The Cost of Inaction: What Unmaintained Electrical Gear Could Be Hiding

In manufacturing, downtime doesn’t just hurt — it halts production, delays delivery, and can drain six figures or more from your bottom line^[1]. Yet too many facilities overlook electrical preventive maintenance (EPM), assuming “no news is good news” when it comes to critical assets like switchgear and transformers.

The reality? Electrical failures don’t announce themselves. They build quietly — until the lights go out, the line stops, and you’re scrambling to recover.

1. The Transformer Failure That Cost Nearly Half a Million

At a Midwest food processing plant, a main service transformer failed late on a Friday. Production halted immediately. With no spare on-site and a three-day wait for expedited replacement, the plant lost nearly $480,000 in spoiled inventory, overtime, and missed shipments^[2]. Post-failure analysis revealed thermal stress, moisture ingress, and insulation breakdown — issues that could have been caught with regular infrared or oil analysis.

2. Hidden Corrosion in Switchgear That Nearly Shut Down a $20M Run

A Tier 1 auto parts manufacturer in Ontario uncovered heat damage and corrosion in their main switchgear during a long-overdue inspection. Mitigation costs were under $10,000—but a failure could have shut down three production lines, costing over $1.2 million in lost revenue^[2].

3. Downtime Causes You Can’t See — Until It’s Too Late

Unlike mechanical systems, electrical equipment degrades silently. Dust, heat, humidity, and loose connections chip away at performance over time. Without structured EPM, plants are flying blind—exposed to hidden failures that only reveal themselves when it’s too late^[3].

4. Common EPM Gaps That Lead to Failure

• Breaker mechanisms seizing from lack of lubrication
• Blocked ventilation causing MCC overheating
• Moisture ingress in outdoor transformers and switchgear
• Loose terminations causing arcing and heat buildup

These issues are preventable—but only if detected early via EPM^[4].

5. Preventive Maintenance Isn’t an Expense — It’s Risk Insurance

Downtime costs have risen dramatically. For example, an hour of unplanned downtime in heavy industry now costs at least **50% more** than two years ago—up to millions per hour in sectors like automotive^[1][5]. Treat EPM as non-negotiable: fewer shutdowns, safer operations, and lower stress.

Bottom line? What you don’t see can hurt you—and in manufacturing, it often hurts your margins first.