Avoid Downtime This Fall: How to Build an Emergency Parts List for Your Plant

As temperatures drop and production ramps up ahead of the holidays, one thing becomes clear: fall is not the season to gamble with downtime. A failed PLC, drive, or HMI can halt entire production lines, delay shipments, and throw off year-end quotas.

That’s why more facilities are preparing now with a fall emergency parts list—stocking high-failure, long-lead, or mission-critical components before problems hit. Whether you're maintaining legacy equipment or running a mixed-brand setup, a little planning can prevent major pain.

Here’s how to build a smart, tailored emergency parts list that keeps your plant running—even when the unexpected strikes.

1. Start with Your Critical Failure Points

Begin by identifying the systems and components that, if they failed, would bring production to a standstill. These are your Tier 1 risks.

Ask your team:

• Which machines are single points of failure?
• Which parts do we wait days or weeks to receive?
• Where have we had past unplanned downtime?

Typical high-risk components to assess:

• VFDs & Servo Drives – e.g., Allen-Bradley PowerFlex 525, Mitsubishi MR-J2S, Yaskawa SGDH
• PLCs & Modules – e.g., SLC 500, Siemens S7-1200, ControlLogix I/O
• HMI Panels – GOT2000 series, PanelView Plus, Weintek displays
• Power Supplies & Contactors – aging support equipment that often fails silently

💡 Pro Tip: Scan your maintenance logs from the past 12–18 months to identify repeat offenders. If a component has failed once, it’s likely to fail again.

2. Check Lead Times & Supply Chain Risks

Not all downtime risks are mechanical—some are logistical. With ongoing tariff shifts, international shipping delays, and brand-specific shortages, certain parts now take 2–8 weeks (or longer) to arrive. That’s a problem if your line goes down.

Ask these questions:

• Which brands or part series are hardest to get right now?
• Are you relying on OEM lead times or third-party stock?
• Do you have any international parts vulnerable to new tariffs?

Stocking long-lead items ahead of time (especially imported PLCs, HMIs, or motors) can mean the difference between a minor hiccup and a major outage.

📌 Inventory Insight: At Industrial Automation Co., we’ve seen extended lead times on select Siemens, Yaskawa, and ABB parts due to tariff-related rerouting. For fall 2025, we recommend checking availability early.

Explore In-Stock Parts →

3. Build a Tiered Parts List (Not Just a Shelf of Spares)

Instead of randomly stockpiling, organize your list into Tier 1, Tier 2, and Tier 3:

• Tier 1: Must-have parts that shut down the line if they fail (e.g. primary VFDs, CPUs, HMI screens)
• Tier 2: High-risk but workaround possible (e.g. I/O modules, auxiliary motors)
• Tier 3: Lower-risk components but still useful during holiday staffing gaps (e.g. sensor cables, relay bases)

This triage model helps maintenance teams and procurement align on urgency, budget, and backup plans. You don’t need every spare on hand—you need the right ones.

🧠 Tip: Label each part with its machine location, estimated failure frequency, lead time, and replacement procedure for faster decision-making under pressure.

4. Balance OEM Loyalty with Cross-Compatible Parts

While many teams default to OEM replacements, that’s not always the fastest—or most cost-effective—option during emergencies. For legacy systems, finding a tested, compatible alternative can:

• Save you 30–50% in cost
• Arrive days or weeks sooner
• Keep legacy lines running without full upgrades

For example:

• A discontinued Allen-Bradley SLC 500 module may have a drop-in replacement from Industrial Automation Co.
• A hard-to-source PowerFlex 700 may be swapped with a compatible PowerFlex 753 you already stock.

🔁 Want help finding fast, plug-and-play replacements?
Contact our support team here.

5. Include Drives, PLCs, HMIs, and Support Gear in Your Emergency Kit

A true emergency parts list goes beyond just the big-name items. Don’t overlook the supporting components that can just as easily bring operations to a halt.

Drives

• AC Drives (VFDs): Common in conveyor belts, mixers, and pumps. Consider backups like the PowerFlex 525 or Mitsubishi FR-A740 for fast replacement.
• Servo Drives: Used in CNC machines, packaging systems, and robotic arms. Stock models like the MR-J2S, Yaskawa SGDH, or FANUC A06B for high-precision motion.
• Accessories: Include HIM modules, braking resistors, or wiring harnesses that are often overlooked until they fail.

PLCs & Modules

• Primary CPUs: A failed PLC CPU can take down an entire line. Have spares for key systems including ControlLogix, Siemens S7-1200, or SLC 500.
• I/O Modules: Digital and analog I/O cards frequently wear out, especially in high-switching environments. Keep extras on hand for fast swaps.

HMIs

• Operator Panels: Touchscreens take heavy daily use. Have replacements ready for aging PanelView Plus, GOT2000, or Weintek units.
• Support Items: Backup SD cards, communication adapters, and power supplies are cheap but critical during unplanned failures.

Support Gear

• Industrial Power Supplies: Voltage drops and surges can damage controls—don’t let a $100 supply cost thousands in downtime.
• Cooling Fans & Filters: Overheating is one of the top causes of drive failure. Replace fans and filters proactively in fall.
• Control Relays, Terminal Blocks & Cabling: Keep common relay types and pre-cut Ethernet or shielded cables on hand for last-minute fixes.

🧰 Remember: Even a small part can be the reason your line sits idle for days. Prioritize replacements based on risk and lead time—not just size or price.

Final Thoughts: Plan Ahead Now—Avoid Downtime Later

Building an emergency parts list isn’t just about inventory—it’s about control. When an unexpected failure strikes, your team won’t be scrambling. You’ll be ready, stocked, and one step ahead.

And with rising lead times, tariff impacts, and seasonal labor shortages, waiting until November is too late. Start now. Audit your lines. Rank your risks. Fill in the gaps.

At Industrial Automation Co., we stock thousands of new and refurbished parts from brands like Allen-Bradley, Siemens, Yaskawa, Mitsubishi, and more—ready to ship today.

• ✅ Get expert guidance.
• ✅ Cut downtime risk.
• ✅ Protect your production goals.

Need help building your emergency parts list? Contact our team now →

Or browse our in-stock parts by brand →