Condition Monitoring Solutions
Connect Insight to Execution.
Deliver performance-based insight into the equipment driving your operations, ensuring safety, increasing uptime, improving asset performance, reducing unplanned downtime, and improving reliability.
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SmartCBM® is Allied Reliability's comprehensive condition-based maintenance solution that combines cutting-edge technologies, industry-leading data analytics, and reliability domain expertise to identify component defects that lead to unplanned downtime, safety risks, and unnecessary expenditures.
The platform is designed to support gathering and analyzing data, presenting KPIs for all monitoring techniques, and capturing value benefits to quantify the return of your reliability efforts. Information can be gathered from various sources, including the control systems, condition monitoring, and operational data.
Through the combination of predictive maintenance technologies, process data, statistical process control, data analytics, specific failure-mode-driven repair recommendations, and Allied’s Business Risk Index, we partner with you to design, implement, execute, and optimize your condition-based maintenance strategy – ensuring the uptime and reliability of your equipment.
Our proprietary failure mode library is derived from analyzing over 3 million components from over 1500 facilities. It identifies common components, parts, failure reasons, and inspection methods that identify the defects that lead to equipment and process failure.
Flexible Data Collection Options
Allied Reliability’s solution for condition monitoring includes a full range of data collection options. From manual route-based collection to sensor-based collection, from inline to wireless periodic monitoring, our experts help you identify the proper monitoring techniques to deploy a comprehensive approach for each asset, resulting in a more holistic and cost-effective solution.
Some forms that maintenance data can be collected include:
- Preventive maintenance (PM)
- Human senses
- Measurement instruments, such as dial indicators, snap gages, and calipers
- Control systems and data historians
- Predictive maintenance (PdM)
- Condition monitoring techniques
By deploying a combination of the approaches listed above and leveraging advanced monitoring and data analytics within a single platform, we help our customers detect the smallest variations and fluctuations in asset performance. Many of these are too subtle or are missed by a single solution or one that is managed across multiple platforms.
Comprehensive Monitoring Techniques
While many service providers offer various condition monitoring services, traditional condition monitoring technologies alone are just one piece of the puzzle. Our experts leverage our domain experience to recommend a customized data monitoring solution to remove risks and increase your overall productivity. Collection approaches could include vibration analysis, oil analysis, infrared thermography, ultrasound, motor circuit, and other analyses as required.
Why is a Comprehensive Monitoring Approach Important?
Condition monitoring is important for several reasons:
- Preventive Maintenance: By continuously monitoring the condition of equipment or assets, potential issues can be detected early, allowing for proactive maintenance before a breakdown occurs. This helps in reducing downtime and costly repairs.
- Cost Savings: Condition monitoring helps in optimizing maintenance schedules and resource allocation. It prevents unnecessary maintenance and reduces the risk of unexpected failures, thereby saving money on maintenance costs and increasing the lifespan of assets.
- Improved Reliability: Regular monitoring allows for better understanding of equipment behavior and performance trends. This enables organizations to make informed decisions about repair or replacement, leading to increased reliability and uptime.
- Safety: Monitoring critical parameters such as vibration, temperature, etc. can help in identifying unsafe conditions or potential hazards before they escalate into accidents or injuries. This contributes to a safer working environment for employees and reduces the risk of accidents.
- Data-Driven Decision Making: A vast array of data sources generate subtle variances indicating unique impacts to equipment performance, which can be analyzed to identify patterns, trends, and areas for improvement. This data-driven approach allows for better decision-making regarding maintenance strategies, resource allocation, and asset health.
- Optimized Operations: By ensuring that equipment is operating within specified parameters, prescribed analytics helps in optimizing production processes and maximizing efficiency. This leads to increased productivity and improves overall performance.
- Compliance: In certain industries, there are regulatory requirements for monitoring the condition of equipment to ensure compliance with safety and environmental standards. Comprehensive monitoring helps organizations meet these regulatory requirements and avoid penalties or legal issues.
