Paul Laskowski

10919 Masters Rd.

Memphis, MI 48041
November 18, 2014
Doug Ouvry
Shop Manager
Spina Electric Co.
26801 Groesbeck Hwy
Warren MI, 48089
Dear, Mr. Ouvry
I am writing in regards to the current shop conditions as well as the missed opportunities of
potential customers. We have had companies come through our shop to see if they would want
us to do their service work. When those companies came, they decided they did not want us to do
their work because of our current shop conditions. As a current technician, this is lost profit for
both the company and its employees and could possibly cause us to lose good business
customers. Therefore, this is a way to change and prevent this from happening again.
The best way to prevent this is by becoming ANSI/EASA AR100 certified. This certification
indicates that a shop is a clean, safe, work environment, and also provides a quality and reliable
customer service. This will attract new customers to our shop and also helps us to improve our
current shop conditions.
In order to become certified we need to follow certain guidelines that they have provided to
make the process go much easier. I believe that by doing this our shop will become much more
profitable as well as safe. Throughout the attached report, I will go over many of the categories
that need to be gone over and how we can become certified. After you have read this, please
contact me so we can get started on this process to make our shop safer.
Sincerely,

Paul Laskowski

Becoming ANSI/EASA AR100 Certified

Prepared for
Doug Ouvry
Shop Manager
Spina Electric Company

Prepared by
Paul Laskowski
Ferris State University

November 18, 2014

Table of Contents
Executive summary

Introduction

Problem

Advantages

Requirements

Housekeeping
Training
Audits
Inspection
Disassembly
Cooling
Shaft
Bearings
Lubrication
Frame
Rotor
Balance
Accessories
Windings
High potential 6
Test run
Shipping
Conclusion

6
6
6
6
6
7
7
7
7
8
8
8
8
8

Work cited

10

9
9
9

Executive Summary
This report is about how keeping an electric motor shop up to date and in the black is
not an easy thing to do. However there are many ways that can help maintain a shop and keep
more customers coming in for service over time. The best way to do this is by becoming
ANSI/EASA AR100 certified. By becoming certified indicates that a shop is in good condition and
also provides quality customer service. There are many things that go into becoming certified,
and many procedures that should be put into place.
When becoming ANSI/EASA AR100 certified there are many things that need to be taken
into account. Many of these are broken down into categories of things that need to be
inspected, and possibly changed in order to make a shop a profitable and safe environment. In
the end the bottom line is keeping customers happy and making sure that no employee gets
hurt during the work day due to faulty equipment or just a dirty shop.
The categories included are;

Housekeeping
Training
Audits
Identification
Connectors
cooling systems
Shafts
Bearings
Lubrication

Frame
Rotor
Balancing
Accessories
Winding
Data
Testing
Shipping
Calibration

All of these are important things that need to be considered and looked at while looking to
become certified. In this report I will go more into depth on these topics and describe many of
the things that need to be done.
When a shop becomes certified, there will be more customers because potential
customer will know that they will be provided a quality reliable service. Just like many
employees will be provided a safe and clean working environment because potential workers
will know that the shop has a high standard of quality. This means that even the technicians will
have a better moral in the shop that they work in because they know it will be a certified shop.

Becoming ANSI/EASA AR100 certified

4

Introduction:
Many things in the electric motor repair field are changing. From these changes it is
important to become ANSI/EASA AR100 certified. There are many things in this certification
that helps shops become more productive and efficient. Many of these things are already preexisting in most shops; however it is very important to adhere too many of the procedures that
are outlined in different programs that are available. Many of these things will help the
business by broadening the customer base, as well as improving overall health and morale in a
shop. In this report I will go over many of the things that are important to the shops, customers,
and employees.
Problem:
Today, it is very important that service shops provide good quality service as well as
exceptional customer service. But its not just important for the customers, it is also important
for the morale of the employees. Without there being a standardized way that shops should
provide service, it is a guessing game for customers to know whether or not they are provided a
quality service. There was no way for customers to know if the motor they were having
repaired was actually being repaired correctly which made many customers skeptical of getting
motors repaired. However, when the economy tanked, many companies could not afford to
buy new motors and consequently had to get the motors repaired instead. To make customers
feel more comfortable that they were receiving a good quality service, therefore, EASA created
the ANSI/EASA AR 100 certification to inform shops and customers of a quality shop.
Not only does the customer benefit, but also the employees benefit from the
shop being certified as well by giving them a cleaner and safer working environment. When
someone is looking for a job, especially in the electric motor industry, the quality of the shop is
important to the potential employee because they want to work in a safe and clean
environment. This was a huge problem because many shops didnt have any standard safety
procedures or cleaning procedures. This caused many employees to get injured at work, and
caused worker compensation rates to increase due to all of the injuries.
Advantages:
This certification indicates that a shop is safe, clean environment and uses a
standardized procedure and standardized materials for performing repairs on customers
motors. This tells potential customers that their motors will be repaired in the proper manner
using the proper materials. Also, this certification will tell potential employees that the shop is
a safe, and clean work environment to be in. Accidents will always be a potential hazard, but by
becoming certified means that there are procedures in place to help reduce the amount of
injuries that occur at work. This will also mean that only the best technicians, winders, and
other employees will be the best ones capable of performing a job.
Requirements:

