Condition monitoring: An introduction to modern maintenance technology

Condition monitoring is a crucial tool in modern maintenance. Continuous monitoring of machines, systems and goods carriers allows critical data to be recorded in real time. This information makes it possible to identify problems at an early stage and initiate targeted maintenance measures. Condition monitoring helps companies reduce downtime, extend the service life of equipment and increase overall operational efficiency.

Condition monitoring pursues a number of important objectives that help companies increase efficiency and reduce costs:

• Early detection of problems: Machine condition monitoring enables wear, malfunctions or unusual operating conditions to be detected at an early stage. By continuously monitoring machine parameters such as vibrations, temperature, pressure or noise levels, anomalies can be identified before they lead to major damage.
• Minimising downtime: A key objective of condition monitoring is to minimise unplanned downtime and potential hazards during transport. Real-time monitoring and analysis of machine conditions and goods carriers allows necessary maintenance work to be planned and carried out before a breakdown occurs. This ensures higher uptime and increases the availability of machines and systems.
• Optimisation of maintenance planning: Condition monitoring enables demand-driven maintenance by providing accurate information about the current condition of machines. Instead of relying on rigidly defined maintenance intervals, maintenance work can be planned based on actual machine conditions. This not only optimises maintenance costs, but also the use of resources and the service life of the machines.
• Cost reduction: Through a combination of early detection, minimised downtime and optimised maintenance planning, condition monitoring leads to significant cost savings. Avoidable breakdowns are reduced, which lowers direct repair and spare parts costs. In addition, production interruptions are minimised, which increases efficiency and improves profitability.

Condition monitoring and the Industrial Internet of Things (IIoT) work hand in hand to maximise the efficiency and reliability of machines. IIoT enables sensors to be integrated on a large scale into machines, systems and goods carriers in order to continuously monitor various operating parameters such as vibrations, temperature, pressure and humidity. These sensors are often wirelessly networked and send their data in real time via the IIoT network to centralised or cloud-based systems.  

The collected data is then transmitted in real time via IIoT platforms and evaluated using advanced analysis tools, including big data and artificial intelligence. This allows anomalies and potential problems to be detected at an early stage. Thanks to IIoT connectivity, machines, systems and goods carriers can even be monitored and controlled remotely. Technicians and managers can access the status of the machines at any time via mobile devices or central control centres and intervene immediately if necessary, even if they are not on site. By combining condition monitoring and IIoT, companies can thus move from a reactive to a preventive and predictive maintenance strategy.

Condition monitoring is not just a technical tool, but an important strategic decision. It enables companies to make optimal use of their machines and systems and avoid unexpected downtime. With advancing digitalisation and the possibilities offered by the Internet of Things, this technology will continue to gain in importance in the coming years. Companies that embrace condition monitoring at an early stage not only gain a competitive advantage, but also secure their production capacities and cost efficiency in the long term. Now is the ideal time to set the course for a future-proof maintenance strategy.