Everything you need to know about condition-based maintenance
March 21, 2025
Don’t you think our lives are a serious combination of conditions? If we crack the aptitude, we move on to the next round. If we score between 80-90, we get an A. Caught up in a clause of “ifs,” we end up making decisions for our own good! So, it’s a no-brainer to say conditions are decisions with “action” in between. A creaking machine and falling-apart cranks can desperately ask for an oil change in the loudest way, but waiting until it gets worse is the only way to get your hands dirty (pun intended). Are you still in the camp that believes nothing can supersede predictive maintenance? We’d love to share that it’s nothing less than winning the Super Bowl with condition-based maintenance, which has its own idealistic visual inspection and regularity. Are you curious to know more about condition-based maintenance and how to integrate it into your shop floor? Read along to know why condition-based maintenance is the future of facility care?
What is condition-based maintenance?
Condition-based maintenance (CBM) is like a health check-up for your shop floor machines, but smarter. Instead of fixing equipment only after it breaks or scheduling repairs on a strict timeline, CBM uses real-time data from sensors to monitor the "vital signs" of machinery, such as temperature, vibration, or noise levels. When the system spots unusual behaviour, it alerts you to take action before a breakdown occurs. This keeps production running smoothly, reduces downtime, and saves money—imagine your shop floor running like a well-tuned orchestra, with every instrument performing at its best! Choose condition-based maintenance for improved operational performance and advanced machine health monitoring. Read along to know how condition-based maintenance improves asset reliability.
How does condition-based maintenance work on a shop floor?
Name something more expensive than the skincare regimen of Tom Cruise: machine care, obviously! Let’s reinvent the wheels of the maintenance schedule to break down challenges and optimise targeted maintenance. Condition-based maintenance (CBM) on a shop floor works by using sensors and monitoring systems to track the health of machines in real-time. In addition, it lends a hand in productivity tracking. Here's how it operates:
By focusing maintenance efforts on actual needs rather than fixed schedules, CBM ensures shop floors run efficiently, minimising disruption, and maximising machine lifespan. Are you worried about the challenges in adopting condition-based maintenance systems? We have carefully curated a digital tool for condition-based maintenance with our lean expertise, technical mastery and industry 4.0 support. Read along to know more.
- Sensor deployment : Sensors are installed on critical equipment to measure parameters like vibration, temperature, pressure, and noise.
- Data collection : These sensors continuously gather data during the machine's operation.
- Analysis and trends : The collected data is sent to a centralised system or software that analyses it to detect patterns, deviations, or early signs of wear and tear.
- Alerts and actions : When the system identifies an anomaly, such as overheating or unusual vibration, it triggers an alert.
- Targeted maintenance : Maintenance teams can then intervene promptly, addressing issues before they cause downtime or damage.
By focusing maintenance efforts on actual needs rather than fixed schedules, CBM ensures shop floors run efficiently, minimising disruption, and maximising machine lifespan. Are you worried about the challenges in adopting condition-based maintenance systems? We have carefully curated a digital tool for condition-based maintenance with our lean expertise, technical mastery and industry 4.0 support. Read along to know more.
Do we need a digital tool for condition-based maintenance?
A digital tool is essential for effective condition-based maintenance (CBM) on the shop floor. While sensors and data collection are the foundation, the true magic lies in analysing that data to predict and prevent failures. Janus, a powerful shop floor data capture tool, takes CBM to the next level. By seamlessly integrating with sensors, Janus collects and organises real-time machine data, delivering actionable insights to your team with active downtime monitoring. With its intuitive dashboard, you can monitor equipment health, identify anomalies, and schedule targeted maintenance before costly breakdowns occur. Make your CBM strategy smarter and your shop floor operations smoother with Janus—because prevention is better than downtime. The impact of condition-based maintenance on cost efficiency is icredibly encouraging.
What challenges are solved by a condition-based maintenance program? How does Janus help?
“Maintenance” used to be just a cog in the machine for shift managers and operators until expenses started adding up. It literally became the engine of smooth operations in the industry 4.0 revolution. Business automation will never be possible if unplanned downtime, production bottlenecks, and delayed maintenance keep popping up. Explore the premimum features of our automated shop floor data collection system-Janus!
