If you’re like most other business owners, the electric motors that power your production, packaging, and shipping operations are the lifeblood of your business. Consequently, when they’re not working at peak performance, your bottom line takes a hit from the unexpected downtime and unplanned repair costs.
The key to electric motor longevity and performance is to discuss the different maintenance options and choose the best one for your business.
Reactive Electric Motor Maintenance Plan
While this is the easiest maintenance plan to implement, it does little to prevent unexpected breakdowns and repair costs. Industry reports indicate that a reactive maintenance plan can increase repairs and downtime costs by 500%. Additionally, a proactive maintenance strategy can reduce maintenance costs by up to 40% while reducing downtime by up to 50%.
As the name suggests, this maintenance model involves reacting to the situation after the damage is done and your production line stops. Before the line can start moving again, you must troubleshoot the problem, secure the necessary parts, and complete the repairs. Based on parts availability and your technical expertise, your electric motor might be down days or weeks at a time.
The following two maintenance terms are commonly interchanged because they can help identify potential component issues before they cause total motor failure. However, there is a significant difference between preventative (preventive) and predictive maintenance for electric motors.
Preventive Electric Motor Maintenance Plan
A preventive maintenance plan uses regularly scheduled equipment inspections and maintenance services to help you postpone or avoid an electric motor failure. Depending on the motor size and specific application, these schedules typically follow the manufacturer’s recommendation in either calendar days or usage.
For example, once a bearing has reached the predetermined number of hours of usage, it is replaced. Or, after X number of hours, the motor must be rewound.
The goal is to replace components before they adversely affect performance, reach the end of their lifecycle, or fail without warning.
Predictive Electric Motor Maintenance
This maintenance option utilizes sensors throughout the system to continually monitor the electric motor while in service. In addition to sensors that collect real-time data, dynamic tests such as thermal imaging and vibration analysis can be analyzed against past performance levels to identify and determine which components require servicing or replacement.
Your maintenance strategy should center on understanding how your electric motors operate and following the manufacturer’s recommended maintenance schedule. Whether you choose a preventive or predictive electric motor maintenance plan, you should assemble the following information and supplies.
Electric Motor Information Database
Assemble the owner or operator guide for each type of electric motor used at your plant or facility. While electric motors share the same basic operating principles, maintenance schedules, lubricants, torque settings, and part numbers can vary significantly between manufacturers.
PDF versions can be found online by entering the motor brand and part number into a search box. You can also download a free copy of the ANSI/EASA Standard AR100-2020: Recommended Practice for the Repair of Rotating Electrical Apparatus. This guide is a must-have resource, outlining industry-recognized best practices for testing electric motor performance.
Create an Inventory of Electric Motor Parts and Supplies
Assemble the part numbers for regularly replaced items, such as bearings, shafts, brushes, seals, gaskets, contacts, and connectors. Having these parts on hand can eliminate any inventory or shipping concerns, reducing potential downtime. Don’t forget that lubricants are necessary for regular maintenance chores and unexpected repairs.
Planning out long-term maintenance schedules allows you to determine when potential downtime or service interruptions occur based upon the ebb and flow of your business. According to Uptime Magazine1, “Motor life span is generally five to 10 years with these preventative measures. Without preventative maintenance, they may survive six to 12 months.”
To keep you up and running, Hi-Speed offers various predictive maintenance services that can further reduce your business’s downtime and repair costs.
- Laser Alignments
- Fan Balancing
- Bearing Replacements
- Full Equipment Changeouts
- Vibration Sensor Installation
- Coast Down Analysis
- PdMA Testing (on and off-line)
- Infrared Analysis
- Ongoing Consulting Services
- Failure Assistance to get up and running again
With over 75 years of continuous service to our, you can trust the Hi-Speed team to create a preventive or predictive maintenance plan that will keep your electric motors operating at peak performance.
If you have questions about electric motor maintenance, please call the Hi-Speed experts at 800-713-0103 or email us today.