What are the Challenges in Condition-Based Maintenance?

In today's fast-paced and interconnected world, industrial machinery and equipment are critical in driving productivity and efficiency. Maintenance strategies have evolved from reactive approaches to more proactive and predictive methods to ensure optimal performance and minimize unexpected downtime. One such approach gaining significant traction is condition-based maintenance (CBM).

Challenges Faced While Implementing Condition-Based Maintenance

Condition-based maintenance relies on real-time data and analytics to monitor the health of equipment, detect potential failures or abnormalities, and schedule maintenance activities accordingly. This data-driven approach offers numerous benefits, including cost savings, improved equipment reliability, and increased operational efficiency. However, like any transformative initiative, implementing CBM has its challenges.

This blog post will explore the intricacies of implementing condition-based maintenance and the hurdles organizations often encounter.

Understanding Condition-Based Maintenance (CBM)

Condition-Based Maintenance (CBM) is a proactive maintenance strategy that focuses on monitoring the actual condition of assets to determine maintenance needs. It allows organizations to optimize maintenance activities, reduce costs, and improve asset reliability.

Preventive Maintenance Vs. Reactive Maintenance Vs. Condition Based Maintenance

Aspect Preventive Maintenance Reactive Maintenance Condition Based Maintenance
Timing of Maintenance Fixed schedule based on intervals After failure or breakdown occurs Based on actual asset condition data
Data-Driven Decision Making Relies on predetermined schedules or historical data No data-driven decision-making Uses real-time or periodic condition monitoring data
Maintenance Optimization Results in over-maintenance or unnecessary component replacement No optimization addresses failures after they occur Optimizes maintenance based on actual asset condition
Cost and Resource Efficiency May lead to higher maintenance costs Potential higher repair costs and unplanned downtime Potential cost savings by reducing unnecessary maintenance and optimizing resource allocation

Importance of Condition-Based Maintenance

CBM offers several advantages over traditional maintenance approaches, such as preventive or reactive maintenance. By leveraging real-time data and condition monitoring techniques, CBM enables organizations to:

  • Reduce unplanned downtime and production losses.
  • Extend asset lifespan through timely and targeted maintenance.
  • Optimize maintenance schedules and resource allocation.
  • Minimize unnecessary maintenance tasks and associated costs.
  • Improve Overall Equipment Effectiveness (OEE) and asset performance.

Challenges Faced in Condition-Based Maintenance

CBM offers several advantages over traditional maintenance approaches, such as preventive or reactive maintenance. By leveraging real-time data and condition monitoring techniques, CBM enables organizations to:

Technological Challenges

One of the biggest challenges in implementing CBM is dealing with the technological complexity that comes with it. From sensors to Internet of Things (IoT) devices to Big Data analytics, CBM requires integrating various complex technologies. The learning curve associated with these technologies can be steep, and errors in usage can lead to inaccurate results, further complicating maintenance procedures. Let's delve a little deeper into these technical challenges:

Data Overload
CBM systems generate vast amounts of data from equipment sensors. This data must be collected, stored, and analyzed for meaningful insights. Managing this data flood can be overwhelming. Employing data management techniques like data cleaning, integration, and transformation can help streamline the process.
Integration with Existing Systems
CBM doesn't operate in a vacuum. It must work in sync with existing maintenance management systems, Enterprise Resource Planning (ERP) systems, production planning tools, etc. Ensuring smooth integration can be daunting, often requiring substantial time and resources.
Accuracy of Sensors
The quality of insights derived from CBM is only as good as the data collected. Faulty sensors can give incorrect readings, leading to false alarms and unnecessary maintenance tasks. Regular system checks and sensor calibrations can help manage this issue.
Defining Threshold Values
CBM systems rely on threshold values to determine when maintenance is necessary. These values must be accurately defined based on understanding machine behavior and operating conditions. Failure to do so can lead to maintenance being performed too early or too late, neither of which is desirable.
Financial Challenges

CBM's implementation can be a costly affair. Significant expenses are associated with acquiring new hardware, software, training staff, and possibly hiring new personnel. Small and medium-sized enterprises (SMEs) might find these costs daunting.

