It is 2 o'clock in the morning when the production plant suddenly comes to a standstill. The automatic emergency notification wakes the maintenance engineer, who is now faced with a challenge: Troubleshooting a complex system under time pressure, while every minute of downtime costs thousands of euros.
Many companies are familiar with this situation - and yet in most cases it could be avoided. The secret lies in forward-looking electrical planning that goes far beyond the simple drawing of circuit diagrams.
The underestimated dimension of system planning
While mechanical components are often the focus of planning processes, electrical planning often remains in the shadows. A fatal mistake: around 70% of all unplanned production downtimes are caused by electrical or control technology problems.
Forward-looking electrical planning not only considers the basic functionality of a system, but also takes the entire life cycle into account:
- How does the system behave under changing loads?
- Which components reach their service life limit and when?
- How can maintenance work be carried out without complete shutdowns?
- Which expansion options need to be considered from the outset?
What is the difference between conventional and forward-looking planning?
The decisive difference lies in the approach:
Conventional electrical planning:
- Focus on current function fulfillment
- Minimum compliance with standards and regulations
- Little redundancy for critical functions
- Limited monitoring options
Forward-looking electrical planning:
- Systematic risk analysis and prediction of potential vulnerabilities
- Integration of condition monitoring for early warning
- Strategic redundancy concepts for high availability
- Modular structures for easy maintenance and expansion
By switching to predictive electrical planning, a medium-sized production company was able to reduce unplanned downtimes by an impressive 83% - with initial planning costs only 12% higher.
Practical approaches for better electrical planning
How can the switch to forward planning be implemented in practice?
1. carry out a criticality analysis Identify which system components would cause the greatest costs in the event of a failure and concentrate your planning resources there.
2. ensure digital continuity Use CAE systems such as EPLAN, which enable end-to-end documentation from planning to operation.
3. integrate diagnostic capability Plan measuring points and interfaces for condition monitoring right from the start - even if these are only used in later expansion phases.
4. prioritize ease of maintenance When planning, take into account that components must be accessible and replaceable without having to dismantle large parts of the system.
5. design modular systems Design electrical systems so that individual modules can be maintained or extended without affecting the overall system.
From theory to practice
The added value of predictive electrical planning is particularly evident in the long term. An illustrative example: In a production line in the automotive industry, predictive electrical planning has reduced maintenance windows by 35%, while at the same time reducing unplanned downtime by 62%.
The necessary investment in additional planning time and quality paid for itself in the first year of operation.
Forward-looking electrical planning is more than just a technical process - it is a strategic investment in the long-term production reliability and cost-effectiveness of systems. The key to success lies in integrating this way of thinking into the planning process at an early stage, ideally supported by modern CAE systems and experienced electrical designers who recognize potential risks before they become a costly reality.
