Condition-Based Maintenance
Keep capacity from leaking out as unplanned downtime. Trigger maintenance on real equipment conditions instead of the calendar, and build toward predictive maintenance as patterns emerge.
Too early or too late
Calendar-based maintenance never runs on the equipment's actual condition.
It runs too early and wastes parts and labor, or too late and causes unplanned downtime. Meanwhile teams spend hours manually reading meters, logging run hours, and writing work orders.
How It Works
From raw equipment signals to actionable intelligence.
1
Monitor Equipment Condition
Live signals from PLCs track run hours, cycle counts, vibration, temperature, and other condition indicators in real time.
2
Understand Thresholds
Establish baselines from real operating data. Define condition triggers based on actual usage patterns, not arbitrary calendar dates.
3
Automate Work Orders
Maintenance Connect pushes work orders directly into your CMMS when equipment reaches real condition thresholds. Include equipment context, readings, and recommended actions.
4
Optimize Maintenance Cycles
Compare planned vs. unplanned maintenance ratios over time. Adjust thresholds as equipment behavior patterns emerge. Reduce both over-maintenance and surprise failures.
Capabilities
What Visual Factory delivers for condition-based maintenance.
Automated meter readings from live equipment data
Condition-based work order triggers (not calendar-based)
Packaged CMMS connectors: Fiix, MaintainX, ManagerPlus, eMaint, UpKeep
Equipment degradation trend monitoring
Planned vs. unplanned maintenance ratio tracking
Progressive path from condition-based to predictive maintenance
54%
reduction in reactive maintenance.
Condition-based maintenance at Perth County Ingredients. Meter-based triggers replaced calendar PMs, and the reactive share of maintenance fell: less overtime, fewer rush parts, and fewer unplanned downtime hours across the year.
“The plant runs 24/7, but maintenance is only here Monday to Friday. So it's very important that we're capturing all this information. We now have alarms that are tripped and warnings to operators that if action is not taken or maintenance isn't contacted that it could shut them down. We've seen old issues fall off. Things like motor pumps and bearings replacements. They've all decreased.”
Tom Dufton, National Reliability Manager, Perth County Ingredients