Understanding the possible consequences of any potential malfunction (whether by human error or due to extreme weather conditions) is key to creating an effective condition monitoring plan. That being said, it is important to establish the condition of each of your tools, service parts, and machines by analyzing their historical performance. Then, as part of your preventive maintenance strategy, ensure that the right levels of preventative maintenance are put in place to reduce the likelihood of incidents. And one of the most effective ways is through condition monitoring.

Condition monitoring is a key element of predictive maintenance (PM) that deals with detecting any unusual or unplanned breakdowns of machinery/equipment and evaluating the repair or replacement cost. Some of the main benefits of condition monitoring include:

• Better system-related reliability
• Better efficiency
• The decreased total cost of operation
• Reduced maintenance cost
• Prevention of unplanned maintenance
• Preventive maintenance increases total cost savings
• Improving the uptime/fault-free operation

What is Condition Monitoring? 

Condition monitoring is a process that follows an entire system to detect potential issues before they develop further complications. It looks at every system in operation to check whether it is operating correctly and if there is anything to be fixed or upgraded.

What Are the Benefits of Condition Monitoring for the Business?

As faults inevitably develop in machinery, even routine maintenance programs cannot effectively stop these failures. This is where condition monitoring helps you take the driving seat and prevent breakdowns. Moreover, it is a non-intrusive process that can help businesses save money in unnecessary maintenance, secondary damages, and lost productivity. Hence, making condition monitoring an integral part of routine maintenance programs can enhance machine functionality and promote long-term productivity.

There are several key benefits to condition monitoring for a business, including

• Automated workflow
• Faster responses
• Future-proofed infrastructure
• Lower operational costs
• Improved safety standards
• Greater profitability
• Immediate response to alarms

Condition monitoring allows for faster repairs and, by analyzing variables, helps ensure better reliability and maintenance. For example, knowing if a machine is malfunctioning, the system may be restored with fewer visits and lower costs. The ability to predict failures is important because it improves life-cycle management and optimizes resources. For example, a motor might be a ticking time bomb with corrosion and an ill-equipped electrical system. Condition monitoring could also detect symptoms that could indicate a component is failing.

The Basics of Condition Monitoring

Condition monitoring is the systematic collection and analysis of data related to a machine’s performance. It is the process of identifying, maintaining, and classifying the effectiveness of machine functionality by quantifying system anomalies with minimal intervention. These anomalies are often due to a range of factors, from malfunctioning electrical circuits to incorrect operation of machine tools.

Conclusion

Whether you are looking to reduce costs and provide greater visibility into asset efficiency, control downtime by improving instrument and system performance, or improve asset availability for your business, condition monitoring can help you make the right decisions, which will allow you to make more effective informed business decisions.

You can consider condition monitoring systems designed for swift installation and integration into your existing monitoring system. Let us know if you have any queries related to condition monitoring.