Predictive and proactive maintenance are two powerful concepts that, until now, were considered to be more of a “nice to have” than a “need to have” for most plant managers. Some recent advancements have been seen in the condition-based maintenance solutions space, taking this necessary step as a protection of plant investments has become easier than ever.

Condition monitoring (CM) is actually a maintenance approach to predict machine health and safety through the combined data of machine sensors to measure vibration and other parameters (in real-time) with state-of-the-art machine monitoring software. This approach can enable plant maintenance technicians to remotely monitor the health of each individual piece of machinery and also offer a holistic, plant-wide view of mechanical operations. Condition monitoring software’s purpose is to send an alert whenever a change is detected in machine health and it also enables your maintenance technicians to immediately assess the situation and determine if corrective action is needed.

The proactive nature of condition monitoring is an innovative step forward on different levels for some manufacturers. If the plant personnel are safer, everyone is collectively safer. Second, plant managers have capacity to prevent unplanned downtime due to machine malfunction while simultaneously trying to make the most of planned maintenance downtime by servicing multiple machines and addressing all known issues at the same time. Further, condition monitoring also removes unnecessary—and wasted—costs associated with over maintaining healthy machines that are based on the static metric of operating hours alone.

Although condition monitoring is an industrial maintenance tool that is tried and true. It is only just starting to be leveraged proficiently in a wider array of manufacturing industries. Today’s condition monitoring systems are able to do much more for us—financially, operationally, and most importantly, from a safety perspective. Today’s condition monitoring solutions have high reliability and have been proven undoubtedly effective across multiple manufacturing industries.

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