One of the most important aspects of this process in becoming certified is proper
housekeeping. When you first plan to become certified, it is important to evaluate the
cleanliness and the housekeeping that is currently going on in the shop. By making an initial
assessment, you will then know what the shop needs, and what it will take in order to make the
shop a professional, safe, and controlled work environment. Another important aspect of
housekeeping is making sure that the materials used in repairs are not contaminated before
getting into the motor. Oils, grease, even metal and copper can become contaminated by a
dirty shop environment and can reduce the service life of a repaired motor. There are many
things that can be used to help maintain the cleanliness in a shop and it is important to analyze
and determine what it is that the shop will need. One of the most important things to consider
is moving air in the shop. When there is little to no ventilation, then there is no way of moving
the dirt outside and keeping the inside clean.
Training employees is another huge part of becoming certified because in order to
provide a quality repair, it is important that all technicians are trained in the repairs that they
may be performing. Some of the important things to train employees in are rewinding,
machining, assembly and disassembly, theory, and many other important principles. Not only is
training in repairs important, but to also train employees about proper housekeeping of the
shop. This way, all employees will be aware of potential dangers in the shop, as well as knowing
to work in a safe manner. Making sure that every employee is trained on keeping a shop clean
and knowing the proper way to dispose of waste materials is just as important as the training in
repairs. Training also can spread too many other aspects of the certification, by simply making
employees more knowledgeable.
When looking at page nine of the EASA Accreditation Program, having internal audits
performed every year also helps to keep everything in check to make sure that all procedures
are being followed. All of the audits should be sent off to an external auditor to review the
audits. Making sure that no information is being falsified and all information is true. All findings
are then documented and stored for future audits or investigations that may take place. It is
also recommended to have an outside auditor come through to check on the shop periodically.
Every motor that comes through the door needs to be inspected. This includes the
information off the data plate like make, model, frame, and year, and extends to failure, cause
of failure, and what the last failure was and its cause. Along with the inspection, pictures of the
incoming motors need to be taken. Taking pictures is important because customers may try and
blame things on the shop that happened during transport or at their shop, therefore when you
take pictures, as well as documenting everything; there is less of a chance for the blame game
to happen. This will help to ensure that nothing is being missed when the actual repair is being
performed. Every motor comes through the door for a reason, and it is critical that the motor is
inspected and repaired properly to ensure that the motor is repaired right. This will help
improve return times of motors back to customers, as well as making and improving customer
satisfaction. This will in turn broaden the customer base because good repairs equal happy
customers.
Also shown on page nine, during the disassembly process, is important to label
connectors properly when they get taken apart. Making sure that a repair is done in a timely
manner; the technician can be concerned with the repair instead of how everything is hooked
up and the labeling of the connections. There have been instances lately where connections are