Initial Investment
The hardware (sensors, IoT devices, etc.) and software (data analytics tools, CMMS, etc.) required for CBM can come with hefty price tags. These costs can pose a significant challenge, especially for SMEs.
Maintenance Costs
CBM systems themselves require periodic maintenance to ensure they're working optimally. These costs, if not accounted for, can eat into the expected ROI of CBM implementation.
Training Costs
As we mentioned earlier, CBM involves the use of complex technologies. Your workforce needs to be trained to handle these technologies effectively. And high-quality training doesn't come cheap.
Cultural Challenges

Organizational culture can often impede CBM implementation. Employees used to traditional maintenance approaches might resist the change, viewing CBM as an unnecessary complication. However, the right change management strategies can help overcome this resistance.

Resistance to Change
This is a common challenge in any significant change initiative. Clear communication about the benefits of CBM and appropriate training can help manage this resistance.
Skill Gap
CBM requires specialized skills for data interpretation and system management. If your existing workforce lacks these skills, you'll need to invest in training or hire new personnel, both of which can be challenging.
Regulatory Challenges

CBM strategies must align with these standards in industries where regulatory compliance is crucial. For example, in the pharmaceutical industry, the FDA requires stringent documentation of maintenance activities, which must be kept in mind while implementing CBM.

Steps to Overcome the Challenges

Establish Clear Objectives and Strategy

Define clear goals, objectives, and performance indicators for CBM implementation. Develop a comprehensive strategy that aligns with the organization's maintenance goals and long-term vision.

Invest in Data Management and Integration

Implement robust data management systems to collect, store, and integrate condition monitoring data. Ensure data accuracy, reliability, and standardization. Leverage CMMS platforms like Cryotos CMMS to integrate CBM data with maintenance workflows seamlessly.

Develop Expertise and Training Programs

Invest in training and upskilling programs to develop in-house expertise in condition monitoring techniques, data analysis, and predictive maintenance. Encourage collaboration and knowledge sharing among maintenance teams.

Select and Implement Appropriate Technologies

Thoroughly evaluate condition monitoring technologies, considering asset type, criticality, and cost-effectiveness factors. Engage with vendors, conduct pilot projects, and validate technologies before full-scale implementation.

Focus on Change Management

Communicate the benefits of CBM to all stakeholders and emphasize the positive impact on operations, asset performance, and organizational goals. Involve and engage employees throughout the implementation process. Provide training, support, and incentives to encourage acceptance and adoption of CBM practices.

Cryotos CMMS and Condition-Based Maintenance

Cryotos CMMS (Computerized Maintenance Management System) can be crucial in supporting and facilitating Condition-Based Maintenance (CBM) practices. Here are some ways Cryotos CMMS can help in CBM:

Data Collection and Integration

Cryotos CMMS provides the capability to integrate with various condition-monitoring sensors and devices, enabling the collection of real-time data on asset conditions. It can gather data on parameters such as vibration, temperature, pressure, and other performance indicators.

Centralized Data Storage

Cryotos CMMS serves as a centralized repository for storing condition data collected from assets. It organizes and stores the data securely, making it easily accessible for analysis and decision-making. This centralized data storage enhances data management efficiency and eliminates the need for manual data handling.

Real-Time Monitoring

Cryotos CMMS can monitor asset conditions in real-time by integrating with IoT devices and sensors. This allows continuous monitoring and provides immediate alerts or notifications when condition thresholds are exceeded or anomalies are detected. Real-time monitoring facilitates prompt actions and interventions when necessary.

Condition Data Analysis

Cryotos CMMS offers robust analytics and reporting capabilities. It can analyze the collected condition data, identify patterns, and generate reports or visualizations to provide insights into asset health, trends, and potential risks. The system's analytics capabilities enable data-driven decision-making and proactive maintenance planning.

