ALL-TEST Pro, LLC

121 Spencer Plains Rd. Old Saybrook, CT 06475

(860) 399-4222 (800) 952-8776
Fax (860) 399-3180
info@alltestpro.com
www.alltestpro.com

Evaluating the Payback on Motor Circuit Analysis

The cost of a motor failure is far greater than the cost of the motor itself, due to the value of lost production. To
project the payback or maintenance earnings on an ALL-TEST Pro investment, you must estimate the amount and
value of production downtime that is avoided through applying the technology. Remember:
This varies by motor based on the processes involved, and the amount of plant output and product that is
affected.
For some motors, the impact includes environmental and or safety issues that should also be taken into
account.

Below are areas that the ALL-TEST can impact a manufacturing facility by reducing downtime.

Troubleshooting
Faster troubleshooting takes minutes rather than hours
Improved diagnostic power when troubleshooting

Detects faults that cannot be seen with conventional instruments (DMM, Megohm meter, HiPot)
Quickly identify and deal with the root cause of failure
Avoid replacing a motor or components that are not faulty
o Positively diagnose a fault within minutes.
o Save time and money when an easily correctable fault (connections, overloads, etc) is identified
rather than a motor fault?

Quality Control
Test new/repaired motors before placing in spares inventory
Test new or spare motors before installing
o Positive insurance against wasted time and resources
o Provides baseline numbers for future trending and comparison

Predictive Maintenance
Scheduled testing and trending of results can detect deterioration or breakdown before a fault occurs.
Detect insulation contamination and deterioration before a fault develops
Detect faults at an early stage before failure
Perform repairs on a proactive versus reactive basis
o Include labor and down costs in your calculations
o Proactive repairs often cost half of what reactive repairs cost
 Calculating R.O.I. On ALL-TEST Motor Circuit Analysis Technology

Average cost of one hour of production in your plant _____________

Cost/Hour

Troubleshooting Return

A. Time spent troubleshooting today: ___________ X _____________ = ______________

Hours Cost/hour Troubleshooting cost A

B. Troubleshooting with ALL-TEST 0.25 hours X _____________ = ______________

Cost/hour Troubleshooting cost B

Savings _________________ _________________ = ____________________

Troubleshooting cost A Troubleshooting cost B Savings per incident

What are the savings in one incident where a fault is diagnosed as being other than the motor?

_______________ X _______________ = _________________

Time Saved Cost/hour Savings per incident

Quality Control Return (testing motors before installation)

Time investment: 7-13 minutes (includes removing connection box cover, test, and evaluation)

What are savings if a single faulty motor is detected before installation?

_______________ X _______________ = _________________

Time Saved Cost/hour Savings per incident

Predictive Maintenance Return

Calculate the average cost of proactive repairs versus reactive repairs including the repair plus both labor and
downtime. One user has calculated the average cost in his plant for a proactive repair at $5905 and a reactive repair
at $9917. Actual costs by incident can vary significantly.

_______________ ______________ = ____________________

Reactive repair cost Proactive repair cost Savings per incident

The Investment:
Hardware and software Training

There are personnel and administrative costs associated with establishing a predictive maintenance program where
none exists.

For more information please visit www.alltestpro.com or E-mail us at info@alltestpro.com.