Condition Based Maintenance in 2025 – Definition, Types, Strategy, Examples, and Checklist

In 2025, maintenance strategies are evolving rapidly as industries embrace advanced technologies to enhance equipment efficiency and reduce downtime. 

One of the most effective approaches is condition based maintenance (CBM), which uses real-time data to determine when maintenance is necessary, rather than relying on fixed schedules.

Also Read: Condition-Based Maintenance: A Complete Guide

With the rise of IoT, AI-driven analytics, and smart sensors, condition-based maintenance is becoming the preferred strategy in 2025, enabling businesses to optimize maintenance schedules and reduce operational costs.

Importance of Condition-Based Maintenance in Industrial Efficiency

Condition based maintenance plays a crucial role in improving industrial efficiency by:

• Minimizing Downtime: Since CBM detects early signs of wear and failure, industries can address issues before they lead to major breakdowns.
• Reducing Maintenance Costs: By servicing equipment only when necessary, businesses avoid unnecessary maintenance and reduce labor and material costs.
• Enhancing Equipment Lifespan: Regular monitoring ensures machines operate at optimal performance, leading to longer service life.
• Improving Safety: CBM helps prevent unexpected failures that could lead to hazardous working conditions, ensuring compliance with industry safety standards.

How Condition-Based Maintenance Differs from Preventive and Predictive Maintenance

Although condition based maintenance shares similarities with other proactive maintenance strategies, it has distinct differences:

Maintenance Type	Definition	Key Features
Preventive Maintenance	Scheduled maintenance at regular intervals	Based on time or usage
Condition-Based Maintenance (CBM)	Maintenance based on real-time equipment condition	Uses sensors and monitoring systems
Predictive Maintenance	Uses advanced analytics and machine learning to predict failures	Requires big data and AI-driven analysis

While preventive maintenance follows a fixed schedule and predictive maintenance relies on AI-driven forecasting, condition based maintenance focuses on real-time monitoring, making it a cost-effective and practical solution for industries in 2025.

Also Read: Condition Based Maintenance for Data Centers

Condition Based Maintenance Definition

Condition-based maintenance (CBM) is a proactive maintenance strategy that relies on real-time data to determine when equipment requires servicing. Unlike preventive maintenance, which follows a fixed schedule, CBM ensures that maintenance is performed only when there are signs of wear or potential failure.

This approach helps industries optimize maintenance efforts by using sensors, IoT devices, and data analytics to monitor equipment health continuously. When the system detects anomalies, it triggers maintenance activities, reducing unnecessary servicing and preventing unexpected breakdowns.

Condition Based Maintenance Types

Condition-based maintenance (CBM) is a proactive maintenance strategy that relies on real-time data to assess the health of equipment and schedule maintenance only when needed. Various monitoring techniques are used to detect early signs of wear, inefficiency, or failure in industrial machines. 

Below are the major types of condition based maintenance:

1. Vibration-Based Monitoring

One of the most widely used condition based maintenance techniques is vibration-based monitoring, which helps detect mechanical issues like misalignment, imbalance, and bearing failures.

How It Works:

• Sensors are placed on equipment to measure vibration levels.
• Any abnormal vibrations indicate possible mechanical issues.
• Data analysis helps maintenance teams identify the exact problem before it leads to equipment failure.

Benefits:

✅ Helps in early detection of mechanical failures.
✅ Reduces the risk of sudden breakdowns.
✅ Enhances equipment lifespan by addressing minor issues before they escalate.

2. Thermal Imaging and Infrared Monitoring

This type of condition based maintenance is used to detect overheating components, which may indicate electrical faults, friction, or insufficient lubrication.

How It Works:

• Infrared cameras capture heat signatures of machines and electrical components.
• Temperature variations indicate potential issues such as worn-out bearings or electrical overloads.
• Maintenance teams can schedule repairs before failures occur.

Benefits:

✅ Non-contact method, meaning no interruption to operations.
✅ Ideal for detecting overheating in electrical circuits and rotating machinery.
✅ Increases safety by identifying overheating components before they fail.

3. Ultrasound-Based Condition Monitoring

Ultrasound monitoring is an advanced condition based maintenance method used to detect leaks, electrical discharges, and early-stage mechanical wear.

How It Works:

• Ultrasonic sensors detect high-frequency sound waves that are not audible to humans.
• Changes in sound patterns indicate air or gas leaks, bearing wear, or electrical discharges.
• Data is analyzed to determine the severity of the issue.