Triggering Maintenance Tasks

Based on the analysis of condition data, Cryotos CMMS can trigger the initiation of maintenance tasks. It can automatically generate work orders or tasks for maintenance technicians when asset conditions indicate a need for intervention. This proactive approach ensures that maintenance tasks are performed at the right time, optimizing asset performance and minimizing downtime.

Maintenance Workflow Optimization

Cryotos CMMS helps optimize the maintenance workflow for condition-based maintenance. It can automatically prioritize maintenance tasks based on asset condition data and criticality. This ensures that resources and efforts are allocated efficiently, focusing on assets that require immediate attention and reducing unnecessary maintenance activities.

Historical Data and Trend Analysis

Cryotos CMMS maintains a historical record of asset conditions, maintenance activities, and performance data. This historical data can be used for trend analysis, identifying patterns, and predicting future asset behavior. It supports the development of predictive maintenance strategies and enhances the effectiveness of condition-based maintenance practices.

Documentation and Audit Trail

Cryotos CMMS captures and documents all maintenance activities related to condition monitoring and CBM. This documentation provides an audit trail of actions taken, allowing for traceability, compliance, and historical reference. It also aids in analyzing the effectiveness of CBM strategies over time.


Implementing Condition Based Maintenance offers significant benefits but has its share of challenges. By recognizing and addressing these challenges head-on, organizations can successfully overcome them and unlock the full potential of CBM. Organizations can streamline maintenance practices by investing in the right technologies, data management, expertise development, and change management strategies. This, in turn, enhances asset reliability and helps achieve long-term operational excellence.

By leveraging the capabilities of Cryotos CMMS, organizations can effectively implement and manage Condition Based Maintenance. The system facilitates real-time monitoring, data analysis, proactive maintenance planning, and optimization of maintenance workflows, ultimately improving asset reliability, reducing downtime, and optimizing maintenance costs. Don't miss out on our expertise; get in touch with us today!


Condition-based Maintenance: A Complete Guide

The Challenges of Implementing Condition-Based Maintenance

Opportunities and Challenges in Condition-Based Maintenance Research

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What Do Our Clients Says ?

Amrapali Exports - Esteemed Clients of cryotos
Anuraj Sharma - Maintenance Manager

The best thing about Cryotos CMMS software is that it always tells me when something needs to be fixed - before it breaks and cost me a fortune!

The software is very user-friendly, and even if I don't know how to do something, the support team is always there to help me out.

Most importantly, unlike other such software, Cryotos is editable and hence the user can modify how the software works as per their need, we made several changes in the workflow & flowchart with the help of development team.

I don't know what I would do without Cryotos! I've been using it for years, and it has saved me so much time and money. I highly recommend it to anyone who wants to manage their assets efficiently.

Resil Chemicals - Esteemed Clients of Cryotos
Jeevan Belliappa - Head, Information Technology

Since we've been using Cryotos CMMS Software, our asset maintenance management has been running more smoothly than ever. We're able to track and optimize our preventive maintenance with ease, thanks to the customized process workflow. This has been a lifesaver for our team!

The Cryotos CMMS software has allowed us to manage our assets more effectively and efficiently. It has helped us to improve our asset utilization. The software is user-friendly and easy to navigate, and the support team is always quick to help with any questions we have. We're very happy with the results we've seen so far and we're confident that we'll continue to see improvements in our asset management as we use the Cryotos CMMS software.

Planys - Cryotos Esteemed Client
Antony Jacob Ashish - Lead, R&D

Cryotos goes above and beyond when it comes to customer satisfaction. Planys Technologies use Cryotos for preventive/ corrective maintenance of our critical systems and not once did we face a problem that was not dealt with immediately. The team is extremely professional and helpful. We can rely on Cryotos when it comes to the operations and processes.

Thanks to the whole team for the amazing performance and thought leadership. It's rare to see teams that can put themselves in the customer's shoes and think from their perspectives - Cryotos team doesthat and more.

We recommend Cryotos if you are looking to put an end to your preventive maintenance problems and sign up with them!

