Setting up a Motor Management Program may appear to be a daunting task but once it is broken down into workable pieces, it becomes easier to handle.

Step 1. Create a program to identify and track your motors

 The first step is to identify all the motors in your facility (including any spares). This becomes your motor inventory.

 There are several ways of creating a motor inventory and tools available to help with this task. MotorMaster+ 4.0 is a comprehensive program that allows you to do this. It is available at no charge at

Advanced Energy has also developed the Motor Survey How-To-Guide, which is available at This document provides step-by-step instructions for planning your inventory, collecting data, creating purchasing policies, repair/replacement policies, etc. that are based on your individual business.

Even if you decide not to use either of these tools, you can create your motor inventory by walking through your plant and identifying each motor in your process by brand, horsepower, speed, frame size, model or catalog number. Be sure to note where that motor is located and what equipment it runs.

Once you have identified all your motors, start with your most critical applications, the ones you can’t afford to be without, and proceed from there. This list should also include your largest horsepower motors, the ones that will impact your bottom line the most.

Step 2 Making the Repair/Replace Decision

Your next step is to call your motor servicecenter (Brithinee Electric) to discuss these critical motors and determine how readily available a new replacement would be or if repair is your best option in the case of failure.

The best time to make you repair/replace decision is BEFORE the problem arises. Your motor servicecenter (Brithinee Electric) can help you with ballpark prices on new NEMA premium efficiency motors and repair/rewind costs.

If you decide a new motor is your best option, you may decide to purchase it now, before the crisis occurs (see Step 3 below). This may be particularly true if the new motor lead-time is longer than you can comfortably live with.

If you decide a repair/rewind is your best option, your motor servicecenter may need to order in special parts to have on hand when the motor needs repair.

Regardless of which direction you decide to go, note that decision on your motor inventory sheet so when the motor fails, you know what you have decided to do. (There’s no point in going through this exercise twice.)

Be sure to note the repair/replace decision you have made on the motor itself with a colored tag that includes specific instructions about repair/replacement upon failure.

Step 3 Develop a Spare Motor Inventory

When you discuss your motor inventory with your motor servicecenter, ask them if the motors that are critical to your operation are standard, off the shelf motors that they would normally carry in inventory, or special – something you need to order in advance and keep in your inventory.

If you do keep spare motors in stock, be sure to note that on your motor inventory and motor tag so you can make use of them when the need arises.

Step 4 Repair/Replacement Policy

As part of this motor management program, you should make company-wide decisions about general repair/replace issues involving non-critical motors.

This might include replacing all failed motors under a certain horsepower and repairing all motors above that horsepower.

It might also include replacing all motors that operate more than a certain number of hours each day with NEMA Premium motors.

You might also want to include replacing a failed motor if the repair cost exceeds a certain percentage of the cost of a new motor.

These guidelines are only some of the tools available to help you with this task. For more information on motor management, go to the Motor Decisions Matter ä website or to the U. S. Department of Energy’s Office of Energy Efficiency and Renewable energy (EERE) at