical).
- Step 3: Program Design: Recommend appropriate PM tier for each motor.
- Step 4: Baseline Testing: Establish initial condition baseline for all motors.
- Step 5: Schedule Setup: Create inspection calendar coordinated with your operations.
- Step 6: Launch Program: Begin regular inspections and build trending database.
- Step 7: Quarterly Reviews: Review findings, track ROI, adjust program as needed.
What You Receive:
Each Inspection Visit
- Detailed inspection report
- Test results (megger, vibration, thermal)
- Findings and recommendations
- Priority ranking of issues
- Estimated repair costs
- Photos of problems found
- Next service due date
Ongoing Program Benefits
- Online trending database
- Predictive failure alerts
- Maintenance planning assistance
- Annual program review meeting
- ROI tracking and reporting
- Spare parts recommendations
- Priority emergency service
Program Pricing Summary
| Program Tier | Frequency | Cost per Motor/Year | Best For |
|---|---|---|---|
| Basic | Semi-annual (2x/year) | $300-400 | Non-critical motors, <25 HP |
| Standard | Quarterly (4x/year) | $600-800 | Standard production motors, 25-100 HP |
| Premium | Monthly + Quarterly | $1,200-1,800 | Critical motors, >100 HP, 24/7 ops |
Volume Discounts:
- 10-24 motors: 15% discount
- 25-49 motors: 20% discount
- 50+ motors: 25% discount
- 100+ motors: 30% discount + dedicated account manager