Industrial reliability: why it is not just about robustness
In the industrial sector, the terms robustness and reliability are often used interchangeably. However, when it comes to electric motors and industrial pumps designed for continuous operation, these two concepts describe very different aspects. Understanding this distinction is essential for engineers, maintenance managers and decision-makers responsible for long-term industrial investments. Robustness refers to the structural strength of a component: materials, thicknesses and the ability to withstand mechanical stress. Reliability, on the other hand, is a broader and more complex concept. It describes the ability of a machine to deliver consistent performance over time, under real operating conditions, while minimizing downtime, inefficiencies and unexpected costs. Robustness and reliability: a necessary distinction A robust product may be designed to withstand high loads, shocks or harsh environmental conditions. However, this alone does not guarantee stable and durable operation over time. Industrial reliability is the result of a balance between several factors: correct sizing quality of internal components thermal dissipation precision of mechanical couplings tolerance management consistency between design and real application In electric motors and pumps, an excessive focus on robustness can even be counterproductive, leading to oversizing. This often results in higher energy consumption, increased mechanical stress and premature wear. Designing with the real life cycle in mind A reliability-oriented approach starts with a key question: under which conditions will the product actually operate? Industrial systems rarely work under ideal conditions. Frequent starts, variable loads, intermittent cycles, dusty or humid environments are the rule rather than the exception. Designing electric motors and pumps with the real life cycle in mind means considering from the very beginning: expected number of starts load variations required service continuity environmental conditions maintenance accessibility and scheduling A reliable product is therefore not defined at installation stage, but much earlier. It is the result of informed design choices aimed at long-term performance, not just initial efficiency. Thermal management and tolerances: critical factors One of the most critical aspects affecting the reliability of electric motors and pumps is thermal management. Poor control of operating temperatures directly impacts the lifespan of windings, bearings and mechanical components. At the same time, manufacturing precision and tolerances play a decisive role. Improper couplings can cause vibrations, noise, efficiency losses and accelerated wear, compromising the overall reliability of the system. For this reason, reliability is never the result of a single feature, but of a comprehensive approach that integrates mechanical, electrical and thermal design. Application experience and customer dialogue Another key element is application experience. Each industrial sector has its own specific requirements, and there is no one-size-fits-all solution. Continuous dialogue with designers, maintenance teams and end users allows manufacturers to refine solutions, anticipate recurring issues and develop products that truly match operational conditions. This is the approach adopted by Sacemi Gamar, where reliability is considered a core design criterion rather than a marketing claim. Reliability as a strategic investment Choosing reliable components is not only about reducing the risk of failures. It is about optimizing the total cost of ownership (TCO), improving operational continuity and making maintenance more predictable. In the medium to long term, a reliability-driven approach helps to: reduce unplanned downtime limit extraordinary maintenance costs extend equipment service life improve overall system efficiency Industrial reliability is not a nameplate value, nor a feature achieved simply by increasing product robustness. It is the result of a conscious design process that considers real operating conditions, life cycle performance and the interaction between all system components. In an industrial landscape increasingly focused on efficiency and continuity, designing for reliability means creating tangible, long-term value for those who rely every day on electric motors and industrial pumps.
