USE CASE This document was generated for Shubham Kapoor on Saturday, January 18, 2020

Machine Condition Monitoring

Overview Early predictions on equipment malfunctions and service maintenance can be

automatically scheduled ahead of an actual part failure by installing sensors inside
equipment to monitor and send reports.
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Machine condition monitoring is used to determine the condition of a machine with

the intent to forecast mechanical wear and failure. The predicted data provides
health information about the machine and helps to predict machinery failure. The
monitoring equipment tracks changes in temperature, vibration, and output of
machines in order to detect an imbalance, corrosion, wear, misalignment, sediment
build-up, or poorly lubricated parts.
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Condition monitoring has gained importance in line with increased company focus
on productivity and asset utilization.
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Applicable Industries Equipment & Machinery

Applicable Functions Discrete Manufacturing

Maintenance

Use Case: Machine Condition Monitoring PAGE 1 OF 5

 This document was generated for Shubham Kapoor on Saturday, January 18, 2020

Case Studies

MachineMetrics helped Carolina Precision saved over $1.5M on

machine monitoring
Gary Bruner, the president of Carolina Precision Manufacturing, a contract manufacturer that
specializes in small-diameter, close-tolerance CNC Swiss turned parts, had a problem. Over
breakfast that m ...

Monitoring of Pressure Pumps in Automotive Industry

A large German/American producer of auto parts uses high-pressure pumps to deburr machined
parts as a part of its production and quality check process. They decided to monitor these pumps to
make sure ...

ThermalSpection™ CVM
Critical vessels in the chemicals, refining, and power industries operate at high temperature and
pressure and are at risk of failure as joints and refractory degrade. The consequences of
undetected f ...

Market Size

Estimate A The machine condition monitoring market was valued at USD 2.21 billion in 2017
and is expected to reach USD 3.5 billion by 2024, at a CAGR of 6.7% during the
forecast period.
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Source: Markets and Markets

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Machine Condition Monitoring Equipment Market to Cross $3.2 Billion by 2023.

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Source: P&S Intelligence

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Estimate B The global Machine Condition Monitoring market is expected to reach USD 2.91
billion by the end of 2023 with 5.55% CAGR during forecast period 2017-2023.
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Source: MaretResearchFuture

Estimate C According to Stratistics MRC, the global machine condition monitoring market is
accounted for USD 2.11 billion in 2017 and is expected to reach USD 4.45 billion

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by 2026 growing at a CAGR of 8.6%.

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Source: Stratistics MRC

User Viewpoint

Business Value How does machine condition monitoring impact an organization’s

performance?

LeonardWiedenroth
Answered Friday, Jul 27, 2018

The use of machine condition monitoring allows maintenance to be scheduled, or

other actions to be taken to prevent consequential damages and avoid its
consequences. It has a unique benefit in that conditions that would shorten normal
lifespan can be addressed before they develop into a major failure.

Key Performance How is the success of the machine condition monitoring system measured
Indicators
for users and for the business?

LeonardWiedenroth
Answered Friday, Jul 27, 2018

There are two important values which businesses should measure regularly on
machines:
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Overall Velocity in mm/s (inch/s) - lower frequency range - which indicates the
general machine condition
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Overall Acceleration in g – higher frequency range – which indicates the bearing

condition

System Capabilities & What are the typical capabilities of machine condition monitoring?
Requirements

LeonardWiedenroth
Answered Friday, Jul 27, 2018

Techniques applied in the industrial and transportation sectors include:

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Vibration analysis and diagnostics

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Use Case: Machine Condition Monitoring PAGE 3 OF 5

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Lubricant analysis
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Acoustic emission
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Infrared thermography
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Ultrasound testing
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Motor condition monitoring and motor current signature analysis (MCSA)

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Model-based voltage and current systems (MBVI systems)

Technology Viewpoint

Sensors What sensors are typically used to provide machine condition monitoring
data into the IoT system, and which factors define their deployment?

LeonardWiedenroth
Answered Friday, Jul 27, 2018

Vibration sensors, infrared sensors (thermal infrared and quantum infrared

sensors), velocity sensors and transmitters.

Implementation Viewpoint

Integration Challenges What integration challenges could impact machine condition monitoring
deployment?

LeonardWiedenroth
Answered Friday, Jul 27, 2018

Continuity of services must be considered. Vulnerabilities to IT operations need to

be identified to minimize impact on the system.

Installation Challenges What installation challenges could impact machine condition monitoring
deployment?

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LeonardWiedenroth
Answered Friday, Jul 27, 2018

System that are installed must fit into the plant IT infrastructure even when minimal
connectivity is maintained.

Use Case: Machine Condition Monitoring PAGE 5 OF 5

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