Catastrophic machinery failure in most cases can be avoided if the early symptoms are detected and appropriate action is taken. This is the essence of new condition monitoring technology which, if well conceived, can extend machine and component lives by as much as an order of magnitude. This paper discusses current condition monitoring methods including available sensor technology. Applications and rationale are also discussed.

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Somewhere in your plant there are all-important pieces of production equipment that simply must operate as intended-or else. And most likely the “or else” is too painful to even think about: injuries, catastrophic damage, contract penalties, irate customers, missed shipping dates, junked parts, ballooning costs, a sickly quarterly financial report, and so on. Those critical types of equipment are candidate for machine health monitoring.

To be more precise, the ideal candidates for machine health monitoring is one that is both expensive and sophisticated, provides a crucial and depended-upon work function, has extensive maintenance requirements, and presents a safety risk upon failure. While all mechanical systems don’t involve all those terms, many do meet one or more. And the advent of new sensor and computer technology has more than ever before made machine health monitoring a viable and cost effective technology that manufacturers can use to their advantage particularly today when the almost universal goal in manufacturing is to produce high-quality work at the lowest cost and at the most productive rate a machine can deliver.

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