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Why Electric Motor Management Reduces Costs


sherlock_holmes.jpgManaging the Maintenance Repair and Operations (MRO) of any industrial facility can be hectic and challenging.  Due to the fact that controls or guidelines are typically minimal at best, maintenance repairs often result in unnecessary expenditures

The most efficient and effective way to control Maintenance Repair and Operations costs is to "anticipate, react and control.”  If your MRO team only reacts and controls, the damage has been done — it’s too late to save money.  You need a better way.  You need a system that enables you to anticipate problems and actually head them off before they occur.

There is no disputing the fact that electric motor management systems is simply the best, most efficient way to manage production-critical motors and match them with the appropriate back-up motor inventory. 

Unless you have clearly defined populations of both active motors and back-ups, you can only "run to failure," then guess if you have the appropriate spare immediately available.  With motor management software, you will not only be tracking your motor assets, but will also be getting vital trending data with all the relevant characteristics about those assets.

With that in mind, HECO developed a proprietary, sophisticated MRO software called TracRat®. TracRat electric motor management software can instantly provide you with repair history, location history, failure analysis and average time between service needs of the entire motor population. Just what you need to reduce motor maintenance costs and reduce downtime.

Is a system like TracRat right for you?

Companies in industries as diverse as pharmaceuticals, steel, food, automotive and energy have found that TracRat has helped them get off of expensive roller coaster ride a typical motor inventory can take you on every day.  It could be right for you, too.

Here are three questions to ask about any software system before going on to the next step.

1. What should your MRO software do?

You’ll want software that tracks and stores data that clearly counts and defines your production assets. And - provides a handle on "where's the spare?" For instance,  TracRat compiles information gained through hands-on research of both production and spare assets. When the surveys are complete, the data is matched and cross-referenced. The resulting reports clearly spell out four benefits for your maintenance program - and your bottom line.

  1. How many assets have appropriate spare back up?
  2. How many assets have no back up?
  3. How many assets have too much back up?
  4. How many spare assets were excessive and/or obsolete?

By adjusting the spare inventory to effectively match the production assets, you can be sure of adequate, timely backup. And by defining the excess spare inventory, software such as TracRat exposes valuable corporate money tied up in virtual useless assets. You then can then begin divesting this excess inventory to recoup money better spent on valuable productive assets. In one instance, information from TracRat® lead to the recovery of more than $10,000,000 in excess inventory for a major steel manufacturer.

2. Should your software be an effective search engine for all repairable assets?

Absolutely. you should be able to effectively manage any selected repairable asset such as pumps, switchgear, power transmission components, conveyor belts or any other important asset. The beauty of TracRat is that there is no need to adapt the repairable asset to the software. In this case, the software adapts to the asset. You’ll want your software to be able to be customized to search for anything by simply reconfiguring the search screen.

3. Can MRO software help effectively plan for the future?

Yes. A good software such as TracRat can contain historical data such as repair reports, cause of failure reports, and average time between failures for individual motors or motor populations. It can define areas within individual plants that seem to experience excessive problems and the nature of those problems. Because all reports of work done on a motor can be downloaded into the program, it not only is a search and find engine, but a tell-all system for current and future decision makers in MRO at a plant.

Once again, the right MRO software provide an asset management database that allows any manufacturing facility the ability to manage the complete lifecycle of its MRO commodities.

By constantly tracking and storing information on equipment and machinery components, it will provide the information you need to cut unnecessary inventory and repair costs, and keep your business running smoothly.

While there are a variety of software programs to choose from, I recommend TracRat because of its proven ability to:

  • Increase returns on equipment investments
  • Increase levels of productivity
  • Minimize operating costs
  • Minimize downtime

Questions MRO tracking software?

HECO can help you with any questions you may have about its TracRat MRO tracking software, and how, when used in conjunction with a HECO powertrain system, it can reduce costs and increase plant efficiency.

Of course, before we recommend anything, we’ll delve into answers to “why.” Why are failures occurring, why are they repeating, why are appropriate spares not on hand, and a variety of other “whys” to help determine exactly what is right for you.

Download What To Look For In An Electric Motor Repair Shop

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To learn more about what our “All Systems Go” approach, please contact:

Justin Hatfield

HECO, Inc.



About the author:

Justin Hatfield is Vice President of Operations of HECO, Inc. He is responsible for Electric Motor & Drive Sales, Electric Motor & Generator Repairs, and Predictive Services. Justin was instrumental in developing HECO MAPPS (Motor And Powertrain Performance Systems) which focuses on “why” you have a motor problem instead of simply “What” product or service should be recommended. HECO is EASA Accredited.

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