TCard Features Table
By combining condition-based maintenance strategies with the robust features of LTS Janus, shop floors can maximise productivity, reduce costs, and ensure uninterrupted operations.
| Shop Floor Challenges | How CBM Solves Them | Janus Features to Resolve Them |
|---|---|---|
| Unplanned Downtime | Detects equipment anomalies early to prevent breakdowns. | Real-time machine health monitoring and instant alerts. |
| Inefficient Maintenance Schedules | Enables targeted maintenance based on actual needs. | Data-driven maintenance insights and predictive analytics. |
| Production Bottlenecks | Keeps machines running smoothly, avoiding disruptions. | Continuous data capture and live status updates. |
| High Maintenance Costs | Minimises unnecessary repairs and parts replacement. | Condition-based tracking and actionable reports. |
| Limited Visibility into Machine Health | Provides real-time insights into equipment performance. | Centralised dashboard for comprehensive machine data overview. |
| Manual Data Tracking Errors | Automates data collection to reduce errors and delays. | Automated data capture with integration capabilities. |
| Delayed Response to Issues | Sends alerts for quick interventions before failures occur. | Customisable alert system for immediate notifications. |
| Difficulty in Trend Analysis | Analyses historical data to identify patterns and risks. | Advanced analytics and trend visualisation tools. |
By combining condition-based maintenance strategies with the robust features of LTS Janus, shop floors can maximise productivity, reduce costs, and ensure uninterrupted operations.
What are the benefits of condition-based maintenance in facility management?
- Reduced Downtime : CBM helps identify potential issues early, preventing unexpected breakdowns and ensuring smoother operations.
- Cost Savings : By targeting maintenance only when needed, CBM reduces unnecessary repairs and spare parts usage, lowering overall costs.
- Improved Equipment Lifespan : Addressing issues promptly prevents excessive wear and tear, extending the life of machinery.
- Enhanced Productivity : Minimised disruptions lead to more efficient production schedules and higher output.
- Better Resource Allocation : Maintenance teams focus on equipment that truly needs attention, optimising workforce efficiency.
- Increased Safety : Early detection of faults reduces the risk of accidents or hazardous failures on the shop floor.
- Real-Time Insights : Continuous monitoring provides actionable data, empowering better decision-making.
- Compliance and Reporting : CBM data helps meet regulatory requirements and creates a record for audits.
- Energy Efficiency : Well-maintained machines consume less energy, reducing operational costs and environmental impact.
- Customised Maintenance Plans : CBM allows tailored maintenance schedules based on actual equipment performance rather than fixed intervals.
Which one is better: Predictive maintenance vs. condition-based maintenance
| Aspect | Predictive Maintenance (PdM) | Condition-Based Maintenance (CBM) | Which is Better? |
|---|---|---|---|
| Definition | Uses advanced analytics and machine learning to predict failures before they occur. | Monitors equipment in real time to identify and address anomalies. | Depends on needs: PdM for long-term prediction, CBM for immediate action. |
| Technology | Requires high-end analytics, AI, and historical data. | Relies on real-time sensors and monitoring tools. | CBM is simpler; PdM offers deeper insights if resources allow. |
| Complexity | More complex to implement and maintain due to advanced algorithms. | Easier to implement, focusing on current equipment conditions. | CBM is easier to adopt for most industries. |
| Cost | Higher initial investment in analytics tools and expertise. | Lower cost, focused on essential sensors and dashboards. | CBM is more cost-effective; PdM justifies cost for larger systems. |
| Data Dependency | Needs historical and real-time data for accurate predictions. | Only requires real-time data from sensors. | CBM is less data-intensive. |
| Response Time | Proactive—provides early warning well in advance of failure. | Reactive—alerts only when an issue starts to develop. | PdM gives more lead time; CBM works well for immediate issues. |
| Scalability | Suitable for large-scale systems with significant resources. | Scalable for small to medium operations. | PdM for large operations, CBM for smaller setups. |
| Better Option? | Best for systems where downtime is extremely costly and predictive accuracy is critical. | Ideal for operations needing straightforward, real-time monitoring. | Combination: Use PdM for critical systems and CBM for general maintenance. |
CBM is simpler, cost-effective, and suits immediate needs, while PdM offers long-term benefits and deeper insights but requires more investment and resources. A hybrid approach often provides the best outcomes.