not labeled properly in a motor when it is disassembled, and therefore, put together wrong.
When this happens, it costs the company money to diagnose the problem and fix it when it
could have been avoided. Also, it is important to inspect the connections themselves on the
wire ends during tear down because a bad connection, can affect corrective actions. That is why
it is important to label and inspect all wire ends properly when a motor comes in.
When electrical components run, they get hot therefore the cooling of these
components is critical because a motor can potentially burn up if they get too hot. Inspection of
the cooling systems on the motors can be a telltale sign to many problems on a motor. Cooling
system components link to the major components in a motor because they are all connected in
some shape or form. Such as the cooling fan is mounted to the shaft, which is turning on a
bearing. Therefore, if a fan is out of balance, this can destroy a bearing, and in turn destroy a
shaft when not caught in time. Proper inspection of the cooling system is crucial in the
inspection process because it can lead to many issues down the road if issues are not caught
when they were supposed to be. Cooling on motors that run in volatile environments is also
very important because if the motor gets too hot, this can cause an explosion which can
potentially injure or even kill people. Therefore, cooling on a motor is a very important as well
as the inspection of the cooling components.
Continued on page nine of the accreditation program, the shaft is the most important
part of the motor because that is what the components that produce the power is attached
too. When the inspection of a shaft is taking place, it is critical to check for cracks, straightness,
out of balance, dimensions, and integrity. All of these aspects need to be recorded and put in a
file with the work order so the information is passed along to everyone else working on the
motor. Since the shaft runs on bearings it is then just as important to make sure that the
bearings are inspected properly. When a shaft is found to require repairs, sending the shaft to a
proper facility to make repairs is important. Many electrical shops do not have the necessary
equipment to perform proper repairs, but if one does, it is important to follow guidelines for
the repair on the shaft.
Bearings need to be inspected, removed, stored, and installed properly. When a bearing
isnt stored correctly, this can cause a bearing to fail prematurely due to contamination.
Installation is just as important because when they are not installed properly; this can also
cause premature failure, as well as cause a shaft to fail along with many other components.
When planning to remove bearings it is important to remove them in a manner that will not
compromise their integrity unless the bearings are going to be replaced. Just like installing a
bearing, proper procedures are just as important. There is equipment that allows for proper
installation like a bearing heater that aids the ease of installation of bearings. Measuring tools
are just as important for ordering a new bearing when it isnt possible to match them up with
old bearings.
All motors require some form of lubrication, which is mandated by the bearing
manufacturer and/or the motor manufacturer. It is important to replace lubrication with the
proper lubrication specified in the manual of the motor. Since using the wrong oil or grease, can
cause premature failure on the motor, using the proper material is important. Also, storage of
the oil or grease is critical to the life of the motor. When oil or grease are not stored properly,
this will cause it to become contaminated. Once it is contaminated, it can cause a motor to fail
prematurely because the bearings will not be lubricated properly or damaged by

contamination. Oil can also be used as a method of cooling the motor therefore it is very
important to keep the oil clean because contaminants can cause improper cooling abilities.
When bearings are removed, or a motor is tore apart, the frame must also be inspected
for damage and/or degradation since that is what holds all of the internals of the motor. When
the frame is damaged due to a failure it may have to be scrapped and replaced because of
having too much damage. Sometimes the damage to housing can be repaired when it is not too
severe. Therefore, it is important to either have the equipment to perform the proper repair, or
have a certified shop to perform the proper repair to the housing. Also, when all the
components are taken apart from the housing, they must all be labeled and identified so they
will come back to the same housing and same orientation. Parts getting mixed up can cause a
headache because it is the service shops responsibility to return a motor in better condition
than what they received it in, and not with missing parts.
Rotors, which are mounted on the shaft, are very important to the motor because that
is where the electrical energy is transformed into mechanical energy. All rotors need to be
checked for mechanical and electrical faults. Whether it is being repaired or not, it is always
important to check it when the motor is taken apart, because not testing it would be pointless if
there was physical damage or internal damage causing the need for a repair. Even a simple
thing like the rotor being loose on the shaft could cause a premature winding failure. All
apparatuses that are used to test the rotor should also be tested or calibrated to make sure
they are working properly and all results should be recorded and kept with the documentation.
When repairing a rotor, make sure to use all the necessary and proper equipment to ensure
that all repairs are proper.
It is also important to check the rotor, shaft, cooling fan and any other rotating
components for balance, because this can easily destroy a motor from vibrations. Not only the
motor, but also what the motor is running can be damaged or destroyed due to vibrations. The
amount of vibrations put out by the shaft needs to be recorded and classified as good or bad.
When classified as bad, the proper repairs need to be made to prevent future failures from
happening. All equipment used to check for balancing needs to be calibrated and made sure
that it is performing properly.
Also on motors there can be accessories attached to them such as temperature sensors
in coils and heaters on the noses of coils. These are used to reduce moisture build up or prevent
the motor from getting too hot and causing a failure. Any accessory attached needs to be
treated just like any original part for the motor. These checks can be for function, and make
sure that they are calibrated right. Any added equipment was placed there for a reason and
should be treated as it belongs there unless it causes the motor not to function properly.
When a motor is tore down and needs the windings to be checked, it is a crucial step to
making sure the motor will run properly. All assessments done to the windings are to be
documented and placed with the work order so all the information can be passed along. Also,
the core of the winding needs to be checked for integrity. You must check these to make sure
they do not over heat and check that they are electrically sound because this is a very
important part since the electricity runs through the windings creating a magnetic field through
the core.
When the windings are classified as bad, they need to be re-wound. All data for the wire
size and turns and connection needs to be documented to ensure the repair is done properly.

