The Hidden Cost of Unplanned Downtime

Unplanned outages threaten industrial productivity and personnel safety. Typical industrial businesses and manufacturers lose up to $50 billion a year due to unplanned downtime. This figure reflects lost production, emergency repairs, overtime labor and penalties for delayed shipments.

Beyond immediate financial losses, reliability directly impacts overall equipment effectiveness (OEE), a critical metric that determines revenue potential in asset-intensive operations. Suboptimal electrical power systems silently erode equipment lifespan, increase environmental risks and compromise worker safety through exposure to arc flash hazards and energized equipment failures. Power Solutions Group employs a bottom-up approach to identify areas for improvement and provide solutions to reduce potential downtime, safety issues and environmental risks.

Critical Power System Reliability Engineering

Achieving sustained reliability requires a holistic approach that addresses three interconnected pillars:

• Engineering design: Identifying design deficiencies, equipment operating beyond rated capacity and obsolete components that no longer meet current codes or operational demands.

• Day-to-day operations: Evaluating how operational practices affect system stress, load distribution and equipment performance during normal and peak conditions.

• Overall electrical maintenance: Assessing whether preventive and predictive maintenance programs adequately protect critical assets from premature failure.

Critical power system reliability engineering is a diagnostic discipline that uncovers systemic vulnerabilities before they manifest as costly failures. Our proactive methodology reduces arc flash exposure, minimizes equipment damage during fault conditions and creates a sustainable framework for long-term operational continuity. Power Solutions Group also provides comprehensive electrical engineering consulting to enhance this integrated approach.

Our Process

Power Solutions Group's power system reliability assessment begins with an on-site diagnostic engagement. Our engineers conduct physical walk-throughs to interview operators, inspect asset condition, review maintenance logs and evaluate existing protection schemes.

Our hands-on approach ensures recommendations reflect real-world operating conditions rather than theoretical assumptions. Through our thorough analysis, we can demonstrate how implementing study recommendations extends equipment life and calculates precise ROI, transforming reliability from an abstract concept into a measurable business outcome. Our NETA-accredited technical field services team works alongside engineering consultants to validate findings and ensure practical, implementable solutions.

As a NETA-accredited testing organization, Power Solutions Group provides unbiased, third-party reliability assessments grounded in industry standards, including IEEE, NFPA and NETA MTS. Our independence from equipment manufacturers and installation contractors ensures recommendations serve your operational and financial interests exclusively.

Optimizing Electrical Equipment Preventive Maintenance

Proper preventive maintenance from our experts can help extend equipment life, reduce emergency callouts and enable scheduled replacements during planned downtime. Effective programs prioritize resources based on asset criticality, focusing maintenance investment on the equipment whose failure would most significantly impact production, safety or regulatory compliance.

Advanced interventions include early-detection monitoring, performance trending of critical parameters and condition-based predictive maintenance that uses real-time data to schedule interventions before failure occurs.

Partner With Power Solutions Group

Our approach allows you to make data-backed decisions that satisfy safety directors, engineering teams and financial stakeholders. Contact us today to schedule your reliability assessment and protect your facility's operational future.