5 Condition-Based Maintenance Benefits
Condition-based maintenance (CBM) differs from other approaches to maintenance in that it involves monitoring an asset’s actual real-time conditions and operating parameters to determine what maintenance is needed. CBM ensures that maintenance is performed only when certain indicators show a decline in performance or an impending failure. Because maintenance is performed on an as-needed basis, the time between repairs is extended.
Today we will discuss various condition-based maintenance benefits. We will then explain how manufacturers and maintenance managers can easily incorporate CBM by using a top-shelf platform like LLumin’s CMMS+.
What Is Condition-Based Maintenance?
Condition-based maintenance is a method of managing equipment and assets that uses real-time monitoring to determine the current state of working equipment. Maintenance is performed only when it is truly necessary by basing maintenance schedules on the actual state of the equipment rather than on a fixed schedule, which can help reduce costs and improve efficiency.
CBM requires leveraging data from existing machine control systems or the installation of machine-level sensors. These sources, along with monitoring software, collect data and parameters such as vibration, temperature, and oil quality. As the next best logical step, collected data can then be analyzed using artificial intelligence (AI)-powered technologies to predict the future state of working equipment and schedule maintenance tasks.
What Are the Top Condition-Based Maintenance Benefits?
Because of its ability to use real-time data and analysis to determine the current state of equipment and assets and schedule and perform maintenance based on their actual status, the CBM approach can provide several benefits to businesses that rely on business-critical equipment functioning at peak performance levels.
This method is especially useful in enabling organizations to make informed decisions about their current maintenance strategies. The top condition-based maintenance benefits include:
- Lower overhead costs
- Reduced unplanned downtime
- Increased safety levels
- Performance tracking
- Predictive maintenance
We will explore these benefits in further detail below.
| Benefits | Description |
|---|---|
| Lower overhead costs | CBM improves budgeting by lowering unnecessary maintenance and repair costs. |
| Reduced unplanned downtime | CBM makes it possible to quickly identify issues, avoiding equipment downtime and improving performance. |
| Increased safety levels | CBM improves maintenance safety by detecting deviations from normal parameters and reducing risks. |
| Performance tracking | CBM allows measurement and analysis of key performance indicators to enhance maintenance processes. |
| Predictive maintenance | CBM uses real-time data analysis to predict maintenance needs and schedule proactive actions to prevent failures. |
1. Lower Overhead Costs
By using condition-based maintenance, abnormal behavior patterns in equipment can be detected early on, enabling maintenance to be scheduled at the right time and well before unexpected failures occur.
Because CBM uses real-time monitoring and continual data analysis to determine equipment condition and performance, it can help businesses reduce overhead costs associated with unnecessary maintenance and repair. It can also help reduce costs attributed to downtime, which can be high when business-critical equipment is not operating optimally.
This maintenance approach can also help businesses optimize their maintenance budgeting and improve how they allocate company resources as they become better able to anticipate future maintenance needs, further reducing maintenance overhead costs and improving efficiency.
2. Reduced Unplanned Downtime
Adopting a CBM strategy that enables the timely identification of problems and maintenance can help an organization prevent equipment downtime and maintain optimal performance for longer periods of time. CBM also allows maintenance to be scheduled at opportune times to avoid disrupting production schedules, allowing companies to make the best use of their time, manpower, and resources.
3. Increased Safety Levels
A CBM strategy can improve maintenance safety and prevent accidents by using data to detect when equipment deviates from normal parameters. This process enables planned maintenance to occur well-before equipment failure, which helps to reduce the risks of dangerous and unexpected breakdowns while helping to identify potential hazards.
4. Performance Tracking
Performance tracking refers to the process of measuring and analyzing key performance indicators (KPIs) related to equipment, such as efficiency, productivity, and uptime. Performance tracking can help a company discover trends, patterns, and abnormal behaviors in equipment performance and use that information to enhance maintenance processes.
Manual tracking is always an option, but it can be time-consuming and frequently result in inaccurate data. Businesses can also use specialized software, such as LLumin’s CMMS+, to automatically collect and analyze performance data, which can help streamline and improve the entire process of monitoring equipment performance over time.
5. Predictive Maintenance
Predictive maintenance, like condition-based monitoring, is based on monitoring the real-time condition of equipment to predict when maintenance is required. The key component of both of these maintenance strategies is the use of machine-level sensors to collect data on the condition of the equipment.
However, their difference centers around how collected data is analyzed and utilized. CBM monitors data for specific parameters that can indicate current wear or failure, whereas predictive maintenance monitors and analyzes data to predict when maintenance will be needed in the future. This advanced data analysis process enables maintenance to be scheduled proactively rather than reactively to prevent equipment failure and downtime.
Companies implementing condition-based maintenance will be better positioned to transition to a more advanced AI-powered maintenance program in the future.
A CMMS Can Help You Reach Maximum Operational Efficiency
There are several clear advantages to using a condition-based maintenance strategy. It can help ensure that equipment is always in good working order, increase uptime, and lower the risk of unexpected failures. Further, this approach can help a company optimize its maintenance budget and resources.
However, if you’re contemplating implementing a CBM maintenance program, you should consider how advanced CMMS software can help your company maximize maintenance and operational efficiency while avoiding future problems and limitations with your CBM implementation project.
LLumin’s CMMS+ is a cloud-based CMMS platform powered by AI technology and machine-level sensors. Your company can use the powerful CMMS+ to automate the many complex tasks associated with monitoring and maintaining company assets. Further, with company-wide visibility and real-time control over machine conditions, you will never have to wonder when equipment will fail again.
Implement Condition-Based Maintenance With LLumin’s CMMS+
LLumin’s CMMS+ software is a complete solution for condition-based monitoring. LLumin’s CMMS+ enables maintenance technicians and managers to stay ahead of machine failures and dramatically reduce unplanned downtime by providing the advanced tools and features required to streamline and improve maintenance operations.
LLumin is different from many other software providers. When you choose to work with us, you will have access to excellent customer service throughout the entire implementation process. Your project will be tailored to your company’s specific goals and requirements. We will provide you with a complete implementation plan, support team, and ongoing support throughout your digital transformation and beyond.
So if you are looking for a cutting-edge CMMS+ accompanied by a seamless implementation process and an expert customer support staff, then LLumin is a perfect fit.
Getting Started With LLumin
LLumin develops advanced CMMS software to support preventative maintenance programs for industrial plants, municipalities, utilities, fleets, and facilities. If you want to learn more about how CMMS software can help provide several condition-based maintenance benefits, we encourage you to schedule a free demo or contact the experts at LLumin to see how our CMMS+ software can help you reach your performance goals.
With over two decades of expertise in Asset Management, CMMS, and Inventory Control, Doug Ansuini brings a wealth of industry knowledge to the table. Coupled with his degrees in Operations Research from both Cornell and University of Mass, he is uniquely positioned to tackle complex challenges and deliver impactful results. He is a recognized expert in integrating control systems and ERP software with CMMS and has extensive implementation and consulting experience. As a senior software architect, Doug’s ability to analyze data, identify patterns, and implement data-driven approaches enables organizations to enhance their maintenance practices, reduce costs, and extend the lifespan of their critical assets. With a proven track record of excellence, Doug has established himself as a respected industry leader and invaluable asset to the LLumin team.