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How to make condition-based maintenance more e ective To search type and hit e

Last Updated: February 21, 2019 | Marc Cousineau |   9 min read

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This article is a complete guide for optimizing condition-based maintenance (CBM), including what CBM is,
the di erent types, how it’s used and how to use it for maximum return. API App Arduino Autom

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Table of contents
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1. What is condition-based maintenance?
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2. When is condition-based maintenance used?
Failure Modes Fiix Fiix Labs
3. What are the bene ts of condition-based maintenance?
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4. Di erent types of condition-based monitoring
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5. How to use condition-based maintenance more e ectively
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Inventory Inventory Managem

Equipment failure is not a single event—it is a process. This concept, that breakdowns are both a journey Maintenance management

and a destination, has become rmly established in the realm of maintenance best practices. Condition- Maintenance Metrics

based maintenance (CBM) can act as a guide on the road to failure and back. Maintenance Strategies

Meter Readings Mobile Mo

We’ve provided some tips, tricks and tools so you can understand condition-based maintenance a little mobile maintenance MSDS
better, use the strategy more e ectively, and make your maintenance operation run like a well-oiled Press Release
machine. Preventative Maintenance

Preventive maintenance

What is condition-based maintenance? Product Update Purchasing

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Condition-based maintenance is a predictive maintenance strategy where various elements of an operating
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asset are observed and measured over time to identify and prevent deterioration and possible failure at the
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earliest possible moment. Under CBM, maintenance only occurs when data indicates a decline in
performance or the early warning signs of failure. This di erentiates CBM from preventive maintenance,
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where tasks are performed at regular intervals.

Root cause analysis using

The goal of condition-based maintenance is to uncover equipment failure before it happens, so
whys method
maintenance can be done exactly when needed. Because CBM is based on collecting and analyzing data, it
can be used to identify trends in asset performance and asses where an asset is in its lifecycle. This makes it Get Your Fiix: Maintenanc
easier to make informed decisions on everything from scheduling and labour to budgeting. you need to know from Fe
2019
One example of condition-based maintenance is monitoring pressure readings on equipment with water
systems. Monitoring pressure levels allows maintenance sta to identify when and where a leak is likely to Troubleshooting for main
occur before it happens, instead of at the point of failure. More than just trial and e

When is condition-based maintenance used? How to make condition-b

Although condition-based maintenance can be used on most assets, equipment must meet certain maintenance more e ect

requirements for CBM to be used e ectively.

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3/16/2019 CBM Guide | Condition-based maintenance tips | Fiix

First, as the name suggests, there must be a condition that can be monitored. If performance can’t be
What is the P-F Curve? | P
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measured, you won’t be able to tell if there is a change Pricing which
in performance, Solutions Resources
indicates the need Support
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Interval
maintenance.

It is also crucial to be able to observe these changes in performance far enough in advance of failure so Categories
maintenance can be completed before the asset fails or deterioration a ects production.
Bene ts of CMMS

“
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Equipment failure is not a single event – it is a process. . .Condition-based
maintenance can act as a guide on the road to failure and back. Case study

CMMS features

Another important consideration is the criticality of your assets. Condition-based maintenance provides the
Evaluating software
best return on investment on your most critical assets. That’s why it’s a good idea to conduct a criticality
analysis to determine which pieces of equipment are most likely to fail and what impact that failure will have Getting started
on your operation. If you are easing into CBM, think about starting with your most critical assets and scaling
from there. Health and safety

Lastly, condition-based maintenance can only be used if the right processes and systems are in place. The Inventory management
maintenance team must be able to capture performance data, analyze it, and make timely decisions based
Maintenance industry new
on the results.

Maintenance metrics
What are the bene ts of condition-based maintenance?
There are several advantages to using condition-based maintenance on assets, especially in a production- Maintenance strategies

intensive, equipment-heavy environment. Here are a few of the major bene ts that can be gained from CBM:
Mobile CMMS
It is much easier to predict failure and x it before it occurs, which means CBM can help reduce
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unplanned downtime and labour hours while increasing throughput.
The time between maintenance increases because repairs are only done on an as-needed basis. This
Preventive maintenance
means less downtime, reduced backlog, and fewer costs.
The likelihood of disrupting production is reduced as CBM is usually performed while assets are working Tips and tricks
and doesn’t normally require equipment to shut down for inspection.
TPM
If an unexpected failure does occur, using CBM can lead to a quicker diagnosis of the problem, thereby
reducing the cost of breakdowns.
Because CBM provides an early warning system for equipment failure, you can control inventory much
more e ectively and won’t need as many emergency spare parts.
Responding to an unplanned breakdown is one of the riskiest tasks for a maintenance technician.
Condition-based maintenance creates a safer workplace by reducing the likelihood of equipment failure.
Overdoing it on maintenance can cause equipment to deteriorate faster. CBM helps prescribe the
optimal amount of maintenance for an asset, decreasing the chances of collateral damage to its
systems.

