Condition-Based Monitoring (CBM)
CBM is a strategic approach to maintenance that leverages real-time data from manufacturing systems to monitor the health and performance of assets. It’s essential for enabling predictive maintenance, real-time equipment monitoring, and operational efficiency in manufacturing environments.
Overview:
CBM is a maintenance strategy that monitors the actual condition of assets to decide what maintenance needs to be done. It helps avoid unnecessary maintenance and prevents unexpected equipment failures.
Components of CBM:
Real-time data acquisition from machines, sensors, and control systems.
Evaluation of asset conditions against predefined thresholds or standards.
Triggering alerts or maintenance actions when deviations are detected.
This approach helps organizations move from reactive or time-based maintenance to a more predictive and efficient maintenance strategy.
Why CBM is Imperative in Manufacturing Industry
CBM (Condition-Based Monitoring) is essential because it transforms traditional maintenance into a data-driven, proactive strategy:
1. Real-Time Equipment Monitoring
Connects shop floor systems (PLCs, SCADA, DCS) with enterprise platforms like SAP ERP.
Enables continuous data capture (e.g., temperature, vibration, pressure) for accurate equipment health assessment.
2. Predictive Maintenance Enablement
Uses analytics to detect anomalies and forecast failures.
Shifts maintenance from reactive to predictive, reducing emergency repairs.
3. Quality & Compliance Assurance
Maintains equipment within operational thresholds.
Ensures consistent product quality and adherence to regulatory standards.
Benefits of CBM
CBM delivers measurable improvements across operations, maintenance, and cost control:
✅ Operational Efficiency
Minimizes unplanned downtime through early issue detection.
Improves production continuity and throughput.
💰 Cost Optimization
Reduces unnecessary preventive maintenance.
Avoids costs from unexpected breakdowns and over-servicing.
🔧 Asset Longevity
Prolongs equipment life through timely interventions.
Enhances ROI on capital assets.
🔄 SAP ERP/PM Integration
Automatically triggers maintenance notifications or work orders.
Streamlines the workflow from detection to resolution.
📊 Informed Decision-Making
Provides real-time insights for prioritizing maintenance tasks.
Empowers teams to act based on actual equipment condition.
Sample CBM dashboard
It provides the complete view of the alerts (Critical and Warning alert types) against each line or machine in the facility. It also provides the list of Top 5 active alerts. The alerts shall be acknowledged by the maintenance team. The dashboard also displays the CBM work order summary for the site along with details of the backlog work orders for CBM. The workorder count includes only the released work orders for CBM for the selected duration. The dashboard will be live with updates in near real time
This dashboard will also provide the navigation to view information of any required site.
Conclusion
The Condition Based Monitoring solution is basically intended to be used by the plant managers, asset care Managers, production and maintenance supervisors and leads, that enables them to take in-time corrective measures eventually maximizing the productivity and enhancing asset life while minimizing any impact on the asset health and maintenance activities. It further leads improved uptime and maintenance cost reductions.
