Condition Monitoring

What is condition monitoring?

In manufacturing and other industrial settings, condition monitoring, also known as condition-based monitoring, is the process of tracking machine performance in real time to understand the asset’s current state.

This is typically achieved through wired or wireless sensors that collect critical machine data and transmit it to a software platform for analysis. The resulting insights can be used reactively (e.g., triggering alerts when a failure is imminent) or proactively (e.g., informing a machine health optimization strategy to prevent future issues).

Rugged and reliable SMARTdiagnostics yellow base station for machine health data.

Route-based condition monitoring

Route-based condition monitoring involves manually collecting data from plant assets on a scheduled basis. This can range from using handheld devices to read condition monitoring tools, to simply recording gauge measurements with pen and paper. The collected data helps maintenance teams identify which assets require immediate attention and which are operating within acceptable limits.

While route-based monitoring was the industry standard for decades, continuous condition monitoring offers significant advantages in terms of accuracy, timeliness, and scalability.

Continuous condition monitoring

Continuous condition monitoring refers to systems that automatically collect and transmit data from devices on assets in real time. Unlike route-based monitoring, which captures data at discrete intervals, wireless condition monitoring systems provide a constant stream of information, reducing the chance of missing critical changes in machine performance.

This approach not only delivers a more complete picture of asset health, but also enables remote access to data, eliminating the need for technicians to be physically present to gather readings.

SMARTDiagnositics vibration sensor placed on motor body to do condition monitoring.

Condition monitoring vs. predictive maintenance

The terms condition monitoring and predictive maintenance are often used interchangeably, but they refer to different concepts. Condition monitoring is one component of a predictive maintenance strategy.

Condition monitoring tells you what’s happening with your equipment right now, identifying signs of current wear, stress, or malfunction. Predictive maintenance takes it a step further by analyzing condition monitoring data over time to forecast future failures, allowing you to take proactive steps before issues lead to costly downtime.

Condition monitoring techniques and technology

Condition monitoring data is the foundation of an effective machine health optimization strategy. However, some manufacturers hesitate to adopt continuous condition monitoring due to concerns about downtime during installation, the burden of managing additional hardware, or complications with cable management.

That’s why selecting the right technology is critical. Look for solutions that offer easy, fast installation, wireless capabilities, and rugged hardware built to perform in the most demanding industrial environments.

Today’s advanced condition monitoring systems can remotely track key indicators such as:

Fluid temperature, humidity, and viscosity
Presence of sediment, contaminants, or water
Vibration levels
Ultrasonic frequencies
Pressure changes

This data is wirelessly transmitted to platforms that clean, contextualize, and analyze it, transforming raw machine data into actionable insights for your team.

When condition monitoring falls short: how to avoid common pitfalls

Condition monitoring is a valuable part of a machine health strategy, but on its own, it often falls short. Without deeper analysis, it can become little more than an expensive alarm system, flagging failures without helping prevent them.

To get the most from your investment, condition monitoring data must be intelligently analyzed to drive proactive decisions that improve performance and reliability across your plant.

From monitoring to optimization: turning data into machine health solutions

Condition monitoring shows when a machine is failing—machine health optimization reveals why. By combining condition data with advanced analytics, expert insights, and machine learning, manufacturers can pinpoint the root causes of failure and eliminate them.

This strategic approach empowers teams to move from reactive maintenance to long-term, scalable solutions that reduce downtime and drive sustainable operational gains.

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