Di erent types of condition-based monitoring

Condition-based maintenance is rooted in condition-based monitoring. This involves keeping tabs on the
state of an asset using certain performance indicators. There are a number of di erent tools and
techniques that allow maintenance teams to do this. These methods can include low-tech approaches, such
as observation by a technician, or more technologically advanced processes, like gathering data through
sensors.

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One of the hallmarks of condition-based monitoring is that it is non-invasive. This means measurements are
taken without shutting down a machine or adjusting the way it operates. Data is collected either at certain
intervals or continuously through sensors, visual inspection, performance data, and/or scheduled tests.

The following is a brief rundown of some of the techniques used in condition-based monitoring:

Vibration analysis

This type of condition monitoring identi es potential failure by spotting changes in normal vibration
signature. Vibration is a ected by amplitude, intensity, and frequency. Sensors can detect abnormalities in
these elements, which can be a sign that something is wrong with an asset. For example, rotating
equipment, such as compressors and motors, exhibit a certain degree of vibration. When they degrade or
fall out of alignment, the intensity of the vibration increases. Sensors can detect when the vibration
becomes excessive and the component can be repaired or replaced.

Infrared and thermal analysis

When certain parts or systems heat up past speci ed temperatures, it can cause them to deteriorate, warp,
break, burn out, or start a re. Infrared cameras and thermal sensors are used to determine when a piece of
equipment has become too hot and alerts the maintenance team so they can take the necessary steps to x
it. Infrared and thermal analysis is frequently used on energized equipment, such as electrical conductors,
and motorized parts that operate at high RPM.

Ultrasonic analysis

Ultrasonic instruments help detect deep, subsurface defects. They do this by measuring sounds that are
inaudible to us and converting them to a pitch we can hear. Once these sounds can be discerned by the
human ear, it’s easier to recognize anomalies in an asset and rectify them. For example, as ball bearings
begin to wear out, they become deformed. This creates irregular surfaces on the bearing and increases the
emission of ultrasonic sound waves. This can signal to a technician that the bearing is on its way to failure.

Acoustic analysis

Acoustic analysis is similar to vibration and ultrasonic analysis. It uses sensors and microphones to detect
sounds that indicate an asset is not operating quite right. However, where the main use of vibration and
ultrasonic analysis is to uncover de ciencies in rotating equipment, acoustic analysis has the added bene t
of being able to target gas, liquid, or vacuum leaks. This is a key advantage for production facilities in the oil,
energy and mining industries.

Oil analysis

Oil analysis helps diagnose the internal conditions of oil-wetted components and their lubricants. This
method can determine the health of an asset that uses oil, fuel or coolant and whether it is nearing failure.
Oil analysis can be as thorough as testing blood samples. This type of condition monitoring can include
testing for dozens of di erent elements, such as the level of wear metals or dirt contamination in oil. It also
captures information on viscosity, acid levels, water content, and more to determine the e ectiveness of the
oil as a lubricant.

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Electrical analysis
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When an electrical current is too strong or too weak, it can cause problems for an asset. Electrical analysis
uses clamp-on ammeters to measure the current in a circuit. Using this tool, it’s easy for maintenance teams
to gauge when a machine is receiving an abnormal amount of electricity. The piece of equipment can then
be shut down and serviced before a bigger, more expensive electrical problem occurs.

Pressure analysis

In many industries, production relies on maintaining the right pressure within equipment so uid, gas, or air
can move through a pipeline or hydraulic hose properly. This is where pressure analysis can play a part. If
the pressure drops in a piece of equipment, it could mean that there’s an internal problem requiring
maintenance. A spike in pressure would be a sign of breakage or an imminent explosion. Conducting
pressure analysis allows maintenance teams to see these changes happening in real-time and respond to
them before issues spiral out of control.

Many of these forms of condition monitoring can be used together to gauge the health of an asset. For
instance, several sensors can be attached to an asset that measures everything from temperature to
pressure, ensuring all systems in a piece of equipment are functioning optimally.

How to use condition-based maintenance more e ectively

Using condition-based maintenance is one thing. Using it e ectively is a whole other story. If you don’t have
the right systems, processes and procedures in place, condition-based maintenance can cost you more
time, money and goodwill than it’s worth. Here are a few ways maintenance teams can harness the power of
CBM and build a sustainable operation around condition monitoring.

