Condition Monitoring for Metals & Steel

Run the math against $30K-$200K/hour for continuous casting 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 Metals & Steel Operations 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 Metals & Steel Operations operations) can see 10:1 or better.

Where OSHA hot work, EPA particulate requires documented preventive maintenance and equipment condition tracking, Condition Monitoring data provides the audit-ready evidence. Measurements traceable to ISO 17359 and ISO 13374, calibrated instrumentation records, written procedures, and finding-to-work-order tie-back. The program isn't structured to be a compliance tool — but the data it generates as a byproduct usually closes 60-80% of an inspector's questions about equipment condition.

Baseline is monthly on critical assets, quarterly on B-criticality. Metals & Steel environments often justify tighter intervals on a subset of assets — specifically those most exposed to rolling mill drive train, furnace integrity, crane reliability. The Condition Monitoring program scope at most Metals & Steel 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 $30K-$200K/hour for continuous casting for downtime cost. A single avoided unplanned shutdown on a critical asset usually pays for six to twelve months of program cost. Most Metals & Steel sites we work with see 3:1 to 6:1 program ROI inside year one, with higher figures at sites with higher hourly downtime costs. Sites with very high downtime costs ($100K/hr+ in some Metals & Steel operations) can see 10:1 or better.