TCO- Paper Manufacturing

TCO- Paper Manufacturing


A North Carolina paper mill was experiencing repetitive failures on a pump motor. Their motor service provider could not help them solve the issue and bearings were failing without a clear root cause. Unplanned downtime cost the operators up to $50,000 an hour in lost production, with an unplanned Total Cost of Ownership (TCO) of $25,920.



After four failures, the customer contacted IPS for analysis and repair. During initial inspection, we documented these findings:

  • The drive shaft journal was found to be improperly machined, causing misalignment.
  • The drive end bearing housing exceeded its maximum tolerance, also causing misalignment.
  • The drive shaft was found to be bent, causing bearing preloading, overheating and failure, which was compiled by overgreasing of the bearings due to not understanding the root cause issue.


IPS properly machined and tested all components and returned the motor to the paper mill. The

motor is currently back in operation and running with no issues.


  • The IPS Solution Savings totaled at $18,920.
  • IPS Risk Elimination totaled at around $1,200,000.


Download the complete case study and calculations below:

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