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Imagine a critical motor on Line 4 has been seized. Production stops. The maintenance team scrambling, spare parts are not available in the store, and downtime expenses are mounting with each passing minute.
This nightmare of a run-to-failure was the order of the day over decades. Next came Preventive Maintenance (PM) replacement of oil and belts periodically. It was beneficial, but it created a different issue, namely, over-maintenance. You must have been repairing machines that did not require repair, wasting manpower and spares.
Industry 4.0 has provided an intelligent approach today. Rather than posing the question, "What is the next scheduled service?" We may inquire about the asset, how are you going just now? This is Condition-Based Maintenance (CBM). And modern CMMS software such as Cryotos makes it not only of aerospace giants anymore but also for your operation.
Condition-based maintenance is a maintenance strategy that monitors the real-time health of an asset to determine what maintenance needs to be performed. CBM dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure.
Think of it like the "Check Engine" light in your car. You do not change the engine because it is Tuesday, but when the sensor alerts you that something is wrong (pressure, temperature, or vibration), you find out.
The purpose of CBM is straightforward: optimization.
While powerful, CBM isn't a "plug-and-play" solution. It will involve a culture transformation from fixing to analyzing data. It requires that maintenance teams should get familiar with sensors and data thresholds and the integration of software systems.
Moving to CBM is a journey. Based on industry best practices, here is the roadmap to getting it right.
Don't slap sensors on every fan and pump. That is a recipe for bankruptcy and data overload.
You can't detect an anomaly if you don't know what "normal" looks like.
You have to have eyes on the machine (sensors) and a brain to interpret the data (CMMS).
Technology doesn't fix machines; technicians do. Your team needs to understand why they are responding to a vibration alert rather than a scheduled work order.
CBM implementations fail even when done with the best intentions. Watch out for these traps:
This is where Cryotos CMMS bridges the gap between complex data and simple action. We designed Cryotos to handle the heavy lifting of Industry 4.0, so you can focus on decision-making.
Here is how Cryotos solves the CBM puzzle:
Cryotos doesn't just store data; it acts on it.
Once the alert is triggered, Cryotos ensures the job gets done right.
You need a single source of truth.
CBM is time sensitive.
Since CBM allows you to plan repairs in advance, Cryotos helps you manage inventory precisely.
Condition-based maintenance is not only a buzzword but also the future of profitable manufacturing, which is sustainable. It transforms your staff into firefighting personnel rather than health staff. Nonetheless, CBM must have a strong digital foundation. You require a system that will be able to absorb sensor data, auto-process workflows, manage inventory, and give actionable insights.
Don't just wait for the next breakdown.
Ready to transform your maintenance strategy? Explore how Cryotos CMMS can seamlessly integrate IoT and CBM into your operations today.
