Managing the Forgotten Asset: A Motor Management & Reliability Program

This document explores the often-overlooked role of electric motors as critical assets in industrial operations. Through case studies and best practices, it details a comprehensive Motor Management & Reliability Program (MMRP) that reduces failures, improves maintenance strategies, and delivers significant ROI. Originally published in Uptime Magazine by Krzysztof Goly of Siemens, it offers a blueprint for optimizing electric motor performance through predictive maintenance, proper inventory control, and structured data management.

Key Points

  • Electric motors are essential but often neglected physical assets in industrial plants.
  • The Motor Management & Reliability Program (MMRP) covers maintenance, procurement, inventory, repair, and data management.
  • Effective inventory control includes optimized storage, regular testing, and condition-based spare management.
  • A case study at a tire plant showed a jump in MTBF from 3 to 10.6 years and a dramatic drop in motor failures.
  • A lack of trained maintenance personnel has led to poor motor reliability in many facilities.
  • On-site and support services include condition monitoring, overhaul, repair standards, and preventive maintenance planning.
  • Software tools like Tango enable condition tracking, predictive analysis, and motor history documentation.
  • The MMRP approach demonstrated substantial cost savings and improved uptime over a 5-year span.