Condition Monitoring for Manufacturing

monthly on critical, quarterly on B-criticality as the starting baseline. Reliability Consulting for Manufacturing Facilities environments often justify tighter intervals on a subset of assets — specifically those most exposed to bearing failures, misalignment, gearbox wear. The Condition Monitoring program scope at most Reliability Consulting for Manufacturing Facilities sites we work with covers 30 to 80 critical assets in detail with broader screening on the supporting equipment. Cost works out to $180-$300 per asset per month for the detailed assets.

Run the math against $3K-$25K/hour per line for downtime cost. A single avoided unplanned shutdown on a critical asset usually pays for six to twelve months of program cost. Most Reliability Consulting for Manufacturing Facilities sites we work with see 3:1 to 6:1 program ROI inside year one, with the higher figures showing up at sites with higher hourly downtime costs. Sites with very high downtime costs ($100K/hr+ in some Reliability Consulting for Manufacturing Facilities operations) can see 10:1 or better.

Direct experience at Manufacturing sites is non-negotiable. Generic industrial Condition Monitoring skills don't transfer cleanly to Manufacturing because of mixed loads, press and conveyor populations and the regulatory layer (OSHA general industry, EPA non-attainment areas). Ask for the lead analyst's hours of Manufacturing-specific work, certifications relevant to ISO 17359 and ISO 13374, and references from comparable plants in the same industry segment. Vendor-provided references screen positive almost universally — call them directly.

Baseline is monthly on critical assets, quarterly on B-criticality. Manufacturing environments often justify tighter intervals on a subset of assets — specifically those most exposed to bearing failures, misalignment, gearbox wear. The Condition Monitoring program scope at most Manufacturing sites we work with covers 30 to 80 critical assets in detail, with broader screening on the supporting equipment. Cost works out to $180-$300 per asset per month for the detailed assets.