Less Downtime, More Run Time

Client Background

A new industrial customer was experiencing frequent production line breakdowns, averaging 6 to 10 call-outs per week for urgent electrical assistance.

Issue

The site was plagued by multiple recurring breakdowns, with an average of 6–8 incidents weekly — a pattern that had become routine under the previous contractor.

Key issues included:

• Safety system failures
• Motors burning out or tripping due to incorrect overload settings
• Excessive dust and debris in switchboards damaging components
• Poorly installed and unsecured cabling, vulnerable to mechanical damage
• Rodent activity causing cable damage

Cause

Prior to our engagement, the site operated under a reactive maintenance model, addressing issues only as they occurred. There was minimal focus on long-term solutions, preventative strategies, or system optimisation.

Rectification

Upon taking over site maintenance, M.A.S.S. Electrics implemented a comprehensive preventative maintenance program designed to reduce downtime and improve system reliability.

Pest Management

• Relocated vulnerable cabling to protected areas
• Sealed switchboards and removed access points
• Installed rodent deterrents to prevent future interference

Safety System Upgrade

• Upgraded the site’s safety infrastructure to a Category 4 Safety System, ensuring compliance and improved protection

Motor Protection

• Conducted a full site survey
• Adjusted motor overload settings to align with correct current ratings, preventing unnecessary tripping and burnout

Switchboard Integrity

• Installed positive pressure systems to prevent dust ingress
• Established periodic cleaning, inspection, and repair schedules

Cable Management

• Re-routed and secured cabling using upgraded support structures
• Ensured all cabling was protected from mechanical damage

Outcome

The implementation of proactive strategies led to a significant reduction in production downtime. Over a two-year period, the site experienced a 90% decrease in monthly call-outs, dropping from 40 to just 2 per month — a clear testament to the effectiveness of preventative maintenance and professional site management.