Should all machines be included in a condition monitoring program?

Condition monitoring is a strategic approach that focuses on assessing the health and performance of machinery in order to predict failures and optimize maintenance. While it might seem beneficial to monitor every machine, practicality and resource allocation play key roles in implementing an effective condition monitoring program.

Including all machines in a condition monitoring program may lead to unnecessary resource consumption, increased costs, and ineffective data management. Not all machines may present the same level of risk or operational importance. Consequently, it becomes essential to prioritize monitoring efforts based on factors such as the criticality of the machinery, its operational impact, the environment in which it operates, and historical failure data.

Monitoring programs typically focus on critical machinery, which are essential for production continuity, or those with high maintenance costs. This targeted approach allows for more effective use of time and resources, resulting in improved reliability while avoiding the pitfalls of overwhelming data for machines where condition monitoring may not provide significant benefits. Furthermore, less critical or redundant machines can be monitored periodically without the intensity of a full-time program, ensuring that maintenance resources are spent efficiently.

Therefore, while condition monitoring is an invaluable tool, it should be applied judiciously, resulting in the decision to exclude all machines from such programs unless warranted by their importance to operations or risk assessment.