Benefits:

✅ Effective for detecting compressed air and gas leaks.
✅ Helps in identifying bearing defects before they become severe.
✅ Useful for monitoring high-voltage electrical components.

4. Oil and Fluid Analysis

Lubrication is crucial for machinery performance, and condition based maintenance techniques such as oil analysis help detect contamination, wear, and degradation in fluids.

How It Works:

• Oil and fluid samples are taken from machines for analysis.
• Tests measure contamination, viscosity, and presence of metal particles.
• Findings indicate potential failures due to lubrication issues or excessive wear.

Benefits:

✅ Extends the lifespan of machinery by ensuring proper lubrication.
✅ Helps identify early signs of internal wear and tear.
✅ Reduces maintenance costs by preventing unexpected breakdowns.

5. Electrical Monitoring Techniques

Electrical monitoring is a key part of condition based maintenance, especially for detecting faults in motors, transformers, and power systems.

How It Works:

• Sensors measure voltage, current, and resistance in electrical components.
• Deviations from normal readings indicate potential issues like loose connections or insulation breakdown.
• Timely maintenance prevents costly failures and downtime.

Benefits:

✅ Helps prevent electrical fires and power failures.
✅ Reduces energy waste by identifying inefficiencies.
✅ Increases safety by ensuring electrical systems operate within safe limits.

Also Read: A Step-by-Step Guide to Implementing Condition-Based Maintenance (CBM)

Condition Based Maintenance Strategy

A condition-based maintenance (CBM) strategy is a structured approach that uses real-time data and monitoring techniques to determine the ideal time for maintenance. 

Unlike traditional preventive maintenance, which follows a set schedule, CBM Maintenance ensures that maintenance is performed only when equipment shows signs of wear or failure, reducing unnecessary costs and improving efficiency.

Implementing an effective condition-based maintenance strategy requires advanced technologies such as IoT sensors, artificial intelligence (AI), and real-time data analytics to monitor machine health and predict potential failures.

How to Develop an Effective Condition-Based Maintenance Strategy

A successful condition based maintenance strategy should be tailored to an organization's specific operational needs. Here’s how to develop one:

1. Identify Critical Assets

Not all equipment requires condition based maintenance. Start by identifying the most critical assets those that impact production, safety, or operational costs the most.

2. Choose the Right Monitoring Techniques

Different equipment requires different CBM techniques, such as:

• Vibration monitoring for rotating machinery
• Infrared thermography for electrical and thermal systems
• Ultrasound monitoring for leak detection and bearing analysis
• Oil analysis for fluid-based systems

3. Deploy IoT and Sensor Technology

Condition based maintenance relies on IoT sensors to collect real-time data. These sensors track parameters such as temperature, pressure, vibration, and fluid levels, providing continuous insights into equipment health.

4. Integrate AI and Predictive Analytics

Artificial intelligence (AI) and machine learning analyze sensor data to detect patterns and predict potential failures. Predictive maintenance, an advanced form of condition-based maintenance, uses AI to forecast equipment deterioration and suggest optimal maintenance timing.

5. Establish a Data-Driven Decision-Making Process

Organizations need to develop a structured process to act on CBM insights. This includes:

• Setting up automated alerts for maintenance teams
• Defining thresholds for different types of equipment
• Establishing protocols for emergency and non-emergency maintenance

6. Train Employees and Build a CBM Culture

Technicians and operators must be trained to interpret sensor data, use CBM software, and take appropriate action. A company-wide shift towards condition based maintenance requires collaboration between maintenance teams, IT departments, and operations managers.

7. Measure Performance and Optimize Strategy

Regularly analyze CBM data to track performance improvements, cost savings, and equipment reliability. Adjust strategies based on findings to enhance overall efficiency.

Challenges and Solutions in Condition Based Maintenance

Challenges	Solutions
High Initial Investment	Start with high-priority equipment before full-scale implementation.
Data Overload	Use AI-powered analytics to filter relevant insights.
Technical Expertise Requirement	Provide training to maintenance and IT teams.
Integration with Legacy Systems	Use IoT gateways and APIs to connect old equipment.
Resistance to Change	Educate teams on the cost savings and efficiency improvements of CBM.

Condition Based Maintenance Checklist

A condition-based maintenance (CBM) checklist serves as a structured guide to ensure a successful CBM implementation. It includes key steps, necessary tools, and performance indicators to track success. 

This proactive approach allows businesses to reduce downtime, optimize maintenance schedules, and improve overall equipment efficiency.

