How Condition Monitoring is driving Maintenance



As data and machine learning propelled computer, human, and things networking, we have experienced the fourth industrial revolution. A definition of "Industry 4.0" that is more precise describes the intelligent networking of people, devices, and systems across the entire value chain by leveraging all digital technology.


Industry 4.0 impacts motor systems by moving from the "automation pyramid" to "networked systems.". By this, we mean that the system's different components, such as motors, drives, and sensors, are linked and connected to a cloud that is a data centre where data can be stored, processed, and analyzed for better decision making in real-time.


Machines are prone to failure. Monitoring their condition can help engineers predict when this will occur.

One of two factors determines maintenance: a strict schedule or a failure of equipment. Maintenance is often performed too early (i.e., preventive, scheduled replacement of a component, even if it is still in good operating condition) or too late under these schemes (e.g., a failure of equipment).


Each of these methods generates waste:

  1. The consumption of resources and parts is strictly preventive, without regard to need.

  2. A purely reactive approach necessitates costly downtime and significant maintenance.


Monitoring equipment condition based on its performance state with the aim of locating and solving potential faults before they cause equipment shutdown, is the solution to minimize these unnecessary efforts.


What is Condition Monitoring?


The causes of machine failure are varied, and each failure is different. If machinery stops working in the manner it was intended to, it fails or no longer serves its purpose. This loss of utility can be categorized into three categories:


Surface Deterioration, Ageing, and Mishaps


The vast majority of machines lose their functionality as a result of surface degradation of machine parts, which primarily includes mechanical wear and corrosion.


Equipment failures cause unplanned halts in production with significant implications for organizational productivity, repair costs, revenue, profitability, and ultimately, competitiveness. As a result, organizations are constantly searching for ways to avoid failures and keep maintenance costs as low as possible.


This is where Condition Monitoring as a foundation for predictive maintenance comes into play.


Proper Condition Monitoring helps companies to:


  • Drop repair costs

  • Reduce maintenance costs

  • Increase plant life

  • Increase personnel safety

  • Increase revenue

  • Increase profitability


Condition Monitoring Definition


Maintenance techniques that assess an asset's current condition to determine whether repairs are necessary are known as condition-based maintenance (CBM).


In contrast to preventive maintenance, which uses methods like calendar-based maintenance to determine when to schedule and perform maintenance, condition-based maintenance only mandates the performance of maintenance when real-time indicators reveal irregularities or signs of declining performance.


It is recommended that maintenance be done only when specific indicators indicate deterioration or imminent failure. The following methods can be used to test a machine for such indicators: non-invasive measures, visual examination, performance data, and planned testing.


When a machine has internal sensors, data about its condition can be collected either at predetermined intervals or continuously. Condition-based maintenance can be applied to both mission-critical and non-mission-critical assets.


What is the Condition Monitoring Goals?


The basic purpose of condition-based maintenance is to help you get the most out of your maintenance resources by executing work only when it's needed, not before. In condition-based maintenance, asset indicators of approaching failure are continuously monitored to ensure that maintenance is planned ahead of time before the failure occurs. This is one of the differences between predictive and preventive maintenance.


Real-time monitoring allows maintenance teams to react before a failure or performance decline occurs.

For condition-based maintenance to be successful, several other factors must be in place. You can do this by employing planned maintenance, which will allow you to inspect and detect irregularities in equipment as well as flagging the need for follow-up repairs. A critical requirement when performance problems are detected and work is initiated is to have the correct parts and materials on hand.


Types of Condition Monitoring


In order for preventative maintenance to be undertaken, workers must know the status of the machine at all times. This is easily accomplished through condition monitoring.

Performing predictive maintenance relies heavily on condition monitoring.

However, in order to conduct such monitoring, measurements must be taken at regular intervals. Measurements of this type are called "condition measurements," and they are crucial for measuring the state of the asset(s) under monitoring.

Gathering and analyzing this information will produce results that will allow a proper diagnosis of the equipment's condition. This allows the equipment's maintenance team to schedule the necessary maintenance to prevent failures and ensure the equipment's continued availability.


These are the different types of conditions that are monitored on every machine



What are the advantages of Condition Monitoring for Manufacturers?


Conditions-based monitoring has been revolutionized by the Internet of Things. With sensors installed on assets, temperatures can be monitored and vibration and oil analyses can be continuously performed. This significantly reduces the need for manual inspections and testing.


In order to detect signs of asset deterioration or imminent collapse, sensors will continuously monitor the condition of the asset. Sensors will use IIoT solutions to alert maintenance teams of indicator changes on their assets. Maintenance teams can respond quickly to the issue and make repairs as soon as possible.


Condition Monitoring Value
Condition Monitoring Value- source google

Manufacturers can benefit in multiple ways from implementing a condition monitoring plan:


Detecting potential equipment issues before they become production problems. Condition monitoring maintenance can assist detect potential equipment issues before they become a problem. Preventive maintenance can be reduced or eliminated, allowing equipment to be optimised and operated for longer periods of time.


By intelligently and successfully arranging planned downtime, the adoption of a condition monitoring maintenance plan will maximise production efficiency.


The application of technology to detect the root causes of actual equipment issues results in more productive and efficient maintenance. In this method, unlike preventative maintenance, maintenance occurs only when it is required. This allows for a more efficient allocation of maintenance resources.


Increased awareness of asset health and performance. Condition monitoring can detect anomalies and alert users by comparing benchmarks and historical data to real-time performance data. You obtain additional knowledge of how to improve equipment performance by collecting and evaluating more data.


Data provides more effective and efficient inventory processes, including MRO purchasing and management, in addition to enhanced accuracy in MRO.


Challenges associated with Condition-based Maintenance


The initial implementation costs of condition-based maintenance can be high due to the investment in measuring equipment sensors and staff training.


The CBM approach introduces new maintenance techniques that can be challenging to implement due to resistance within an organization.


Depending on the age of the equipment, sensors and monitoring equipment may not be easy to retrofit, or access to spot measures may not be easy during production.


When CBM is in place, the performance data collected by a system still must be turned into proactive maintenance items that can be implemented.

Let’s Wrap up


Your company's suitability for condition-based maintenance must be weighed on a case-by-case basis. Utilizing condition-based maintenance, preventative and corrective maintenance can be scheduled at the most appropriate times, lowering the overall cost of ownership.


The monitoring of conditions has become more common in the industry as a way to maintain asset safety and improve efficiency. The ability to plan and direct maintenance activities, as well as the elimination of unnecessary procedures, can save time and money as well as guarantee production goals are met.


It can be a very beneficial tool once implemented correctly and run by a well-trained staff. Examples include:

Improved reliability of the system,

Enhanced productivity,

The cost of maintenance is lower,

There is a reduction in downtime,

Diagnosis of problems more quickly, and

The number of maintenance intervals is reduced.


A proactive approach to maintenance is the only way to ensure the company stays competitive in every manufacturing setting.


Please connect with us, as we offer customized solutions for your maintenance needs. Get a free consultation. You can follow our LinkedIn page and our hashtag - #dxsolutionadvisor, on LinkedIn.


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