Key points
This article takes a deep dive into the key elements that define Condition Monitoring (CM) what makes for an effective strategy and deciphers the difference between its well-known counterpart, predictive maintenance (PdM) and other maintenance methodologies.
What is condition monitoring?
Condition Monitoring is the term used to describe the monitoring of machine performance.
In its prematurity, condition monitoring was a method carried out by engineers who simply listened to a machine to determine if it was running correctly. It was only up until 10 years ago, that traditional methods were still used, required businesses to front significant costs and effort only to see value later down the line ruling out rapid return on investment. Developments over the years, particularly in the defence and aerospace industries have allowed more advanced versions of condition monitoring to come to fruition.
Modern condition monitoring methodology utilises current technological advancements by using sensors and intelligent analysis to accumulate key data from machines and assets, this permits information to be analysed by asset managers and transformed into actionable insights.
The accrued data allows asset managers to determine if machinery is on the brink of failure, providing them with foresight to execute any necessary maintenance ahead of the indicated breakdowns. This prevents unplanned downtime and helps systems run and optimal efficiency whilst extending asset life.
Condition monitoring acts as a technology enabler for other maintenance methodologies such as predictive maintenance
Condition Monitoring is a technology enabler, not a maintenance methodology
Condition monitoring acts as a technology enabler for other maintenance methodologies such as predictive maintenance. Each organisation will establish their own mix of methodologies when beginning a maintenance project, however it essential that they understand what mix is required to optimise their operations before beginning any kind of deployment. These mixes include a range of methods which span from corrective maintenance, condition-based maintenance to preventative maintenance.
How does condition monitoring differ from predictive maintenance?
Condition Monitoring and Predictive maintenance both act as proactive maintenance strategies, designed to increase reliability and reduce overall downtime. The key factors that differentiate them is the way the maintenance is measured.
PdM uses formulas in addition to measurements derived from sensors, e.g. vibration, noise and temperature, meaning that any work is carried out based on these key variables. Condition monitoring relies on real-time sensor measurements. This means that if a variable hits an unacceptable limit, maintenance work arranged.
Effective condition monitoring
To implement a successful condition monitoring strategy, it is essential that businesses map out what they want to achieve and how viable these aspirations are. This is the first key step to monitoring assets correctly with suitable sensors.
- Set Goals
Looking to achieve regulatory compliance, improve machine efficiency or cost reduction? It is essential that organisations set these goals according to their and sector and align with any unique requirements.
Once a plan is confirmed, the next step is to verify its validity. - Decide key metrics
To establish validity and achieve ROI from condition monitoring, key metrics must be established.
Key metric(s) can be singular or a combination of:
• Wastage reduction
• Reduction of spare parts in inventory
• Reduction of planned maintenance
• Extend asset lifetime
• Maintain uptime
• Maintain quality - Culture review
Assessing the cultural readiness of the organisation to implement maintain and optimise condition monitoring is a key step. They will need to be ready for change.
Before embarking on a CM journey, it is important to consider these factors:
• Organisations current level of knowledge and understanding of condition monitoring
• Commitment needed from senior management for operations and training
• Appetite and current attitude to change - Determine costs
Ensure that the overall cost of implementation and ongoing monitoring is less than the expected gains e.g. enhanced machine productivity, cultural benefits. This can be achieved by conducting a cost benefit analysis.
To do this, take the overall cost of CM implementation and ongoing monitoring such as:
• Technology
• Training
• Upskilling
• Processes
• Data analysis
Then determine the potential savings and expected gains such as:
• Downtime avoided
• Extending life span of assets
• Improved production quality
Organisations can then conduct an in-depth financial analysis to enable well informed decision making and begin their implementation journey with confidence.
- Measurement
Finally, decide what asset to measure and keep it simple. It is often advised to start with an asset that has known issues. This way businesses can establish ‘easy’ methods to collect the data that you can scale and build on.
To implement a successful condition monitoring strategy, it is essential that businesses map out what they want to achieve and how viable these aspirations are
Beginning with a pilot will make measuring simpler and provide a clear ROI. However, organisations should aspire to scale and measure all assets within time.
The methodology of condition monitoring plays an imperative role in optimising maintenance strategies through leveraging modern technology to collect real time insights. Organisations can only benefit from this approach and should seek to embrace it into their operations to maximise their efficiency and boost cost savings.
