How Electrical Predictive Maintenance Reduces Unplanned Downtime in Manufacturing Plants

Downtime Is the Enemy of Productivity

In manufacturing, every minute counts — and every second of downtime costs money. Whether you’re producing automotive components, pharmaceuticals, food and beverages, or high-precision electronics, unplanned shutdowns can mean:

• Lost revenue and production output

• Missed customer delivery targets

• Quality and compliance issues

• Strained supplier relationships
  

In today’s competitive environment, preventing downtime isn’t optional — it’s essential.

That’s where predictive maintenance comes in.

By using advanced diagnostic technologies like infrared thermography (IR), dissolved gas analysis (DGA), and circuit breaker testing, manufacturers can detect early warning signs of electrical failure long before they cause production stoppages.

At Assured NDT, we help manufacturing facilities implement predictive maintenance programs that protect equipment, extend asset lifespan, and keep lines running efficiently — all while maintaining compliance with NFPA 70B, OSHA, and insurer requirements.

Photo by Homa Appliances on Unsplash

Why Predictive Maintenance Is Transforming Manufacturing Reliability

Traditional maintenance models — reactive (“fix it when it breaks”) or time-based (“inspect every six months”) — leave manufacturers exposed to risk.

Reactive and time-based maintenance often result in:

• Costly unplanned equipment failures

• Excessive overtime for emergency repairs

• Safety hazards and regulatory exposure

• Reduced overall equipment effectiveness (OEE)
  

Predictive maintenance replaces guesswork with insight.

By continuously monitoring and analyzing electrical and mechanical performance data, facilities can:

• Identify faults before failure occurs

• Schedule repairs during planned downtime

• Extend asset lifespan

• Improve reliability and uptime

• Reduce insurance risk and claims
  

In short: predictive maintenance gives manufacturers control over when — and how — maintenance happens.

Infrared Thermography: The First Line of Defense Against Electrical Failure

Infrared thermography uses non-contact thermal imaging cameras to detect heat patterns in electrical systems — an early indicator of malfunctioning equipment.

In manufacturing environments, infrared inspections can uncover:

• Overheating transformers and motors

• Loose or corroded electrical connections

• Imbalanced loads in switchgear and panels

• Faulty drives, MCCs, and relays

Because it’s fast, non-invasive, and safe, infrared thermography is ideal for high-volume manufacturing where downtime isn’t an option.

ROI Insight: Studies show that thermal imaging can reduce electrical-related unplanned failures by up to 80%, offering one of the best returns on investment in modern maintenance strategies.

Dissolved Gas Analysis (DGA): Protecting Transformer Health

For high-voltage or power-intensive manufacturing operations, Dissolved Gas Analysis (DGA) is critical.

This test measures gases dissolved in transformer oil, providing an early warning of internal faults like:

• Arcing or partial discharge

• Overheating

• Insulation degradation

Benefits of DGA Testing Include:

• Detecting transformer faults early — before catastrophic failure

• Avoiding unplanned shutdowns in production areas

• Protecting downstream electrical systems

• Ensuring compliance with NFPA and IEEE standards

Bottom line: Transformers are expensive to replace — DGA testing keeps them healthy and your plant online.

Circuit Breaker Testing: Verifying Your Last Line of Defense

Circuit breakers are the final layer of protection in your electrical system. If they fail to operate during an overload or fault, the result can be devastating — damaging motors, drives, and production assets.

At AssuredNDT, our predictive maintenance programs include:

• Trip-time testing – ensures breakers trip within safe limits

• Insulation resistance testing – verifies electrical integrity

• Contact resistance analysis – identifies wear and degradation

These tests validate that your breakers — and your entire protection system — will perform when you need them most.

The Financial Case for Manufacturing Predictive Maintenance

Let’s put the numbers in perspective:

Average cost of manufacturing downtime: $10,000 to $250,000 per hour — depending on process complexity and throughput.

