The lights flicker briefly, the monitors go black and suddenly production comes to a standstill. A typical Monday in production at metal component manufacturer Bergmann GmbH - until six months ago. The last unplanned power outage was six months ago. What has changed?
"We have stopped accepting power outages as an unavoidable evil," explains Operations Manager Michael Lenz. "Instead, we got to the root of the problem."
Why it is not enough to simply check the fuses
Most companies only react once the damage has already occurred. Traditional checklists on fuses, cable connections and load limits are important - but often fall short. Truly effective prevention strategies start at a deeper level:
Surprising insight no. 1: In over 60% of cases, the problem is not defective components, but incorrect load allocations in the original planning.
Ask yourself:
- Do you know the actual peak loads of your systems?
- Do you know which loads are on which circuits?
- Have you correctly integrated the extensions of recent years electrically?
The three pillars of a reliable power supply
1️⃣ Systematic circuit diagram revision * Checking the load distribution * Identification of creeping overloaded circuits * Simulation of load scenarios
2️⃣ Intelligent monitoring instead of a blind spot * Continuous measurement of critical parameters * Define early warning indicators * Use long-term trends for wear forecasts
3️⃣ Preventive instead of reactive maintenance * From periodic to condition-based inspections * Targeted elimination of weak points * Modernization of neuralgic points
At Bergmann GmbH, it all began with a detailed EPLAN-based analysis of the electrical infrastructure. "We had no idea that our extension from 2019 would push the grid to its absolute limits on some days," admits Lenz.
What does a power cut really cost?
The direct costs of production downtime are just the tip of the iceberg:
✓ Rejects due to interrupted processes
✓ Restart times
✓ Security risks
✓ Data loss
✓ Reputational damage with customers
"The return on investment for our prevention measures was less than four months," calculates Lenz. "Since then, we have been making continuous savings."
What can you do TOMORROW?
Not every company has the resources for a comprehensive electrical renovation. But anyone can implement these three steps immediately:
- Complete documentationCreate an up-to-date overview of all loads and their assignment to circuits.
- Identify critical areasWhich system components would cause the highest costs in the event of failure?
- Expert checkHave a specialist electrical company or electrical designer carry out a load analysis of your main circuits.
A professional EPLAN service provider can then create a structured weak point analysis and suggest specific optimization measures - so that power failures are a thing of the past for you too.
Because as Michael Lenz emphasizes: "Electricity is the lifeline of modern production. Protecting this lifeline is not an optional extra, but a duty."
