Equipment earns its keep at the customer site. Condition signals sit apart from the parts warehouse. Field work is still often dispatched after the failure. The installed base still has to run.
01
Motor test risk flagged before final assembly is complete
Use in-process tolerance measurements the line already captures to predict end-of-line test outcomes — and focus quality attention on the parameters that matter.
02
IE3/IE4 documentation kept current across the product range
Organize efficiency test reports and technical files against applicable Ecodesign requirements — and surface gaps for compliance-team review before the audit.
03
Cross-station vibration disagreement made visible
Compare bearing vibration results across your own test stations, so borderline decisions get corroboration where historical disagreement is highest.
On the installed base
Industrial equipment businesses lose money in three places that rarely share one screen: an asset that fails without a joined condition view, a spare that is not where the technician needs it, and a service visit that starts after the customer already stopped. Most of that is already in IoT tags, parts ledgers and work orders — after the fact.
The assetIFS's 2025 State of Service in Manufacturing report found that 94% of manufacturers had been impacted by unexpected equipment downtime — while only 21% said they run predictive maintenance at scale.
The spareMcKinsey's aftermarket research ranks poor spare-parts availability among buyers' top three service concerns, alongside field-talent quality and slow repair turnaround. A missing part turns a planned visit into extended downtime.
The service networkThe same IFS survey reported that 95% of manufacturers experienced supply-chain disruptions that affected service delivery, and 98% faced skills or labor shortages that slowed issue resolution and strained customer satisfaction.
Sending another truck is the easy correction. It is also how the service day is spent.
INSUS works from asset tags, work orders, spare-parts tickets and service history a company already keeps. If the gap is an unread alarm, a stockout, or a failure mode that never joined the serial-number file, that is what we will say. Recommendations stay advisory. Existing control, EAM and field-service systems stay in charge.
Industry figures
Four external figures, each with its source. Nothing on this page is an estimate we made up. Where we cannot cite a number, we describe the situation in words instead.
Downtime
94%
of manufacturers in IFS's 2025 State of Service survey reported being impacted by unexpected equipment downtime.
PdM at scale
21%
said they have fully embedded and optimized predictive maintenance, with a further share still only partially deployed or piloting — leaving most fleets without scaled condition-based intervention.
Parts & service
70%
of aftermarket buyers surveyed by McKinsey said they had seen no improvement in service-provider performance over the last ten years — with spare-parts availability among their top concerns.
Source: McKinsey, How aftermarket service providers can meet new customer expectations
Skills
98%
of manufacturers in the IFS 2025 service survey reported skills gaps or labor shortages, which respondents linked to slower issue resolution and lower customer satisfaction.
Common problems
None of these show up as a single alarm. They show up in the end-of-line fail, the incomplete efficiency file, and the station that disagrees with the next one.
A motor may already carry significant assembly effort when a dimensional miss shows up as a torque, ripple or NVH fail. Quality attention stays spread across many tolerances without knowing which drive the result.
See: Motor Manufacturing Tolerance-to-Test PredictionLoad-point test reports and product files sit across systems. When Ecodesign thresholds change, a broad manual review is often the only way to know which variants are still covered.
See: EU Motor Efficiency Ecodesign ComplianceEach station's pass/fail is treated as independently authoritative. Borderline results may not be evaluated against station-specific disagreement by model and frequency band.
See: Bearing Vibration Test Consistency AdvisorUse cases
Each is a specific starting point — this motor line, this product range, this bearing test cell — and a next conversation if it is worth your time.
Predict electric motor end-of-line test outcomes from in-process tolerance data and flag at-risk units before final assembly and testing.
See the full use case
Organize and check IE3/IE4 motor efficiency documentation against EU Ecodesign requirements across electric motor and VSD product ranges. Compliance teams retain final sign-off.
See the full use case
Compare bearing vibration test results across test stations, identify station-sensitive measurements and flag borderline results for quality review.
See the full use caseFAQ
A practical look at what INSUS needs, where it fits and what your team can expect.
The work that fits is the data an OEM or equipment operator already produces: in-process measurement and end-of-line test records, efficiency documentation and Ecodesign evidence, multi-station vibration-test history, work orders and warranty files. MotorTrace, MotorComply and TestConsistency can start from records you already keep. Closed-loop equipment control, automatic release/scrap, automatic compliance certification and automatic recalibration of test stations are not promises we will make on day one.
Machinery on this site focuses on the plant that builds machines — CNC cells, setup, scrap and shop-floor OEE. Industrial Equipment focuses on installed fleets and aftermarket reality: condition at the customer site, spare-parts readiness, field service and warranty history.
Usually not for hours, fault codes, work orders and parts ledgers. Many fleets already have some telemetry and an EAM or FSM system. If a critical asset is unread or a BOM is incomplete, that comes before any model.
No. The person who knows this product family and this customer site stays responsible. The aim is to stop the next visit starting only after a break-fix call, and to flag a developing asset issue while the outage can still be planned.
No. It advises the service engineer or the reliability team. Existing PLCs, OEM controllers and safety interlocks stay in charge of the loop.
No. Uptime and service performance depend on asset condition, parts logistics, customer operating practice and contract scope. We will not invent an uptime or fill-rate target for your network.
It is the share of manufacturers in IFS's 2025 service survey who said predictive maintenance was fully embedded and optimized — not a measurement of your installed base. Your work orders and condition logs are the numbers that matter.
Yes. One asset class, one depot, or one service region is usually the practical start. Measure that, then decide whether to widen.
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