Find the failures that cost you most, before you buy anything
A reliability engineer spends half a day on your floor with your maintenance and operations leads, then builds a business case and a working-backwards plan from your own failure history. There is no charge for the assessment.
Half a day
On your floor with maintenance and operations leads
12 months
Of your maintenance and downtime records behind the business case
No charge
For the visit, the business case and the plan
What you get
Three things you keep, whether or not you work with us
Half-day site visit
We walk the floor with your maintenance and operations leads to find critical, high-maintenance and hard-to-access assets, and the failure modes behind them.
Business case
Built from twelve months of your maintenance records, downtime logs and production statistics: the problem statement, the business impact, your pain points and what you need from a solution.
Working-backwards plan
A staged plan from site visit to scaled deployment, with the target assets, success criteria and alert-to-repair workflow a pilot would need.
Working backwards
From the failures that hurt to a scaled deployment
We start from the failures that cost you production, not from the sensor catalog. Each stage has a clear output before the next one starts.
- 1Identify
Site visit
- Key pain points
- Critical assets
- High-maintenance assets
- Hard-to-access assets
- Failure modes
- 2Define
Business case
- Problem statement
- Business challenges
- Business impact in hours and dollars
- Business goals
- Business needs
- 3Plan
Pilot planning
- Target use cases
- Success criteria
- Alert-to-repair workflow
- Resources needed
- 4Test
Pilot
- Asset installation
- Training
- Alert management
- Measured results
- 5Launch
Deployment
- Business proposal
- Budget and IT approval
- Deployment plan
- Scaled rollout
On the floor
The questions the site visit answers
Where do we have a problem? What is critical? What is expensive to repair? We look across three plant areas.
Material handling
- Conveyor rollers and bearings
- Motors and gearboxes
- Lifting station motors
- Sorters, merges and inclines
Process equipment
- Mixing and extruding equipment
- Hydraulic and refrigeration pumps
- Chiller pumps
- Wood chippers and shot blasting
Utilities and auxiliary equipment
- Cooling water pumps and cooling tower fans
- Air compressors and vacuum pumps
- Exhaust fans
- Air handling units
Failure modes
What we check each asset for
| Failure mode | Where it shows up | How it is usually found |
|---|---|---|
| Imbalance | Fans, motors, rotating shafts | Rising vibration at running speed |
| Misalignment | Motor to pump and motor to gearbox couplings, pulleys | Vibration trend, then a laser or straightedge check |
| Looseness | Mounting bolts, bases, bearing housings | Vibration spikes, then a torque check |
| Bearing wear and bearing creep | Motors, idlers, pillow block bearings | Vibration and temperature trend, confirmed with ultrasonic listening |
| Cavitation | Pumps | Vibration pattern after a valve or setpoint change |
| Belt tracking and belt alignment | Conveyor and drive belts | Vibration on the drive motor, then a visual check |
| Drive shaft and key damage | Couplings and keyed shafts | Vibration trend, then inspection |
| Debris build-up | Belt drives, rollers | Temperature rise at the bearing |
| Electrical connections | Motor terminals and panels | Heat found with thermography |
Sensor plan
Where the sensors go
Led by a reliability engineer with your site maintenance team.
Locate the target assets
Walk the site floor and confirm each asset on the list, with its position name.
Pick the sensor positions
Mount each sensor close to the failure point: the idler bearing, the gearbox, the motor bearing.
Plan the gateway
Find the power source and network connection for each gateway, within signal range of its sensors.
Sensor count
How many sensors you will need
A starting point per asset type. The site visit sets the final count per asset.
| Asset type | Sensors |
|---|---|
| Electric motor (small) | 1 |
| Electric motor (large) | 2 |
| Fan | 2 to 4 |
| Bearing | 1 |
| Compressor | 2 |
| Gearbox | 2 |
| Pump | 2 |
| Conveyor | 2 to 4 |
Business case
What the business case looks like
Illustrative example for a site with 500 motors and pumps. We replace every number with yours during the assessment. Model inputs: 500 motors and pumps, 200 failures per year on critical motors and pumps, 10 technicians, a three-month manual inspection round.
Problem statement
The site sees 200 failures a year on critical motors and pumps, causing unplanned downtime. Root cause: mechanical issues such as bearing wear, misalignment and imbalance.
Business challenge
Ten technicians inspect 500 motors and pumps by hand. One full round of inspections takes three months, so failures develop between visits.
Business impact (modeled)
- 300 hours of unplanned downtime a year
- $5M a year in unplanned downtime cost per site
- $500K a year in reactive maintenance spend
Business needs
- Vibration and temperature condition monitoring to track rotating equipment remotely
- Work orders created automatically from abnormality alerts, so critical issues get a fast response
Beyond maintenance
The same visit can cover more than rotating equipment
Tell us when you book, and we will add one of these to the visit.
Process optimization
A first look at one production line: where flow stalls, where cycle times and staffing are out of balance, and whether a full value stream mapping review would pay off.
Computer vision
We review one quality inspection or line visibility use case with you, using your camera positions or sample footage, and tell you whether vision can catch it.
AI development
We scope one AI use case against the data you already have, such as a maintenance assistant over your work order history, and outline what it would take to build.
Questions about the assessment
What does the free assessment include?
A half-day site visit, a business case built from your records, and a working-backwards plan for a pilot. There is no charge for any of the three. If you decide to run a pilot afterwards, we quote it separately.
What data should we share?
Twelve months of maintenance records, downtime logs and production statistics. If some of it is missing, we build the business case from what you have and mark the gaps.
Who should be there on the day?
Your maintenance and operations leads, and ideally the technician who knows the problem assets best. From our side, a reliability engineer leads the visit.
We already run Amazon Monitron. Is this still useful?
Yes. Amazon Monitron is no longer available to new customers, and we offer a separate transition plan for sites that run it today. The assessment is a good way to decide which assets to move first.
Book your free assessment
Tell us about the site and the assets that worry you. We will propose a date for the visit and the records to bring.