Overall, a comprehensive monitoring solution plays a crucial role in enhancing operational efficiency, reducing costs, ensuring safety, and prolonging the lifespan of assets, making it a key aspect of modern maintenance strategies.
Examples of Equipment that should be Monitored with a Comprehensive Approach
Condition monitoring can be applied to a wide range of equipment across various industries. Some common types of equipment that are typically monitored include:
- Rotating Machinery:
- Motors
- Generators
- Pumps
- Compressors
- Turbines
- Engines
- Conveyors
- Fans
- Mixers
- Non-Rotating Machinery:
- Boilers
- Heat Exchangers
- Furnaces
- Conveyors
- Mixers
- Presses
- Tanks
- Vessels
- Electrical Systems:
- Transformers
- Switchgear
- Circuit Breakers
- Cables, Busbars, and Distribution System
- HVAC Systems:
- Chillers
- Air Handling Units
- Cooling Towers
- Heat Pumps
- Vehicles:
- Mobile Equipment
- Excavators
- Trucks
- Cars
- Trains
- Aircraft
- Ships
- Structures:
- Bridges
- Buildings
- Dams
- Pipelines
- Industrial Processes:
- Chemical reactors
- Refinery units
- Mixing tanks
- Distillation columns
- Manufacturing Equipment:
- CNC machines
- Injection molding machines
- Extruders
- Robots
- Power Plants:
- Steam turbines
- Gas turbines
- Boilers
- Heat recovery steam generators (HRSGs)
- Renewable Energy Systems:
- Wind turbines
- Solar panels
- Hydroelectric generators
SmartCBM® Tool Suite (formerly iReliability)
Our offering is underpinned by a world-class set of proprietary tools and techniques for monitoring and reporting on the condition of your assets. These tools enable the development of a maintenance strategy that prescribes necessary activities and their frequency to mitigate design-failure modes and maximize equipment reliability and availability.
While some companies focus on providing notifications and repair recommendations of the risks to monitored assets, Allied brings domain expertise to not only highlight the risks of known equipment defects, but shed light on unknown risks. Through the use of Allied’s Business Risk Index algorithm, not only are we monitoring and prioritizing your known risks and issues, but we also cover where it’s most important - your unknown risks.
These risks occur when your monitoring strategy has gaps or when a condition assessment does not take place at the scheduled time. These underlying risks keep you up at night and have the potential to wreck the best-laid plans. Surprised or caught off guard due to unknown risks is a thing of the past.
Our reliability software suite, SmartCBM, is designed around reliability and the Industrial Internet of Things (IoT). Regardless of how data is collected, SmartCBM is the centralized location for making sense of the data and providing prescriptive analytics and repair recommendations in real-time. Automatic and immediate notifications of anomalies are delivered before affecting production and causing unplanned downtime. For a guided tour of the interface, watch Leveraging SmartCBM® Software for Business Decisions or schedule an online demo at your convenience.
SmartCBM: Mobile App
The SmartCBM Monitor mobile app provides current, on-the-go, high-level business views down to site specifics for individual facilities and the specific asset and component level.
It gives your organization an easy-to-use mobile solution for quick, complete viewing of your reliability program in real time. If you are an area supervisor and need to quickly understand the risks and likelihood of potential failure of the critical equipment you operate, SmartCBM Monitor was designed for you.
Real Results
Companies that implement comprehensive monitoring techniques within their maintenance programs have healthier and more reliable equipment and a healthier work environment for employees, free from hazardous working conditions. Ultimately, more reliable operations mean better productivity and better operating margins.
30-90%
reduction in days to identify defects
10-20%
reduction in unexpected downtime
15-50%
reduction in maintenance costs
Success Stories
See how Allied Reliability’s solutions have had an impact on business operations for companies in a variety of industries.
Industry: Automotive Rubber
Wireless monitoring prevents production loss
Industry: Automotive
Predictive maintenance program delivers ROI
Industry: Chemical Processing
Continuous monitoring saves time and money
Industry: Plastic Fabrication
Delivering value with semi-continuous data collection
