Condition Monitoring for Plastics & Rubber

Where OSHA machine guarding, EPA VOC 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.

Site walk to scope the asset population, criticality scoring of the extruder gearbox wear, injection mold hydraulics, calender alignment, baseline measurements on the top 30-60 assets, then a regular cycle of monthly on critical, quarterly on B-criticality. Findings get written up against ISO 17359 and ISO 13374. For Reliability Consulting for Plastics & Rubber Manufacturing facilities the engagement usually includes coordination with the plant's existing compliance program — pulling Condition Monitoring results into the OSHA machine guarding, EPA VOC audit file. Initial scope runs $15K-$45K depending on asset count, then ongoing at $180-$300 per asset per month.

Run the math against $5K-$25K/hour for extrusion line for downtime cost. A single avoided unplanned shutdown on a critical asset usually pays for six to twelve months of program cost. Most Plastics & Rubber 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 Plastics & Rubber operations) can see 10:1 or better.

Where OSHA machine guarding, EPA VOC 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 to 80 percent of an inspector's questions about equipment condition.