What is

Condition Based
Maintenance (CBM) and
How Do You Assign
Intervals?

Nancy Regan
 2/26

A Condition Based
Maintenance (CBM) task is
performed at a defined
interval to detect a Potential
Failure Condition so that
maintenance can be
performed before failure
occurs.
 3/26

In other words, maintenance

is performed only on the
evidence of need.
 4/26

CBM can be an effective way

to manage random Failure
Modes because most Failure
Modes give us a “warning”
that failure is in the
processing of occurring.

That “evidence” is called a

Potential Failure Condition.
 5/26

Some examples of Potential

Failure Conditions are
Increased vibration
Illuminated warning
lights
Gauge readings
Noise
Heat
etc.
 6/26

How can a Potential Failure Condition

be detected?
Using simple techniques such as
monitoring gauges or measuring
brake linings.

Employing more technically involved

methods such as vibration analysis
and oil analysis.

Continuous monitoring with devices

installed directly on machinery.
 7/26

Now we have to figure out how

often to look (e.g. inspect) for
the Potential Failure Condition
so that we don’t miss the failure.

That’s where the P-F Curve and

the P-F Interval come in.
 8/26

Welcome to the P-F Curve! The X-axis is

time/age (which can be considered in
any number of units like miles, hours,
cycles, etc.). The Y-axis is the Resistance
to Failure.
P-F Curve
 9/26

Let’s say we put a new item into

service. We're at the very top of the Y
axis, which means our Resistance to
Failure is at its greatest.
 10/26

But we know that degradation

eventually occurs. Most of the time, we
get a warning. That warning is called
the Potential Failure Condition.
 11/26

If we ignore the Potential Failure

Condition (or don‘t look for it),
eventually failure occurs.
 12/26

The point at which a Potential Failure

Condition is detectable to the point
that failure occurs is called the P-F
Interval.
 13/26

How often we do a CBM task

is determined by the P-F
Interval.

P-F Curve
 14/26

Let’s look at a simple example

and populate our P-F Curve.
Our Failure Mode is:
Filter clogs due to normal use
P-F Curve
 15/26
Once a new filter is installed, after a certain
period of time (it doesn’t matter how long),
the filter will start to clog. Now we need to
determine what the Potential Failure
Condition is. Let’s say it’s a differential
pressure of 5 psi.

Differential Pressure 5 psi

 16/26
Let’s say we define Failure as
Filter Clogs.

Differential Pressure 5 psi

Filter Clogs
 17/26
Now we have to determine how long the
P-F Interval is.

In other words, how long does it take to

go from a differential pressure of 5 psi to
Filter Clogs? Let’s say it’s 1 month.

Differential Pressure 5 psi

1 Month Filter Clogs

 18/26
To determine the CBM task interval, the
general rule of thumb is to take half of the
P-F Interval. In this example, we would
schedule the task: Record the
differential pressure every two weeks. If
greater than 5 psi, change the filter.

Differential Pressure 5 psi

Filter Clogs
1 Month
 19/26
Note: We must inspect at
intervals less than one month
or we will miss the failure.
That is the key to CBM.

Differential Pressure 5 psi

Filter Clogs
1 Month
 20/26
Note: You may record the
differential pressure for a year
or so before you find a
differential pressure of 5 psi.

Differential Pressure 5 psi

Filter Clogs
1 Month
 21/26
That does not mean you can increase the
inspection interval, because the
inspection interval is based on the P-F
Interval. In other words, how quickly
failure occurs once a Potential Failure
Condition is detectable.

Differential Pressure 5 psi

Filter Clogs
1 Month
 22/26
POINT: It doesn’t matter how often the
failure occurs. What matters is how
quickly failure occurs once the Potential
Failure Condition is detectable.

Differential Pressure 5 psi

Filter Clogs
1 Month
 23/26

Here are Four Key Points about CBM

1. CBM task intervals are NOT based
upon MTBF.

2. CBM task intervals are NOT based

upon the useful life of a component.

3. CBM task intervals are NOT based

upon criticality.

4. CBM task task intervals are based

upon the P-F Interval.
 24/26

This is a widely misunderstood

concept in our industry.

It is vital that everyone involved in

Maintenance and Reliability
understands the basics.

This is one of those essential

fundamentals that must be
understood and it goes a long way
to developing an effective
Reliability Culture.
 25/26

PS
In step 6 of Reliability Centered
Maintenance (RCM), you consider
CBM as a solution!
 26/26

Thank you for

reading!