How to get started with condition-based maintenance

Condition-based maintenance means monitoring machinery and equipment in real time to get an indication of when service is due. It’s a form of preventive maintenance with proactive actions taken before problems occur. A typical example is tracking the temperature trend of an industrial pump so a bearing can be replaced before it seizes.

With sensors and smart condition-based maintenance systems, data is collected continuously to detect wear early. When measurements deviate from normal, the system triggers automatic alerts. This approach extends equipment life and reduces unnecessary spare parts handling.

Differs from preventive maintenance

Condition-based maintenance is more precise than preventive maintenance, because replacements are only made when measurement data shows a component is worn. Preventive maintenance relies on scheduled intervals where machine parts are replaced after a certain number of months or produced units, even if the component is still functioning flawlessly. For example, you might routinely replace a drive belt after 5,000 operating hours, but with condition-based maintenance it can stay in service until the vibration level indicates it is worn.

Both strategies have their place in modern industry, but companies that implement condition-based maintenance often see a notable reduction in unplanned downtime—saving time and resources over the long term.

Common measurement methods in industry

There are several established ways to monitor machine condition, which vary by equipment and industry. Some of the most common methods for collecting data are:

• Vibration measurement: Commonly used on rotating machinery to detect imbalance, gear wear, or worn bearings. This is standard practice in, for example, paper mills where hundreds of rollers run around the clock.

• Thermography: Thermal cameras detect overheating in electrical cabinets, transformers, or mechanical components before it causes a fire or short circuit.

• Oil analysis: Laboratory testing of the lubricant reveals whether there are metal particles from internal machine wear, a method commonly used on large industrial gearboxes.

• Ultrasound: Helps technicians locate hidden leaks in compressed air systems or detect friction in sealed systems.

When is condition-based maintenance appropriate?

Condition-based maintenance fits any industry where avoiding failures has high economic value, especially for business-critical equipment where a sudden stoppage incurs major costs through lost production. Examples include the main conveyor belt in a mine or a large compressor in the process industry.

Benefits

• Less downtime: You resolve issues calmly during planned maintenance shutdowns.

• Reduced material costs: Parts are only replaced when they are worn out, which reduces expenses for consumables and spare parts.

• Increased service life: When your machines avoid running with hidden faults such as minor imbalances or insufficient lubrication, they operate better and achieve a longer service life.

Implement a condition-based maintenance system

To fully leverage all collected data, you need a platform that can ingest and structure the information. A modern CMMS for condition-based maintenance consolidates all alarms and automatically generates a repair work order when a threshold is crossed.

Mainter helps you connect machine alarms with your technicians' daily work. The result is a seamless workflow from detected deviation to an ordered part and a completed work order.

Here’s how to get started – step by step

Reworking your operational routines requires structured, systematic planning. We recommend the following four steps to ensure a successful implementation:

• Start small: Select the machines that are most critical to your production and install sensors there first. For example, this could be the plant’s main pump or primary fan system.

• Get to know the equipment: Collect data during a test period to learn how the machines behave under normal operating conditions.

• Connect to the system: Then you can integrate the alarms with your CMMS to create automated workflows.

• Adjust and scale up: Evaluate the results and adjust the alarm thresholds before rolling out the technology across the rest of the facility.