Avoiding Downtime: Top 5 Emergency Parts to Keep On Hand in 2025

Every minute of unplanned downtime chips away at your revenue, customer satisfaction, and production goals. And while predictive maintenance has come a long way, not every failure can be predicted. That’s why leading manufacturers and MRO teams maintain a strategic stock of emergency spare parts—especially for critical automation components.

In this guide, we’ll explore the five most important categories of parts to keep on hand in 2025—and why delaying your spares strategy could cost you big.

Why Emergency Spares Matter More Than Ever

The supply chain instability of recent years—combined with global tariffs and vendor shortages—has exposed just how fragile automation systems can be. A drive that took 2 days to replace in 2019 might now take 8 weeks or more, especially if it’s a legacy product or comes from a region affected by trade restrictions.

Stocking emergency parts is no longer just smart—it’s a competitive advantage.

1. Spare VFDs (Variable Frequency Drives)

Drives are at the heart of motor control, and their failure often leads to total line shutdown. Whether you're running conveyors, pumps, or chillers, a failed drive means everything stops.

Recommended spares to stock:

• Allen-Bradley PowerFlex 525 or PowerFlex 70
• Siemens Micromaster or G120
• WEG CFW series
• Schneider Electric Altivar 320 or 630

🔧 Tip: Keep drives with matching voltage, enclosure type, and communication options to your main systems. It doesn’t have to be identical, but it should be compatible enough to swap in quickly.

2. Servo Drives and Motion Amplifiers

Servo systems are precise, but when they fail, you often can’t manually override them. CNC machines, robotics, and indexing systems require fast motion replacement.

Popular models to keep:

• Mitsubishi MR-J2S or MR-J2 series
• Yaskawa SGDH / SGDB / SGDV
• FANUC A06B series

3. HMIs and Operator Panels

A broken HMI can render your system unusable—even if the PLC and drive are fully functional. They’re especially vulnerable to screen burnout, touch issues, or power surges.

Consider stocking:

• Allen-Bradley PanelView Plus terminals
• Mitsubishi GOT2000 units
• Siemens TP or KTP panels

4. Power Supplies and PLC Modules

Control voltage failure is a common cause of plant shutdowns. And input/output modules are another weak link—especially when surges or environmental wear take their toll.

Essential modules to keep around:

• 24V DC power supplies
• Allen-Bradley 1769 I/O
• Siemens S7-1200 digital and analog I/O

5. Communication Modules and Critical Cables

It’s easy to overlook the importance of a communication bridge—until it fails. Many drives require external modules or adapters to speak to your PLC or SCADA system.

Common spare items:

• 22-COMM-E (EtherNet/IP for PowerFlex)
• Profinet or Profibus connectors
• Serial and USB-to-RS232 cables

Pro Tip: Build a Spares Strategy Based on Your Top 10 Downtime Risks

Instead of trying to stock everything, analyze which components your line depends on most. Then rank them by downtime cost and replacement lead time. That becomes your high-priority list.

Why Customers Trust Industrial Automation Co.

• 30,000+ monthly site visitors and thousands of in-stock parts
• Fast same-day shipping and free technical support
• Expert help identifying the right spares for your application
• 2-year warranty on all parts we sell

🔗 Browse available parts or get in touch with our team today.