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When & How to Apply Condition Based Monitoring/Maintenance (CBM) in an Industry?

By 26th November 2020 No Comments
Condition Based Maintenance & Monitoring (CBM)- 5 Questions To Ask When Building a System for Condition Monitoring | Seven Steps Global

Though condition monitoring can play a beneficial role in any organizations maintenance blitz, it’s regularly implemented in a paced manner without a full in depth understanding of some factors that will always impact its effectiveness in the system.

Let’s have a look at some key points to consider for a strategic, rather than direct rushed, adoption of CBM.

What are the Questions for Choosing A Condition Based Monitoring program?

1. Is it able to monitor specific/particular failure modes of the equipment?  

A failure mode can be defined as a particular cause of the failure or breakdown or one of the possible ways in which a system can fail or break. More the complexity of the equipment, modes of failure will be high.

Understanding these modes and their impact will help the organization to identify and adopt the right condition-based monitoring solution which is an important aspect of improving equipment reliability.

Some methods analyze only the causes that happened of any failures and help us to understand its frequency and deep impacts. One of these methods is the Failure Modes and Effects Analysis (FMEA). Which can calculate the impacts on each piece of equipment. This step is part of the initial condition-based monitoring process.

Also, Read How to Analyze Abnormalities in the Industry Through Daily Management

2. Is the technology interfaces with existing ERP/CMMS systems?

With the continuous up-gradation in technology in the way we use data, it is increasing must obvious that all our data channels must be interfaced effectively with zero disruptions to operations.

Such channels would normally include software like (ERP) Enterprise Resource Planning, Systems Applications and Products in Data Processing (SAP) or Computerized Maintenance Management System (CMMS) . Some organizations are using tools from the Internet of Things (IoT) such as wireless technology.

Whatever the case is, the data stream from the monitoring sensors must work with the other systems already in place.

 3. What is the simplicity of the implementation?

Some condition-based monitoring sensors and solutions are very much easy to implement than other solutions.

Considering the time, labor, and effort required for implementation because it can be significant depending on:

  1. How large is your existing system?
  2. How complex is the equipment We’re using?
  3. How easy is it to install the required sensors?
  4. How fast can your maintenance team accept the new solution program?

4. Can overtime be improved by generating accurate alerts?

Before applying any solution, consider how reliable are the produced alerts will be.

False positives are not uncommon in condition-based monitoring settings and they is only one reason why an organization may decide to discontinue the process after implementation. If technicians are continuously called on to alerts to failures or breakdowns that end up being false many times, then everyone will lose confidence in the applied system.

Therefore, one leader must check the record of the true versus false positives that happened in the last interval of time.

Also, Read How to Improve Machine Performance, Reliability and Efficiency of Capital Equipments and Process Machines

 5.What are the Benefits Of Condition Based Maintenance (CBM)?

All proactive maintenance approaches always bring positive advantages to the notice and CBM is also one of them.

Here are some major benefits of using condition-based maintenance(CBM):

  1. A vast reduction in the number of unplanned Breakdowns & failures
  2. Improved equipment OEE through its availability, reliability and worker safety
  3. Reduction in time span of maintenance activities at Gemba (by doing maintenance work only when it is actually needed)
  4. Maintenance work can be scheduled during non-peak times
  5. Increased equipment lifespan
  6. Improved equipment efficiency through its performance
  7. Minimizing inventory costs RM, WIP

Seven Steps Business transformation systems is a member of  Seven Steps Academy of Excellence specialized in Business turnaround facilitation.  Our team of Business consultants is specialized in

Our services find useful in

Some of the focused industries include

  • Aircraft manufacturing,
  • Defense equipment production,
  • Food production,
  •  Agriculture
  • Foundry
  • Pharmaceuticals
  • FMCG
  • Forgings
  • Warehousing
  • Transportation
  • Software
  • App development
  • Telecom
  • Government
  • Research organizations and
  • Service organizations

Our consultants operate worldwide for online consulting.

Our regional presence in India for onsite- Gemba visit covers Bangalore, Hosur, Chennai, Mysore, Shimoga, Pune, Mumbai, Calcutta, Hyderabad, Salem, Tiruchy, Madurai, Tiruppur, Coimbatore, Hubli, Belgaum, Delhi, Chandigarh and another tier 1 and tier-II cities.

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