Condition-Based Maintenance Advantages and Disadvantages (With Real Examples)

At a factory where I provided advice, a single unexpected equipment breakdown resulted in over $50,000 in lost time and repairs. This incident made the management team realize they needed to predict failures, not just fix machines. I've spent more than ten years as a maintenance expert focusing on industrial reliability and asset management. 

My work has spanned manufacturing, oil and gas, and transportation sectors. One of the biggest changes I've seen is companies starting to use Condition-Based Maintenance (CBM). CBM uses data to guide maintenance. It keeps an eye on how equipment performs in real-time using sensors, diagnostic tools, and AI-powered systems. 

Unlike preventive maintenance, which replaces parts on a set schedule, CBM alerts teams when something needs attention. This approach saves time, cuts costs, and stops major breakdowns from happening. 

Before you put CBM into action, you need to know its pros and cons. While it can boost uptime and make operations more cost-effective, it also brings challenges. These include the money you need to spend upfront and the technical know-how required to make it work.

Advantages of Condition-Based Maintenance (CBM)

1. Less Unexpected Downtime 

Teams can spot problems before equipment breaks down when they use condition-based maintenance. This keeps operations going without surprise interruptions. 

Example: At a car factory, constant checks on robot arms found a joint that was getting harder to move. They fixed it just in time so production didn't stop. 

2. Cheaper Upkeep 

Unlike fixing things on a set schedule, which might mean working on equipment that's still fine, CBM calls for repairs when they're needed. Over time, this focused method saves money on work and parts. 

Example: A power company cut its yearly maintenance costs by 20% after it started using CBM on its transformers avoiding changing parts that were still good. 

3. Longer-Lasting Equipment 

CBM helps equipment last longer by fixing small issues and not overdoing maintenance. 

Example: A mining company said that checking its crushers' condition led to fewer breakdowns from stress making the equipment last almost two years longer. 

4. Better Safety and Following Rules 

Finding problems before they turn dangerous helps keep the workplace safer and meet the rules set by regulators. 

Example: In the oil and gas field, checking for vibrations in spinning equipment helped spot early problems cutting down the chance of leaks and making sure they stuck to safety rules.

5. Better Use of Resources

CBM allows maintenance teams to focus their efforts on equipment that genuinely needs attention, optimizing workforce allocation.

Example: A logistics firm restructured its maintenance schedule using sensor data, resulting in a 30% improvement in technician productivity.

6. Enables Data-Driven Decision-Making

CBM systems collect and analyze large volumes of equipment data, which can inform long-term asset management strategies.

Example: An aerospace firm used historical CBM data to identify recurring issues in turbine components and collaborated with suppliers to improve design.

Disadvantages of Condition-Based Maintenance (CBM)

1. High Initial Investment

Implementing CBM requires advanced sensors, data infrastructure, and software, making it costly at the outset.

Example: A mid-sized food processing company hesitated to adopt CBM due to the upfront cost of retrofitting older machinery with modern sensors.

2. Integration Complexity

CBM must be integrated with existing systems like CMMS (Computerized Maintenance Management Systems), which can be technically challenging.

Example: A paper manufacturing plant faced a three-month delay in CBM deployment due to compatibility issues with legacy monitoring tools.

3. Requires Skilled Personnel

Analyzing sensor data and interpreting trends requires skilled technicians and data analysts, which may not be available in every organization.

Example: A water treatment facility had to invest in upskilling its maintenance team to effectively use CBM dashboards and analytics.

4. Data Overload and False Alarms

Excessive data without proper filtering can overwhelm teams or trigger unnecessary maintenance actions due to sensor errors.

Example: A chemical plant initially experienced frequent false alerts from a miscalibrated temperature sensor, leading to confusion and wasted labor hours.

5. Not Suitable for All Equipment

CBM works best on high-value, critical, and continuously operating machinery. Low-risk or non-critical assets may not justify the investment.

Example: A textile mill chose not to implement CBM on older, low-cost looms due to limited returns on investment.

Implementing Condition-Based Maintenance (CBM) can deliver significant operational and financial benefits, but it's not a one-size-fits-all solution. Before investing in sensors, software, and training, businesses must evaluate whether their infrastructure, culture, and resources are ready for this data-driven maintenance strategy.

As someone who has helped industrial plants transition from reactive and preventive models to CBM, I’ve seen projects succeed and others stall depending on how well-prepared the organization was from the start.

CBM isn’t just a technology upgrade; it’s a mindset shift. It requires leadership buy-in, cross-functional collaboration, and a commitment to using data for strategic maintenance decisions.

Check out the Complete Guide on Condition Based Maintenance