Every condition monitoring technique your assets need, from one team
Wireless vibration and temperature sensing is where most programs start. It is not where they end. We combine seven techniques so each failure mode is watched by the method that catches it earliest.
7
Condition monitoring techniques
3
Plant areas covered: material handling, process, utilities
1
Alert-to-repair workflow for all of them
Sensing techniques
Seven ways to see a failure coming
Vibration analysis
Finds signs of mechanical failure in vibration patterns, early enough to plan the repair.
Performance monitoring
Tracks equipment parameters, efficiency and deviations from normal operating conditions.
Data-driven analytics
Machine learning on historical data to predict equipment failures and maintenance needs.
Ultrasonic testing
Finds leaks, mechanical faults and electrical issues in high-frequency sound.
Acoustic emission
Finds defects and stress-related issues in the sound waves equipment gives off while it runs.
Thermography
Thermal imaging shows abnormal heat patterns that point to electrical or mechanical issues.
Oil analysis
Lab samples show wear, contamination and lubrication quality inside the machine.
Matching technique to failure
Which technique catches what
| Failure mode | First technique | How it is confirmed |
|---|---|---|
| Bearing wear | Vibration and temperature | Ultrasonic listening tool |
| Misalignment and imbalance | Vibration analysis | Alignment check on the coupling or pulley |
| Overheating motor | Temperature trend | Infrared camera to pinpoint the heat source |
| Electrical connection faults | Thermography | Panel inspection |
| Gearbox wear and oil leaks | Vibration analysis | Oil analysis and visual inspection |
| Compressed air and vacuum leaks | Ultrasonic testing | Leak survey |
| Gradual efficiency loss | Performance monitoring | Process data review |
Business value
What changes when condition monitoring is in place
| From | With condition monitoring | Business outcome |
|---|---|---|
| Reactive maintenance: fix when failed | Proactive corrective action | Lower unplanned downtime cost |
| Scheduled preventive maintenance | Fewer unnecessary PMs, more productive technicians | Lower preventive and reactive maintenance spend |
| Periodic outsourced vibration route | A continuous, self-managed monitoring program | Problems found between routes, not at the next visit |
| Below-target OEE | Better uptime on rotating equipment | Higher OEE and on-time delivery |
| Failed batches after unplanned stops | Fewer stops mid-batch | Less scrap |
Why it is hard alone
The three barriers, and how the program removes them
| Barrier | How we remove it |
|---|---|
| Sensors are expensive to install and retrofit | Pre-configured wireless sensors and gateways: no wiring, no development work |
| Capturing and moving the data securely takes infrastructure | Tactical Edge runs the cloud pipeline, the data lake and the integrations as part of the program |
| Turning sensor data into failure warnings takes data science skills | ISO 20816 vibration rules and machine learning anomaly models come built in, tuned with technician feedback |
Not sure which technique fits?
The free assessment ranks your assets and matches each failure mode to the technique that catches it first.