Essential Components for Implementing Condition-Based Maintenance:

To successfully implement condition based maintenance, organizations must follow a systematic approach. Below are the essential components:

1. Asset Selection

• Identify critical equipment that requires condition based maintenance.
• Prioritize assets based on operational impact, failure history, and maintenance costs.

2. Data Collection and Monitoring

• Deploy sensors to monitor key parameters like vibration, temperature, pressure, and fluid levels.
• Implement real-time data tracking through IoT-connected devices.

3. Integration with CMMS (Computerized Maintenance Management System)

• Ensure that CBM data integrates with existing CMMS or ERP systems for efficient tracking.
• Automate maintenance alerts based on sensor readings.

4. Training and Workforce Development

• Educate maintenance teams on interpreting CBM data.
• Train staff to use predictive analytics and diagnostic tools.

5. Risk Assessment and Failure Prediction

• Use historical data to predict failures and establish risk levels.
• Implement AI-powered predictive models to enhance maintenance decision-making.

6. Maintenance Action Plan

• Define maintenance actions based on threshold triggers.
• Establish emergency and scheduled maintenance protocols.

Condition Based Maintenance System

A Condition-Based Maintenance system is a structured framework that helps organizations implement CBM effectively. It includes hardware (sensors and monitoring devices), software (analytics and dashboards), and integration capabilities with existing enterprise management tools.

Key Features of a Condition Based Maintenance System:

1. Real-Time Monitoring: Uses sensors to track parameters like vibration, temperature, pressure, and fluid levels.
2. Automated Alerts: Notifies maintenance teams when equipment conditions reach predefined thresholds.
3. Predictive Analytics: AI and machine learning algorithms analyze historical and real-time data to predict failures.
4. Remote Monitoring: Cloud-based CBM systems allow access to data from anywhere, enabling remote asset management.
5. Integration with Enterprise Systems: Connects with CMMS (Computerized Maintenance Management System) and EAM (Enterprise Asset Management) software for seamless maintenance planning.

Condition Based Maintenance Examples

Condition Based Maintenance (CBM) is widely used across industries to improve asset reliability, reduce downtime, and optimize maintenance costs. Below are real-world examples of how CBM is implemented in different industries, along with case studies showcasing its impact.

1. Manufacturing Industry

Example: CNC Machines in Automotive Factories

How CBM is used:

• Sensors monitor vibration, temperature, and lubrication levels in CNC machines.
• AI-driven analytics predict tool wear and trigger maintenance before breakdowns occur.

Impact:

• Reduces unplanned downtime by 30-40%.
• Improves production efficiency and extends machine life.

✅ Case Study: Ford Motor Company
Ford implemented Condition Based Maintenance in its assembly lines by installing IoT sensors on robotic arms and conveyor belts. This led to a 25% reduction in unexpected equipment failures and improved overall production efficiency.

2. Aviation Industry

Example: Aircraft Engine Monitoring

How CBM is used:

• Jet engines are equipped with sensors that monitor pressure, vibration, and temperature.
• Real-time data is transmitted to ground-based maintenance teams for predictive analysis.

Impact:

• Reduces mid-flight failures and ensures passenger safety.
• Optimizes engine maintenance, reducing airline operational costs.

✅ Case Study: Rolls-Royce “TotalCare” Program
Rolls-Royce uses Condition-Based Maintenance for aircraft engines by continuously monitoring their performance using advanced telemetry systems. This has helped airlines reduce maintenance costs by 15% and improve engine efficiency.

3. Healthcare Industry

Example: MRI and CT Scan Machine Maintenance

How CBM is used:

• Medical imaging machines have sensors that detect overheating, abnormal vibrations, and electronic failures.
• Maintenance teams receive automated alerts when conditions exceed normal thresholds.

Impact:

• Reduces machine downtime, ensuring uninterrupted patient diagnostics.
• Increases the lifespan of expensive medical equipment.

✅ Case Study: GE Healthcare
GE Healthcare implemented Condition-Based Maintenance in hospitals to monitor critical medical equipment. This led to a 20% decrease in equipment failures and improved patient care by ensuring machine availability.

Condition-Based Maintenance (CBM) is revolutionizing asset management by enabling businesses to transition from reactive maintenance to a proactive, data-driven approach. By leveraging real-time monitoring, IoT sensors, and AI-powered analytics, CBM helps industries reduce downtime, lower maintenance costs, and extend equipment lifespan.

As industries continue to evolve, Condition Based Maintenance will play a critical role in ensuring seamless operations, minimizing unexpected failures, and optimizing maintenance strategies for long-term success.

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