You recently accepted a new job as plant maintenance manager. Working under you are two electrical maintenance supervisors and their crews, two mechanical supervisors and their crews, and a supervisor with a crew of “general maintenance techs.” The plant has a high rate of motor failures. You were offered this job mostly because management believed you could solve that problem.

In nearly every case, the failure mode involves the motor bearings. The electrical supervisor assures you the motors are properly grounded and the supply voltage is correct. The mechanical supervisor assures you the motors are properly aligned and the gearboxes function correctly. The general supervisor assures you the motors are lubricated at the correct intervals per factory recommendations.

How can you solve these failures?

First, ask the electrical supervisor if the motors are properly bonded; grounding them doesn’t serve any electrical purpose. Ask the mechanical supervisor for the alignment data and for something that shows vibration trending. Hire a specialist to conduct ultrasonic bearing analysis.

Then turn your attention to the lubrication. Many lubricants are incompatible with each other. Determine which lubricants are being used, if any are being mixed, and how much is being applied in what manner. Lubrication errors have killed many a motor.

Look at the lubricant storage system. Are containers properly labeled, secured, and protected from contamination? Is each grease gun used with only one lubricant? Consider hiring a lubrication specialist.