Predictive Maintenance Playbook

Lockout tagout image showing machine locks and DO NOT OPERATE tag.

Are you stuck at stage one?

Most manufacturers stop at the “instrumented” stage—sensors installed, a few assets online—but no deeper insights, no integration with maintenance plans, and no clear return on investment.

Sound familiar?

This playbook helps you move from basic data collection to a fully optimized, insight-driven maintenance program. One that eliminates unplanned downtime, empowers your team, and delivers real financial impact.

Overcome the plateau and unlock the full potential of PdM Maintenance.

Download the PDM Playbook

What you’ll learn in this guide:

Discover how to maximize the four (4) stages of predictive maintenance system maturity.

See where you are now and learn what it takes to level up.

Why PdM Efforts Plateau—and How to Break Through: Identify the internal roadblocks that are holding you back and learn how to overcome them.

How to Scale PdM Systems Across Your Organization: Turn scattered sensors and dashboards into a connected, strategic program that delivers measurable value across teams and sites.

Proven Steps Backed by 289,000+ Hours of Machine Health Data: This playbook is built on real-world experience monitoring over 6,000 assets across manufacturing, chemical, energy, and heavy industry sectors.

Download the PDM Playbook

Why the right play matters

Unplanned downtime costs manufacturers an average of $260,000 per hour. Reactive maintenance wastes time, labor, and spare parts. And even many “predictive” systems aren’t delivering the impact they promised. This playbook gives you the framework to fix that.

You’ll learn how to:

Shift from reactive to proactive strategies
Align teams across operations and maintenance
Justify technology investments with real ROI
Build a scalable machine health program
Reduce downtime, optimize maintenance, and improve safety

Download the PDM Playbook

Motors lined up on maintenance shelves ready for predictive maintenance steps.

What's inside the playbook?

Stage 1: Why Most PdM Programs Stall
The real reason initial wins don’t scale

Stage 2: Integration
How to connect PdM data with your existing workflow

Stage 3: Insight
Moving beyond alerts to diagnose an action

Stage 4: Optimization
Scaling PdM across the enterprise with continuous improvement

Maturity Checklist
Assessing your current stage and what do do next

SMARTsensing suite MCSA unit shown in front of data panel showing results.

"KCF has given us the ability to focus our people where they need to be, with a lot less exposure on dangerous equipment."

Tony Chacos, Mechanical Specialist
Energy Transfer

Customer Success Story

"In the past 6 months there have been about 2,000 triggers and those triggers result in about a 100 actionable items that we're able to take you know whether it be greasing or a premature failure and we're able actually prevent failure from occurring."

Jeff Detwiler, President of Construction Materials
New Enterprise

Customer Success Story

Download the predictive maintenance playbook.

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Predictive Maintenance Playbook

Are you stuck at stage one?

What you’ll learn in this guide:

Discover how to maximize the four (4) stages of predictive maintenance system maturity.

Why the right play matters

What's inside the playbook?

Gain a competitive edge with KCF

Download the predictive maintenance playbook.