Checklist for choosing the right condition-based maintenance software for your shop floor
Want your shop floor to witness smooth operations like a well-oiled machine? See for yourself how Janus can be your lean, mean machine working against all the odds that can derail your work order management, production schedule and maintenance operations?
1. Real-Time Monitoring Capability
✅ Ensure the software captures real-time data from sensors to monitor equipment health continuously.
✅ Look for software that offers instant alerts for anomalies and customisable notification settings.
✅ The software should offer an intuitive and user-friendly dashboard for visualising machine data.
✅ Check if the software includes predictive tools for analysing trends and preventing future failures.
✅ Choose software that can scale with your shop floor as your operations expand.
✅ The software should integrate effortlessly with current shop floor sensors and machinery.
✅ Ensure the software provides value for its price with minimal implementation and operational costs.
✅ Opt for software that is easy to use and requires minimal training for shop floor staff.
✅ Check if the software provider offers excellent customer support and training for your team.
✅ Ensure the software meets data protection standards and regulatory compliance for your industry.
1. Real-Time Monitoring Capability
✅ Ensure the software captures real-time data from sensors to monitor equipment health continuously.
- How Janus Helps: Janus integrates seamlessly with shop floor sensors to provide real-time data on machine performance.
✅ Look for software that offers instant alerts for anomalies and customisable notification settings.
- How Janus Helps: Janus enables users to set tailored alerts, ensuring quick responses to potential issues.
✅ The software should offer an intuitive and user-friendly dashboard for visualising machine data.
- How Janus Helps: Janus provides a centralised dashboard with easy-to-understand graphs and analytics for better decision-making.
✅ Check if the software includes predictive tools for analysing trends and preventing future failures.
- How Janus Helps: Janus uses advanced analytics to detect patterns and recommend proactive actions.
✅ Choose software that can scale with your shop floor as your operations expand.
- How Janus Helps: Janus is designed to adapt to the growing needs of small, medium, and large-scale shop floors.
✅ The software should integrate effortlessly with current shop floor sensors and machinery.
- How Janus Helps: Janus supports seamless integration with a wide range of sensors and devices.
✅ Ensure the software provides value for its price with minimal implementation and operational costs.
- How Janus Helps: Janus offers a cost-effective solution with comprehensive features, ensuring a strong return on investment.
✅ Opt for software that is easy to use and requires minimal training for shop floor staff.
- How Janus Helps: Janus features an intuitive interface that makes it accessible for users of all skill levels.
✅ Check if the software provider offers excellent customer support and training for your team.
- How Janus Helps: Janus includes dedicated support services and detailed training resources to ensure smooth implementation.
✅ Ensure the software meets data protection standards and regulatory compliance for your industry.
- How Janus Helps: Janus prioritises data security with robust protection protocols and compliance with industry regulations.
Step-by-step guide on how to implement condition-based maintenance in your business
Step up your game of maintenance management for advanced performance monitoring. Follow the step-by-step guide for best practices for condition-based maintenance in industries.
Step 1: Identify Critical Equipment and Install Sensors
Step 1: Identify Critical Equipment and Install Sensors
- Action : Start by identifying key machines and equipment that are critical to your operations. These are the machines you’ll want to monitor closely.
- How Janus Helps : Janus supports a wide range of sensors that can be installed on critical equipment to monitor vital parameters such as temperature, vibration, and pressure in real time.
- Action : Integrate sensors with your software system to begin collecting data on equipment performance. This will provide insights into their operational health.
- How Janus Helps : Janus offers seamless integration with existing shop floor sensors and systems, ensuring smooth data collection from multiple sources into one centralised platform.
- Action : Determine the thresholds for key parameters (e.g., temperature, vibration) that indicate when maintenance is needed. Set up automated alerts to notify your team when these thresholds are breached.
- How Janus Helps : Janus allows you to configure customised alerts for each piece of equipment, so your team can be immediately notified when critical parameters exceed predefined limits.
- Action : Continuously monitor the performance of equipment in real time to track any fluctuations or anomalies.
- How Janus Helps : Janus provides a real-time dashboard that lets you monitor machine health, track data trends, and see live updates from all connected sensors, ensuring you’re always informed of equipment status.
- Action : Regularly review the historical performance data to identify patterns and trends that could help predict potential failures before they happen.
