The Most Common Questions We Get About IBEs

When customers first hear about Installed Base Evaluations, the reaction is almost always the same: curiosity mixed with a little skepticism. Do I really need this? Is it worth the time and cost? Won’t this slow down production?

These are fair questions. In fact, they’re the right questions. Because if you’re going to invite someone into your facility to open up panels, catalog hundreds (sometimes thousands) of part numbers, and analyze the state of your inventory and equipment, there should be a good reason for it. And there is.

Over the years, we’ve done countless IBEs for manufacturers across Connecticut and New England. Every site is different, but the questions we get tend to sound pretty familiar. So let’s walk through the most common ones we hear and offer some straight answers, based on what we’ve actually seen.

Do I need to shut down production for an IBE?

Short answer: absolutely not. An IBE is designed to work alongside your normal operations. We don’t walk in and start removing covers or touching live equipment. Everything we do is visual. A member of your facility’s team handles any panel access; we’re simply there to observe, record, and report.

From a safety and disruption standpoint, it’s a non-intrusive process. If anything, it gives you a rare opportunity to take a guided look at what’s happening behind the doors of your electrical enclosures.

You’d be surprised how many critical systems are running with outdated components, improper wiring, or no safety labeling at all. And you’d be even more surprised how many of those issues go unnoticed until it’s too late.

What counts as a “panel,” anyway?

That’s a very important question, not just because it affects pricing but because it highlights just how varied industrial setups can be.

When we talk about panels in the IBE context, we’re referring to the back panel inside an enclosure. That’s where your components are mounted. It’s not about the number of doors or boxes, it’s about how many unique assemblies we’re opening and evaluating.

And here’s where it gets nuanced. Not every panel is created equal. Some are sparse, some are jam-packed. That’s why we look at total panel count and density to scope the project accurately. A facility with 10 densely packed panels might take longer to evaluate than one with 20 half-filled ones. And that affects everything from the timeline to the quote.

This is also why we spend time with you up front to define scope, expectations, and outcomes. A well-defined panel count helps us give you a fair price and ensures we show up with the right team and tools to get it done quickly and accurately.

How long does it take?

There’s no one-size-fits-all answer here, and that’s kind of the point. An IBE’s duration depends on three key things: how many panels you have, what scope level you choose, and the size of your storeroom.

We’ve completed some in under half a day. Others have stretched into full workweeks. Most, though, fall in the 1–2 day range. That’s enough time to get a complete picture without dragging down your production schedule.

Scope levels matter here. Suppose you’re evaluating just Rockwell repairables (drives, PLCs, HMIs), which takes less time. However, if you add third-party equipment, consumables, and everything in between, the workload increases. Level 1 is fast and focused. Level 4 is a deep dive. Most facilities land somewhere in the middle.

Either way, our goal stays the same: in and out quickly, without cutting corners. We respect your time, and we know how to get this done efficiently.

Is this just for Rockwell components?

It’s a fair question, especially considering that an IBE is a service sold by Rockwell. However, the reality is that we evaluate everything.

We’ve seen Siemens, ABB, Omron, Schneider, and third-party panels built 20 years ago that still run like clockwork; we document it all. The scope level you choose determines how deep we go. Some levels focus only on Rockwell repairable equipment. Others include third-party, consumables, and more.

The flexibility here is by design. We know no two facilities are built the same. And we don’t believe in forcing you into a box. Want us to catalog everything down to the relays and breakers? Great. Prefer to focus only on the PLCs and drives that keep your line running? That’s fine, too. The point is: we meet you where you are.

What do I actually get out of this?

The deliverables from an IBE are what turn a list of part numbers into something actionable. Once we’re done cataloging, we compile the data into a detailed report. You’ll see every component broken down by location, machine, and asset. Each part gets tagged with its lifecycle status: active, mature, discontinued, or obsolete.

Then we overlay that with what you’ve got in your storeroom. That’s when the picture starts to come into focus.

You might discover you’ve got 50 obsolete parts installed in your most critical processes and zero replacements in inventory. Or maybe you’re sitting on $100,000 worth of spare parts that don’t support any equipment you currently operate. We’ve seen both. And we’ve seen what happens when that knowledge leads to smarter decisions.

This isn’t a static report. It’s a blueprint. A roadmap. And we don’t just hand it to you and disappear. After the IBE, we’ll sit down with you and walk through the findings. We’ll highlight risk areas, suggest replacement strategies, and help you prioritize what matters most, because not everything needs to be fixed at once.

What if I already have a list of parts?

That’s great, but is it accurate?

We’ve walked into facilities with beautifully maintained spreadsheets that were three revisions behind. We’ve seen ERP systems show dozens of parts in stock that were actually installed years ago. We’ve also seen the opposite: racks full of spares that nobody knew were there.

The IBE reconciles paper with reality. It gives you a line-by-line match of what’s actually on your floor, in your panels, and on your shelves. That’s the foundation for any solid inventory strategy. And when you're ready to modernize or standardize, it gives you the clarity to make smart, confident decisions.

Is it worth the cost?

That depends. What does an hour of downtime cost you? What about a day?

We’ve seen unplanned failures bring entire lines to a halt for lack of a single part. In some cases, the value of that lost time dwarfs the cost of the evaluation itself.

On average, a first-level IBE ranges from $5,000 to $15,000, depending on the scope of the procedure (like the number of panels). That might sound like a lot until you compare it to what it costs to scramble for a replacement after a failure, or to buy a discontinued drive off the secondary market at double the price.

The IBE helps you plan. It helps you prepare. And if it helps you prevent even one unplanned outage, it’s already paid for itself.

The Bottom Line

Whether you found this article while researching IBEs or received it as part of a conversation with our team, you're probably asking the same core question: is this worth it?

We hope the answer is clearer now. An Installed Base Evaluation is a strategic tool that gives you the visibility to reduce risk, prevent downtime, and make smarter upgrade decisions. It’s about knowing exactly where you stand and what to do next.

If you're still early in the process, consider this your starting point. If you’re already in touch with us, think of it as a deeper dive into what’s ahead. Wherever you are in your journey, we're here to help you take the next step, on your terms, at your pace.

Contact us today if an IBE is something your facility can’t wait for. We’ll be happy to answer any and all questions you have, not just the ones included here.