Any changes made to the windings to change or maintain the efficiency need to be
documented to monitor them for that reason. All data taken and written needs to be verified
by the service shop to make sure the repair matches with standards. Any changes made to
windings also need to be verified for to prevent failure.
All stator windings, insulation, conductors and the coils should all be checked to ensure
they were not damaged, or if they were what needs to be replaced. These are all internal
components in a motor, and are essentially the driving force of the motor. All repairs made to
these need to be standardized with the manufactures recommendations. If there are any
customizations required, it must be verified by the customer and by the manufacture to ensure
that any customization does not affect the integrity of the motor. All instruments used to test
these must be recommended by the manufacturer to ensure nothing is missed while testing.
All repaired windings and coils need to be varnished/resin treated and cured to what is
recommended by the manufacturer. The oven used to cure the varnish must be set to the
recommended settings given by the varnish manufacturer. Also any coil or winding that has
gone through the process must also be tested to ensure the integrity of them was not
compromised. They need to be voltage checked as well as check for hot spots that will indicate
a short in the windings. Finally any windings that were made new or were repaired need to be
tested for a high potential. All of these tests need to be documented and recorded so the
information can be filed for future repairs.
Once a motor is rebuilt, it must be tested to make sure it runs before it can be sent back
to the customer. The motor needs to be hooked up to the test panel with no load or with load
depending on what the manufacturer specifies. While running you need to check for vibrations,
amperage draw, and other things before putting the stamp of approval on the motor and
saying that it is good to go. When a customer gets a motor back that does not run, that will be
bad for both the shop and the customer due to lost time, and productivity.
Finally, once the motor is ready to be sent back, it is very important that the motor is
packed and shipped with care. The motor is to be cleaned and painted indicating that the motor
is repaired. Any motor that requires oil for lubricating purposes needs to be shipped without
oil, but have a note indicating there is no oil and it needs to be filled. This will prevent any miss
understandings and make sure that there are no accidental startups that could cause the motor
to fail.
Conclusion:
As I have discussed, by following these criteria, any shop would be able to become
certified with EASA. Most shops find it scary to start attempting to be certified because of the
required paper work along with required actions. However, many shops have everything
required to become certified already in place, it just needs to be documented. By becoming
ANSI/EASA AR100 certified will broaden your customer base and help produce better quality
work and working environments for the companys future. By becoming certified, possible
customers will know that the shop will provide a quality service, and have all the proper
equipment necessary to do the job. This will also state that the shop is a safe and clean work
environment for its employees and customers.

Appendix 1
There are many things that electric motor repair shops need to consider about how their
repairs are being performed. They also need to be aware of the type of environment that the
repairs are being done in. That is why many shops are looking to become ANSI/EASA AR 100
certified to show to their customers that the repairs in their shops are being done properly.
Becoming ANSI/EASA AR100 certified.
Five primary areas of focus for the accreditation process.
Service center policies and
Equipment Needs
procedures
Beta internal audit
Training of personnel
Initial external audit
Categories Involved
Housekeeping
Physical Required
Training
Winding removal and core integrity
Internal audits
Rewind data
Identification and condition assessment
Stator windings, insulation system,
Terminal leads, connectors, and boxes
conductors and coils
Cooling system
Winding Impregnation
Shafts
Winding Insulation and coil tests
Bearings
High-potential tests
Lubrication
Bearing Insulation
Frame and bearing housings
No load tests
Squirrel cage rotors
Finish and handling
Balancing
Calibration
Accessories
Electrical Equipment Required
Loop test
Milli-ohmmeter
Growler
Ohmmeter
Test Panel
Voltmeter (AC)
Outside micrometers
Ammeter (AC)
Dial indicators
Wattmeter (AC)
Mechanical Required
Megohmmeter
Inside micrometer
High-potential tester
Digital tachometer
Surge tester
Terminal crimpers
Core tester
Vibration meter
Burnout oven water mist system
Balancing machine
Burnout oven analog or digital recorder
Gauge blocks
Bake oven temperature control
Temperature meters
Winding machine with turns counter
Burnout oven part temperature control
VPI system vacuum gauge
VPI system pressure gauge

Work Cited
Anderson A, Bishop T. EASA Accreditation Program.
Franding, Fredrik. Evaluating Electric Motor Repair Shops. EC&M Electrical Construction&
Maintenance. 107. (2008)
Ramsey, M.H, Armintor, J.K. Recommended practice for repair of electrical motors. Industry
Applications, IEE Transactions. 29. 52-59. (2002) DOI: 10.1109/28.195888
Raynes, L., Yung, E. C., & Bishop, E. T. Electrical Apparatus Service Association (EASA) Reviewers.