- How Janus Helps : Janus stores historical data and uses advanced analytics to help identify trends and predict potential failures, enabling proactive maintenance decisions based on past performance.
- Action : Based on the data insights, perform maintenance tasks only on equipment that needs attention, avoiding unnecessary checks or repairs.
- How Janus Helps : With Janus, you’ll receive detailed reports on equipment health, so maintenance is only performed when needed, saving time and resources.
- Action : Continuously assess the effectiveness of your CBM program. Adjust your thresholds, alerts, or maintenance strategies based on new insights or issues that arise.
- How Janus Helps : Janus makes it easy to adjust settings and refine your maintenance program. You can monitor the success of your strategies through detailed performance metrics and make adjustments as necessary.
- Action : Educate your shop floor team on the new CBM system and encourage a culture of proactive maintenance and continuous improvement.
- How Janus Helps : Janus offers user-friendly interfaces and training resources, making it easy for your team to get up to speed and use the system effectively. Its simplicity ensures that everyone from operators to maintenance staff can adopt the system without confusion.
- Action : Ensure your maintenance activities comply with relevant regulations and industry standards. Generate reports to track maintenance actions and equipment status for audits.
- How Janus Helps : Janus helps you generate detailed, automated reports, ensuring compliance with industry standards and providing a clear audit trail for all maintenance activities.
- Action : Periodically review the performance of your CBM program, measuring the reductions in downtime, cost savings, and improved equipment lifespan. Use this data to refine your maintenance approach.
- How Janus Helps : Janus provides comprehensive performance reports and analytics that let you assess the effectiveness of your CBM program, helping you make informed adjustments to continuously improve your maintenance processes.
Maximise your shop floor efficiency with Condition-Based Maintenance – Try Janus today!
Condition-based Maintenance (CBM) is the key to proactive, cost-efficient machine care, enabling you to monitor equipment health in real-time and prevent unexpected breakdowns. By tracking critical parameters like temperature, vibration, and pressure, CBM ensures you only perform maintenance when truly needed, saving both time and money. With Janus, you can take your CBM to the next level—its seamless integration with sensors, real-time data tracking, and customised alerts empower you to act swiftly, optimise performance, and extend the lifespan of your machines. Don’t wait for a failure to happen; unlock the power of CBM with Janus and keep your shop floor running smoothly!
FAQs
1. What is condition-based maintenance (CBM)?
Condition-based maintenance is a proactive maintenance strategy that involves monitoring the condition of equipment to determine when maintenance should be performed, reducing unnecessary maintenance and downtime.
2. How does condition-based maintenance work?
CBM uses sensors and monitoring tools to track key performance indicators such as temperature, vibration, and pressure to assess equipment health and schedule maintenance only when needed.
3. What are the benefits of condition-based maintenance?
CBM helps reduce maintenance costs, improve equipment lifespan, minimize downtime, and increase operational efficiency by addressing issues before they lead to failures.
4. How do you implement condition-based maintenance?
To implement CBM, you need to install condition-monitoring systems, set up regular assessments, train your team, and establish thresholds for maintenance actions based on data insights.
5. What is the difference between CBM and preventive maintenance?
Unlike preventive maintenance, which involves performing maintenance at scheduled intervals, CBM is based on the actual condition of the equipment, leading to more targeted and cost-effective maintenance actions.
Condition-based maintenance is a proactive maintenance strategy that involves monitoring the condition of equipment to determine when maintenance should be performed, reducing unnecessary maintenance and downtime.
2. How does condition-based maintenance work?
CBM uses sensors and monitoring tools to track key performance indicators such as temperature, vibration, and pressure to assess equipment health and schedule maintenance only when needed.
3. What are the benefits of condition-based maintenance?
CBM helps reduce maintenance costs, improve equipment lifespan, minimize downtime, and increase operational efficiency by addressing issues before they lead to failures.
4. How do you implement condition-based maintenance?
To implement CBM, you need to install condition-monitoring systems, set up regular assessments, train your team, and establish thresholds for maintenance actions based on data insights.
5. What is the difference between CBM and preventive maintenance?
Unlike preventive maintenance, which involves performing maintenance at scheduled intervals, CBM is based on the actual condition of the equipment, leading to more targeted and cost-effective maintenance actions.
