February 07, 2007
Motor System Maintenance and Management
President, SUCCESS by DESIGN
The term motor management is tossed around to describe many programs that are just aspects of a complete program. A true motor-system maintenance program extends far beyond just the storage, general or advanced maintenance, energy consumption, the development of specifications or other functions. Such a program actually involves all aspects of the electric motor system from incoming power to driven equipment, from cradle to grave.
First, we must consider the impact of the electric motor system on our basic operations. Whether we are an industrial or manufacturing, military or commercial, organization, there will be at least one critical machine. The electric motor associated with the machine will have an impact on safety, environment, process/mission, will have a significant cost associated with repair or replacement and/or will have some other important aspect to the company (ie: branding, appearance, etc.). How we manage the system, and any other critical systems, will have a direct impact on our success. It does not matter whether the motor is 1/64th horsepower or 40,000 horsepower, the criticality of the machine rests solely on its impact on the business or mission.
A full motor-system maintenance and management program includes aspects of:
1. Motor-system inventory (knowing what you own)
2. Selecting the criticality of the machine
3. Evaluating the condition of critical systems
4. Determining a maintenance strategy (ie: RCM) with a periodic review (MER)
5. Purchasing and repair specifications
6. A spare motor storage strategy
7. A general and CBM maintenance strategy
8. Solid relationship between operations, purchasing, vendors, maintenance and other stakeholders.
9. Methods of communicating between aspects of the motor management team
10. Commissioning new and repaired equipment
11. Energy and reliability
12. Includes distribution systems, controls, motor, coupling, load and process components.
In effect, it will involve some level of change in how you do business. This, of course, will require a culture change within the organization. As over 60% of companies have only a reactive program in place, it may require a substantial initial investment. This change can be drastic at all levels. Such a shock requires a good solid management team, buy in from the trades and some sacrifices.
The good news is that for such a program there will be a good level of return on the investment seen immediately with the most significant benefits appearing 12-24 months after the program is initiated and has started to become mature. So, in addition to the culture change that must occur, the business must be patient as the full benefits of the program will come in the future.
For more information on setting up successful motor management programs, email us at
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