What Are the Challenges Faced While Implementing Condition-Based Maintenance?

Condition based Maintenance Challenges

Condition-based maintenance is helpful to organizations as it helps in decreasing downtime. It is not easy to implement but once implemented successfully then this maintenance will provide several benefits. What are the challenges that occur while implementing condition-based maintenance and how can you overcome those challenges? That we will discuss in this blog, but first let us know what condition-based maintenance software is!

What Is Condition-Based Maintenance Software?

Condition-based maintenance software helps organizations in monitoring asset conditions in real-time. It also enables organizations to determine what kind of maintenance needs to be performed.

Condition-based maintenance only performs maintenance when it is required, not like other scheduling maintenance strategies.

For this purpose, the software is equipped with several KPIs (key performance indicators) that are helpful in providing maintenance on time.

Moreover, asset tracking tags and senses are used for asset health monitoring. For example, tags and sensors tell us if leakage is occurring or whether the smoke or vibration of the machine is regular or irregular.

Furthermore, data analysis is done such as engine oil analysis is done to check condition is normal or not and calibration management is performed, if required.

According to Mordor Intelligence, “The condition monitoring equipment market is valued at USD 1.99 billion in 2020 and expected to grow at a CAGR of over 5.59% during the forecast period 2021 - 2026 to reach a value of USD 2.61 billion in 2026.”

What Are the Challenges in Condition-Based Maintenance?

Condition-based maintenance challenges are given below:

1. Employee Training

An organization is equipped with lots of assets and equipment which are complex in nature & managing them needs proper training to run them. That is why it is important to provide training to employees.

Training will help the maintenance team to understand equipment better. It will be helpful in performing equipment maintenance efficiently. There is no doubt that giving training to employees is an important part!

Moreover, it has been rising as one of the major challenges, especially in condition-based maintenance. Condition-based maintenance is different from other maintenance types because assets need to be inspected and monitored regularly. Most importantly, employee training is costly.

2. Inventory Availability

Imagine a scenario where the maintenance team is performing maintenance and suddenly, they require specific inventory. But that inventory is not available.

As a result, productivity suffers, human resources are wasted, and assets are not perfectly maintained either.

This type of scenario occurs frequently. Therefore, while performing maintenance, it is essential to keep track of inventory. If the inventory is not available, then the maintenance team will have to perform maintenance again.

In order to avoid this maintenance challenge, organizations can use automated inventory tracking software that helps in keeping track of inventory in an automated way.

3. Prioritizing Equipment Maintenance

Prioritizing equipment maintenance is one of the major challenges in condition-based maintenance.

As the maintenance team has lots of work so they do not when they do not know the exact priority of the equipment, then they work according to the FCFS (First come first serve) basis.

As a result, crucial assets are still waiting to be maintained. This impacts the productivity of the organization and production work speed gets hampered.

Therefore, deciding the priority of each piece of equipment is essential to overcome this challenge.

4. Tracking Maintenance

Without automated software tracking, maintenance is difficult as there are lots of assets. For instance, which asset got the maintenance, and which did not? Which asset is performing up to the mark and which asset needs to be removed?

This type of question cannot be answered with a manual process. Therefore, you do not get a complete view and complete asset information when you process manually. Thus, you do not get complete value from your assets.


Most of the condition-based maintenance challenges can be resolved with our asset management software.

As this software has features of setting reorder levels that will be helpful in keeping track of inventory and when inventory is about to finish it will alert the person responsible so that inventory is refilling in no time.

Furthermore, this software provides real-time information which is an important feature requirement for condition-based asset maintenance.

There is no doubt that you can make the most of your assets with asset management software. It will help you in managing your assets efficiently.

You can always keep track of your assets with this software. It will also be helpful in reducing errors in spreadsheets.

Furthermore, this software will centralize asset information. Moreover, this software comes with cloud technology and mobile technology, so you can access it from anywhere, anytime.

With cloud technology your data is secured as the cloud service provider will take the responsibility for data security. Since it comes with mobile technology, you are not restricted to your workstation anymore and you can inspect your assets, check asset condition, and schedule maintenance on the go.

Frequently Asked Questions (FAQs)

When Condition Monitoring Maintenance Can Be Used?

When asset performance is not up to the mark then condition monitoring maintenance can be used. If the condition of the asset is not good and that is discovered in asset inspection, then condition monitoring maintenance can be used.

Although condition-based asset monitoring can be used on almost all assets. and asset condition must be noticeable. So that the maintenance team knows what are the issues that need to be resolved.

What Are the Benefits of Condition-Based Maintenance?

The benefits of condition-based maintenance are given below:

1. Maintenance frequency is minimized.

2. Decreased maintenance expenses.

3. Maximum value achieved from assets.

4. Maintenance is only provided to assets when it is required.

5. Asset downtime decreased and uptime increased.

6. The maintenance team needs to invest less time.

Is Condition-Based Maintenance Based on Proactive Maintenance or Reactive Maintenance?

It depends upon the requirements of the organization. As some assets have high priority and some assets have less priority. For instance, if an asset has high priority, then proactive condition-based maintenance can be used. If the asset has less priority, then reactive maintenance can be used.

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