Condition-based maintenance, also referred to as condition-oriented maintenance or Condition-Based Maintenance (CBM), is a maintenance strategy in which maintenance actions are performed based on the actual condition of machines and systems. Instead of carrying out maintenance at fixed intervals, the condition of equipment is monitored continuously or periodically in order to identify maintenance needs at an early stage and take targeted action.

Objectives and Benefits

• Avoidance of unplanned downtime: Continuous monitoring makes it possible to detect signs of wear or functional issues early and address them before a failure occurs.
• Optimized maintenance intervals: Maintenance is only performed when it is actually required, reducing unnecessary work and associated costs.
• Increased operational safety: Condition-based maintenance improves the safety of machines and systems by ensuring that critical issues are identified and resolved in time.
• Cost savings: Targeted maintenance helps reduce repair and spare-part costs while extending the service life of assets.

Methods of Condition-Based Maintenance

1. Sensor-based monitoring: Use of sensors to continuously monitor parameters such as temperature, vibration, pressure, humidity, and other relevant operating data.
2. Periodic inspections: Regular manual inspections and measurements carried out by maintenance personnel to assess machine condition.
3. Diagnostic systems: Use of advanced diagnostic systems and software to analyze collected data and predict maintenance requirements.

Typical Measures

• Vibration analysis: Monitoring machine vibrations to identify irregularities that may indicate mechanical issues.
• Thermography: Use of thermal imaging cameras to detect overheating or uneven heat distribution that may point to electrical or mechanical problems.
• Oil analysis: Examination of lubricants for contamination and wear particles to assess the condition of bearings and gearboxes.
• Acoustic emission analysis: Monitoring sound emissions to identify anomalies and wear conditions.

Implementation

Successful implementation of a condition-based maintenance strategy requires careful planning and the right equipment. Key steps include:

• Equipping assets with suitable sensors: Selecting and installing sensors appropriate for monitoring specific machine parameters.
• Data analysis: Establishing systems for continuous data collection and analysis.
• Staff training: Ensuring maintenance personnel are trained in the use and interpretation of monitoring technologies.
• Documentation: Recording and evaluating condition data to identify trends and plan preventive actions.