Thanks to the team for an awesome job.

Xpert IFM - Esteemed Clients of Cryotos
Siva Shankar - AGM, (Operations & BD)

On behalf of Xpert FMS we would like to express our sincere appreciation for the excellent support Cryotos team have provided us for our building and facility management. Cryotos has always provided support that is timely and meets our expectations. Professionalism and quick response are the hallmarks of this team.

Sincere appreciation for the team's brilliant performance and wish them continued success. We highly recommend Cryotos as they have executed well on all assigned tasks and continue to outperform.

Thanks to all the hard work, our lives have become easier.

ST Jude India Childcare Centers - Cryotos Esteemed Client
Mukesh J - CIO

We are able to raised the workorder and tracking of these till the closure as helped us to provide better services our beneficiaries. Workflow-based work order management has helped us to define processes for each locations separatley. System provide notification once order is raised for assignment to engineer.

Maspro - Esteemed Clients of Cryotos

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Al Zain Farms LLC - Esteemed Clients of Cryotos
Mr. Vishnu S Nair

Since we've started using Cryotos, our team has been able to stay on top of all the various SOPs. Checklists and safety procedures are now easily accessible to everyone, and we can quickly reference them whenever we need to. The software has definitely helped to improve our team's communication and efficiency. Plus, the fact that it's cloud-based means we can access it from anywhere, which is a big plus. It has been a great help in keeping everyone on the same page and up to date with the latest procedures.

Dinex - Esteemed Clients of Cryotos
B S Vijaya K. - Maintenance Engineer

At starting it felt some what difficult for scheduling but now it made to easy access.

Review from Capterra

Korrun - Esteemed Clients of Cryotos
Nithin G. - Maintenance Incharge

Overall: Nice Software
Pros: Scheduling, work order creation, asset inventory, records.
Reasons for Choosing Cryotos: Compared to other products it's easy to use and easy to understand the feature.

Review from Capterra

Aptiv8 IT Solutions
Hashim - Business Project Manager

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Gurit - Esteemed Clients of Cryotos
Mr. Mohanmurali R

I recently purchased Cryotos CMMS Software for asset management needs at my organization and after a few months of testing and monitoring, I'm incredibly pleased with the results. The software is user friendly, accessible and the design is very intuitive. It covers all the aspects of managing maintenance and repair, starting from preventive maintenance and standardizing operation cycles, to scheduling and streamlining workflows. I am highly satisfied with the performance and the range of features offered by Cryotos. Highly recommendable!

Metro Tyres - Esteemed Clients of Cryotos
Mr. Sanjay Beri

Before using Cryotos, asset management and maintenance seemed like an uphill task for my team. Manual processes laden with human errors did not work for us at all. We decided to go with Cryotos after checking out similar products in the market.

The user interface of the software is intuitive and easy to use, making it simple to navigate through the different features and functionalities. I particularly appreciate the ability to track all assets in real-time, allowing me to keep a close eye on their performance and maintenance needs.

Customized work order and workflow creation has reduced the needs to always follow a particular template. Depending on our needs we can create tailor made workflows to suit our requirements.

I highly recommend Cryotos to anyone who would like to unburden themselves of maintaining and managing their critical assets.

Dinex - Esteemed Clients of Cryotos
Mr. Yuksel Aksin

As a customer of Cryotos CMMS software for asset management needs, I must say that I am thoroughly impressed with the features and functionality offered by the platform. Cryotos CMMS software has made managing my assets a breeze, and I no longer have to worry about missing maintenance or inspections.

One of the standout features of Cryotos CMMS software is the ability to generate work orders and schedule maintenance tasks. This has made it easy for me to stay on top of maintenance and repair tasks, ensuring that my assets are always in optimal condition.

The software also allows me to track inventory levels which has streamlined my inventory management process. The ability to generate reports and analyze asset performance data has also been invaluable in helping me make data-driven decisions about my assets. Overall, I would highly recommend Cryotos CMMS software to anyone looking for a reliable and efficient asset management solution.

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