Predictive maintenance impact:

• 25–30% reduction in maintenance costs

• 20–25% increase in equipment uptime

• 10x ROI vs. reactive maintenance programs

By investing in predictive tools like IR scanning, DGA, and breaker testing, manufacturers can prevent millions in losses, improve OEE, and maintain production continuity — even during peak demand periods.

Why Manufacturers Choose Assured NDT

At Assured NDT, we don’t just identify problems — we help you prevent them.

Our predictive maintenance solutions are:

Non-invasive – minimal disruption to production

Compliant – aligned with NFPA 70B, OSHA 1910, and insurance standards

Data-driven – providing clear, actionable reports

Proactive – designed to keep your equipment safe and reliable

We partner with manufacturers nationwide to strengthen reliability, reduce risk, and improve operational efficiency through science-based diagnostics and compliance expertise.

Future-Proof Your Facility Today

Unplanned downtime doesn’t just stop production — it stops progress.

With Assured NDT’s manufacturing predictive maintenance programs, you can:

• Detect hidden electrical faults before failure

• Schedule planned repairs strategically

• Maintain compliance and documentation for insurers

• Maximize uptime and asset performance

Contact Assured NDT today to schedule your electrical reliability assessment and discover how predictive maintenance can keep your plant running — without surprises.

Frequently Asked Questions About Manufacturing Predictive Maintenance

1. What is predictive maintenance in manufacturing?

Predictive maintenance is a proactive strategy that uses real-time data, diagnostics, and trend analysis to identify equipment issues before they cause downtime.In manufacturing, tools like infrared thermography, dissolved gas analysis (DGA), and circuit breaker testing help detect early electrical and mechanical faults — allowing maintenance teams to fix problems during planned shutdowns instead of reacting to breakdowns.

2. How is predictive maintenance different from preventive maintenance?

Preventive maintenance follows a fixed schedule — replacing or servicing equipment based on time intervals.Predictive maintenance, on the other hand, uses condition-based data to determine when maintenance is actually needed.This approach helps manufacturers avoid unnecessary work, reduce costs, and prevent unexpected equipment failures.

3. What are the main benefits of predictive maintenance for manufacturing plants?

The key benefits include:

• Reduced unplanned downtime and production losses

• Extended equipment lifespan and reliability

• Improved OEE (Overall Equipment Effectiveness)

• Lower maintenance and repair costs

• Compliance with standards like NFPA 70B and OSHA 1910Predictive maintenance gives manufacturers greater control over uptime, safety, and profitability.

4. How often should predictive maintenance inspections be performed?

The frequency depends on your facility’s equipment, production load, and environmental conditions.Most manufacturers perform infrared thermography and breaker testing annually, while DGA testing may occur semi-annually for high-voltage systems.AssuredNDT can help tailor a predictive maintenance schedule based on your facility’s unique risk profile.

5. Is predictive maintenance required for NFPA 70B compliance?

Yes. The 2023 edition of NFPA 70B mandates condition-based electrical maintenance, including predictive inspection methods such as infrared thermography and electrical testing.Following NFPA 70B guidelines not only ensures compliance but also helps demonstrate due diligence to insurers and safety auditors.

6. What is the ROI of implementing predictive maintenance?

Predictive maintenance delivers a strong return on investment:

• 25–30% reduction in maintenance costs

• 20–25% increase in uptime

• 10x ROI compared to reactive programsBy preventing catastrophic failures and optimizing scheduling, manufacturers recover their investment quickly through improved reliability and reduced risk.

7. How can AssuredNDT help my manufacturing facility implement predictive maintenance?

AssuredNDT provides end-to-end predictive maintenance services designed for manufacturing environments, including:

• Infrared thermography inspections

• Transformer DGA testing

• Circuit breaker analysis

• NFPA 70B compliance programsOur experts help you detect hidden electrical issues, schedule repairs proactively, and maintain detailed documentation for insurers and auditors.