What is Condition-based maintenance (CBM)? Importance and Examples
Condition-based maintenance (CBM) is a smarter way of managing assets that’s quickly gaining traction across industries. Businesses implementing condition-based maintenance have reported up to a 30% reduction in repair and breakdown costs.
The tangible benefits highlight the viability of condition-based maintenance (CBM). Essentially, CBM is a data-driven strategy that transforms how organizations manage their assets. It relies on real-time equipment condition and performance data rather than fixed maintenance schedules. Let’s cover more about this useful maintenance strategy.
What Is Condition-Based Maintenance?
Condition-based maintenance is a proactive approach in which maintenance activities are triggered based on the actual condition of the equipment instead of a predetermined schedule. It leverages various monitoring techniques to evaluate the overall condition of the equipment at a given point in time.
Visual inspections, sensors, monitoring devices, and scheduled tests and inspections continuously or at specific intervals gather data such as temperature, vibration, and oil quality to assess the health of critical assets. An alert is generated when this data deviates from established norms, prompting maintenance before a failure occurs.
Unlike traditional preventive maintenance, which operates on a set schedule, Condition-Based Maintenance (CBM) initiates repairs only when there is clear evidence of declining performance.
Concentrated towards the conditional aspect of the equipment, this proactive strategy reduces unnecessary maintenance tasks and tailors the maintenance approach to be more efficient and cost-effective. Essentially, CBM shifts the focus from reactive or corrective maintenance to proactive interventions guided by real-time insights.
This is how it compares with other maintenance strategies:
| Strategy | Basis | Pros | Cons |
|---|---|---|---|
Condition-based Maintenance (CBM) | Real-time condition |
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Reactive Maintenance | Fix after failure |
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Preventive Maintenance | Calendar schedules |
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Predictive Maintenance | AI forecasts |
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Reliability-Centered Maintenance (RCM) | Criticality and failure analysis |
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What are the important Parameters to Assess in Condition-based Maintenance?
Following are the important parameters that must be carefully looked at when conducting condition-based maintenance for reliable equipment performance:
- Vibration Levels
- Temperature
- Lubrication Condition
- Pressure
- Flow Rate
- Electrical Current
- Humidity and Moisture
- Noise Levels
- Wear and Tear Indicators
- Vibration Frequency
- Oil Quality and Contamination
- Structural Integrity
Monitoring vibrations helps detect issues such as imbalance, misalignment, or wear in machinery, preventing failures before they occur.
Abnormal temperature fluctuations can indicate overheating or inefficiencies in the system, signaling the need for maintenance.
Assessing the quality and quantity of lubrication prevents excessive friction and wear, extending the life of moving parts.
Pressure readings in systems like hydraulics or pneumatics can help identify blockages, leaks, or component failures.
Changes in flow rate can indicate pump issues, pipeline blockages, or other equipment inefficiencies.
Monitoring electrical current helps detect issues such as overloads, short circuits, or malfunctioning electrical components.
Excessive moisture can cause corrosion, electrical failures, and other damage, especially in sensitive equipment.
Unexpected or high noise levels can signal mechanical faults like worn bearings or misaligned parts.
Visual or sensor-based monitoring of wear can help identify when parts like belts, filters, or seals need replacement.
Specific vibration frequencies are linked to particular equipment issues, such as gearbox or motor faults.
Checking oil for contamination, viscosity, and acidity helps prevent engine or machine failures due to poor lubrication.
Monitoring for cracks, deformations, or other structural issues in equipment or facilities can prevent catastrophic failures.
How Condition-Based Maintenance Works
Condition-Based Maintenance (CBM) maintenance plan operates through a systematic three-step approach to monitor equipment health and address potential issues before they result in failure.
1. Data Collection
The process begins with the continuous condition monitoring of equipment through sensors installed on critical machinery. These sensors track essential parameters such as temperature, vibration, and oil quality.
For instance, a vibration sensor on a motor can detect rising abnormal vibration levels, signaling the early stages of bearing wear. This constant data flow ensures that the system can capture any deviations from normal operating conditions in real-time.
2. Data Analysis
Once the sensors collect data, it is transmitted to a Computerized Maintenance Management System (CMMS) or specialized maintenance software. The system cross-references the incoming data with predefined baseline values—known thresholds for “normal” operations.
Any variation from these baselines, such as higher vibration or fluctuating temperatures, triggers the system to identify potential issues, providing valuable insights into the current condition of the equipment.
3. Action Triggers
When the system detects an anomaly, it automatically generates alerts and work orders. These notifications are sent directly to the maintenance team, enabling them to take immediate action.
The targeted nature of these alerts allows the team to perform maintenance through precise repairs or replacements before any failure occurs, helping to extend the life of the equipment and avoid costly downtime.
Why is Condition Based Maintenance Important?
There are several compelling reasons why the condition-based maintenance strategy have become indispensable for modern maintenance needs:
Cost Efficiency
One of the foremost benefits of the CBM program is that it comes with actions that reduce maintenance costs. Traditional preventive maintenance often results in performing routine servicing irrespective of the actual wear on the equipment. This leads to expenditures on parts and labor that may not be necessary, which in turn drives up overall maintenance costs.