Step 1: Map out your assets, failure modes, and baselines

It would be an understatement to say that you need to know your assets inside-out before implementing
condition-based maintenance. You must understand everything about how equipment functions so you can
properly calibrate sensors, spot problems as soon as possible, and prescribe the right cures.

First of all, you have to map out all your assets and their possible failure modes to understand if each piece
of equipment has the key ingredients for CBM. The rst key ingredient is a condition that can be monitored.
Condition monitoring doesn’t work for every asset, so knowing which ones don’t support sensors or other
monitoring tools and techniques can save you lots of time and money later.

“ Overdoing maintenance can cause equipment to deteriorate faster. CBM

helps prescribe the optimal amount of maintenance for an asset,
decreasing the chances of collateral damage to its systems.

For the remaining assets, determine if the failure modes identi ed by condition monitoring can alert you to
a problem with enough time to x it in a cost-e ective way. If the answer is yes, the asset is likely a good
candidate for condition-based maintenance.

Once you have your group of quali ed assets, it’s important to set baselines for normal operation. Baselines
are the established thresholds that indicate a healthy and fully functional system. For example, the baseline
vibration frequency for a bearing may be 1000 Hz to 2000 Hz. Any number between those two frequencies
means the bearing is operating at its optimal level. If it reaches above 2000 Hz or below 1000 Hz, it could
signify a problem.

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Baselines can be established in many ways, from manufacturer recommendations to historical trends.
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Creating baselines for each system takes the guessing Pricing Solutions
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decisions much more e cient and e ective.

Step 2: Understand and use the potential failure (P-F) curve

Talking about condition-based maintenance without the P-F curve is like talking about a car without wheels;
it just doesn’t work.

The P-F curve demonstrates the relationship between machine breakdown, cost, and how it can be
prevented. It is based on the fact that equipment might be in the early stages of failing even if seems to be
working ne. Along the X-axis of the curve is time. As you move through time, the machine moves from the
point of potential failure to the point of actual (functional) failure. As you move through time, there are also
instances when faults can be detected before total failure.

Along the Y-axis is the machine’s condition. The machine progresses from top working condition to point of
failure, and then down from there until actual failure.

The most important part of the P-F curve is the P-F interval. The P-F interval is the time between an asset’s
potential failure and its functional predicted failure. For successful CBM, you must ensure your inspection
intervals are smaller than the P-F interval so you can catch a failure after it’s detectable, but before it actually
occurs. Fine-tuning your maintenance intervals is also crucial to optimizing condition-based maintenance.

Understanding the P-F curve and the P-F interval is key to building an e cient CBM strategy. The P-F curve
and interval allow you to determine how often you should complete a CBM task. The frequency of
maintenance is reduced, as are the costs and time commitments associated with maintenance.

Step 3: Leverage maintenance technology

Condition-based maintenance combines recommended guidelines with repair and performance data to
determine what tasks need to be completed and how often. When these parameters are decided, it’s
maintenance software that can be used to help you get a jump on everything from logging sensor data to
triggering work orders and scheduling maintenance.

Integrating sensor data with maintenance software, such as a CMMS, can help reliability engineers,
maintenance managers and technicians capture, organize and analyze information much easier, quicker and
more accurate.

Maintenance software also gives you the ability to automatically trigger a work order when certain
measurements fall outside the established baseline. For example, you can set up a CMMS to schedule
maintenance on a lter when the di erential pressure exceeds 20psi. This way, maintenance can be
scheduled at the most appropriate time, reducing the likelihood of failure while maximizing resources.

Optimized inventory purchasing is another great byproduct of using maintenance software to manage
condition-based maintenance. Because software can track work order history and create reports on parts
usage, it makes it easy to adjust inventory levels so you’re only ordering the parts you need, when you need
them. Not only will the parts always be on-hand (eliminating downtime), but inventory prices can be cut.

Step 4: Create a solid training program for sta

While condition-based maintenance relies heavily on technology and automated systems, like sensors and
software, there will always be a human element involved. For your CBM strategy to be as e cient and
e ective as possible, it’s vital that all members of the maintenance team are properly trained on the concept

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of CBM, its bene ts and how to use the systems. This will increase buy-in, eliminate user error and increase
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reliability throughout the process.

Training should include a thorough breakdown of the di erent types of condition monitoring and how they
a ect each asset at your facility. It should also be clear how every member of the team can ensure sensor
data is logged correctly and how resulting maintenance tasks should be treated. It’s a good idea to create an
asset management policy at this stage of CBM implementation as it will help everyone in your facility, not
only the maintenance team, understand how CBM is impacting the organization as a whole and their place in
ensuring the strategy works to its full potential.

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