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The Top 3 Condition Monitoring KPIs

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117 views10 pages

The Top 3 Condition Monitoring KPIs

Uploaded by

satya krishna chaganti
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© © All Rights Reserved
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Magazine: April 2022

The Top 3 Condition


Monitoring KPIs
Wes Cash, Noria Corporation

Condition Monitoring is becoming the mainstay for maintenance


and reliability groups in virtually all industries; as such, there
needs to be a system in place to demonstrate the effectiveness
of the activities involved. While it is hard to argue the impact of
detecting problems early, the question remains: how in-tune are
we with our equipment? The best condition monitoring programs
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utilize metrics to answer this question along with others. What


follows are are the top three condition monitoring Key
Performance Indicators (KPIs) in no particular ranking.

Percent abnormal

readings/measurements/results
-
The key to good condition monitoring is to take routine
measurements in the field. These may include oil or grease
samples, vibration readings, ultrasonic inspections and myriad
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others. When we interpret these measurements, we should be
looking to find the equipment that is in an “alarm” or “abnormal”
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state. By comparing the number of machines in this state
compared to the total number of machines in the program, this
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percentage takes shape. Programs in their infancy are often
inundated with the number of problem samples coming back, so
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this serves as a metric to show the evolution of the program over
time as well as a leading indicator of unplanned downtime. While
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the goal is to have as low of a percentage as possible, it is likely
that some percentage of equipment will be flagged for some
reason, such as contamination, fluid health or machine health.
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person (non-
instrument)
inspections -
Much emphasis is put on the
technology side of condition
monitoring, but it’s important to remember the value of the daily
inspection. This KPI is so important because it can be a shared
metric across multiple departments within the facility. It is not
uncommon for mechanics, operations and lube technicians to all
have a set of daily routes and rounds that they have to
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accomplish at the beginning of their shifts. Since we have
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the abnormalities or problems found during these events.
Remember that what gets measured gets done; all too often, the
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never to be reviewed. By having a dashboard or bulletin board
indicating the number of “saves” found by the inspectors, you can
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promote a culture of equipment care across multiple sets of
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Finding problems early is the ultimate
goal of condition monitoring, but we need to look beyond finding The Care and Selection of Lubricants for S…
the issues and work to determine how well we are correcting the
problems. This can be done based upon how long the equipment
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stays in an “alarm” state and, even better, can be crossed with the
specific action taken to remediate the problem. Not only will this
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metric answer the question of “are we addressing the problems,”
but it also serves as the beginning of a decision matrix that
should be developed for each type of alarm that is triggered
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when the equipment develops issues. The matrix can be
reviewed and makes the troubleshooting and correcting of the
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problem much simpler as opposed to just guessing at what may
fix the issue. Obviously, good documentation is key to this one as
the information recorded in the decision matrix will serve as the
foundation for equipment corrective action in the future.

While there are many more metrics that


could be measured and tied to specific
condition monitoring activities, starting
with the few key metrics will help narrow
the focus of the program to exactly what
we are trying to achieve.

About the Author


Wes Cash
Wes Cash is the director of technical services for Noria
Corporation. He serves as a senior technical consultant for
Lubrication Program Development projects and as a senior
instructor for ... Read More

Machinery Lubrication (4/2022)

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The widespread adoption of industrial robotics has revolutionized


manufacturing processes across the globe. The efficiency and
precision that robots bring to various industries are undeniable,
but with great innovation comes great responsibility. Proper
lubrication is a cornerstone of effective robotics maintenance,
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However, the supply chain challenges associated with sourcing
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