With CBM, maintenance is triggered by specific, measurable deviations from normal operating conditions. This targeted approach ensures that resources are used only when needed, cutting down on wasted labor and reducing the expenses associated with over-servicing. Additionally, by catching problems early, CBM minimizes the risk of extensive damage that would require maintenance, ultimately leading to a more predictable maintenance budget.
Increased Uptime
Unplanned downtime is one of the most significant drains on productivity in any industry. Equipment failures not only halt production but can also have a ripple effect on subsequent operations. CBM addresses this challenge through continuous condition-based monitoring of critical assets, allowing maintenance teams to detect early signs of deterioration.
When issues are identified well before they escalate into complete failures, maintenance can be scheduled during planned downtime rather than during peak operational periods. This proactive scheduling ensures that production lines remain in operation for the maximum possible time, directly boosting overall equipment uptime and, by extension, the company’s productivity and profitability.
Enhanced Safety
Safety is a non-negotiable priority in any industrial setting. Equipment that is allowed to degrade can pose serious hazards, not only risking costly repairs but also endangering maintenance personnel. CBM contributes significantly to a safer work environment by identifying potential issues before they lead to catastrophic failures. For instance, by monitoring parameters like temperature and vibration, CBM systems can alert the maintenance staff to conditions that may eventually compromise equipment integrity.
The early warning system minimizes the likelihood of sudden, dangerous malfunctions, ensuring that maintenance is performed while the equipment is still in a stable state. The overall effect is a reduction in safety incidents and a more secure working environment, which is essential for both regulatory compliance and employee well-being.
Better Resource Allocation
Traditional maintenance models often result in the inefficient use of resources, with maintenance teams forced to spend time and effort on tasks that might not be immediately necessary. In contrast, CBM allows organizations to focus their resources on assets that truly require attention.
By using precise data to identify when and where maintenance is needed, teams can better prioritize high-risk equipment and allocate spare parts and labor more effectively. This targeted deployment of resources not only improves maintenance efficiency but also ensures that critical operations receive the attention they need without unnecessary expenditure of time and funds on equipment that is still functioning properly.
Data-Driven Decision Making
One of the most transformative aspects of CBM is its reliance on real-time, data-driven insights. When sensors continuously feed data into a CMMS, managers gain a clear, objective picture of equipment health. The result, maintenance based on actual performance metrics rather than historical averages or assumptions helps achieve transparency thereby enabling informed decision making.
The integration of sensor data with CMMS also allows for automated work order generation, ensuring that maintenance tasks are executed promptly and with minimal human intervention. Over time, the accumulation of data enhances predictive accuracy, allowing for even more refined maintenance strategies. This systematic, data-driven approach leads to continuous improvement in maintenance processes and overall operational efficiency.
Examples of Condition-Based Maintenance in Practice
Condition-based maintenance is a commonly used maintenance practice and following are the use-cases that demonstrate how the maintenance strategy helps organizations.
- Vibration Monitoring on Pumps
- Load Balancing in Power Plants
- Temperature Monitoring on Electric Motors
- Oil Change in Engines
- Battery Replacement in UPS Systems
When a pump starts shaking more than usual, it’s usually a sign of trouble. Vibration sensors can pick up on this early, giving the maintenance team a heads-up before the pump completely gives out. No need to check every month—just when the machine’s telling you it’s time.
In a power plant, if a generator is operating under stress (overloaded), CBM can automatically redistribute the load across other generators to prevent overuse. Maintenance crews are alerted only when the load exceeds certain safety limits, triggering inspection or repair only when necessary.
If an electric motor in a factory starts to overheat, it can lead to a major failure. By using temperature sensors, the system keeps tabs on how hot the motor is running. If it crosses a set limit, maintenance is triggered, saving the company from an unexpected breakdown.
In the case of a fleet of vehicles or industrial engines, CBM can use oil condition sensors that not only monitor oil quality but also decide when it’s time for an oil change. Once the oil’s condition drops below a specified threshold, the system schedules an oil change. This prevents the engine from operating on degraded oil and prolongs its life.
Rather than relying on a calendar schedule for UPS battery replacements, CBM monitors battery performance and checks factors like charging cycles and voltage drops. When a battery is nearing the end of its usable life, maintenance teams are alerted, and a replacement is scheduled automatically, saving the company from unexpected power failures.
Get a Strategic Shift Towards Condition-Based Maintenance
For maintenance leaders and executives aiming to overcome traditional maintenance challenges, now is the time to adopt a more pragmatic approach to maintenance management.
Condition-based maintenance is the key to achieving this shift, and adopting a holistic maintenance management software is the first step to schedule maintenance using CBM.
By implementing a condition-based maintenance program with the help of FieldCircle’s maintenance software, organizations can transition to a more efficient, proactive maintenance strategy.
Assess your current maintenance strategy, consider a pilot project with a modern CMMS integration, and take the first step toward a smarter, more efficient future.