• Condition monitoring and KPIs

    Condition Monitoring - Increase
    your production performance

    Transparency about the performance of your machine

    An optimal combination - condition monitoring and key performance indicators (KPIs).

    Condition monitoring refers to the continuous monitoring of the condition of machines and systems by recording and analysing various operating parameters. The aim of condition monitoring is to recognise potential problems and failures at an early stage before they lead to serious operational interruptions. By recognising anomalies in good time, companies can take proactive measures to prevent failures and ensure operational continuity. Key Performance Indicators (KPIs) are quantifiable measures used to evaluate the performance and efficiency of production processes. The selection of relevant KPIs depends on the objectives and requirements of your organisation.

    The connection between condition monitoring and KPIs is that condition monitoring helps to provide the data required to calculate and analyse the KPIs. By continuously monitoring the condition of your machines and systems and recording relevant operating parameters, we can generate meaningful data that can be used to evaluate performance against the defined KPIs. By integrating condition monitoring into the evaluation of KPIs, companies can gain a holistic view of the performance of their production processes.

    Important KPIs in production

    Keep an overview of them!

    ruhlaSmart Condition Monitoring

    Advantages of KPI and condition monitoring in production

    Overall, condition monitoring enables a proactive and data-driven maintenance strategy that improves the reliability, availability and efficiency of production facilities.

    Early detection of problems

    By continuously monitoring systems and machines, potential problems can be detected early before they lead to breakdowns or production interruptions.

    Optimized Maintenance
    Optimised maintenance planning

    Condition monitoring enables demand-oriented and predictive maintenance, in which maintenance work is carried out based on the actual operating conditions and the condition of the systems. This reduces maintenance costs and extends the service life of the systems.

    System Availability
    Increased equipment availability

    Proactive monitoring and maintenance can minimise downtime and maximise the availability of production equipment, leading to an increase in overall equipment effectiveness (OEE).

    Improved product quality

    Stable operation of production equipment, supported by condition monitoring, helps to keep production processes consistent and minimise product quality issues due to equipment malfunctions.

    Cost savings
    Increased efficiency

    By optimising maintenance processes and avoiding unplanned downtime, condition monitoring can help to increase the efficiency of the entire production plant and reduce operating costs.

    Key Performance Indicators (KPIs) in production offer a variety of benefits for the machine operator

    Performance monitoring

    KPIs allow companies to continuously monitor and evaluate the performance of their production facilities. This gives them a clear insight into the efficiency, productivity and quality of their manufacturing processes.

    Identification of bottlenecks

    By analysing KPIs, companies can identify potential bottlenecks or inefficient processes in production. This enables them to take targeted measures to eliminate bottlenecks and increase productivity.

    Optimisation of resources

    KPIs help companies to use resources such as labour, machinery and materials more efficiently. By identifying areas of low efficiency, companies can reallocate their resources to where they are most needed.

    Quality management

    KPIs related to product quality allow companies to monitor and ensure compliance with quality standards. This helps to reduce waste, increase customer satisfaction and minimise the risk of product recalls.


    KPIs serve as the basis for well-founded decisions in production management. By analysing KPI data, companies can make strategic decisions to optimise production, reduce costs and increase profitability.

    Optimized Production Processes
    Continuous improvement

    KPIs promote a culture of continuous improvement in production. By setting targets and regularly monitoring KPIs, companies can improve their performance over time and constantly evolve.

    FAQs Condition Monitoring and KPIs

    What technologies are used for condition monitoring?

    A variety of technologies are used for condition monitoring, including vibration sensors, temperature and pressure sensors, lubricating oil and grease analyses, ultrasonic measurements, electrical measurements and image processing techniques. These technologies enable comprehensive monitoring of the condition of machines and systems and provide detailed insights into their operating status.

    What is condition monitoring?

    Condition monitoring is a process in which the condition of machines, plants or other systems is continuously monitored in order to recognise potential failures at an early stage. Various techniques such as vibration sensors, temperature measurement, oil analyses and electrical measurements are used to detect deviations from normal operating parameters.

    What are the benefits of KPIs in production?

    The data for a digital twin comes from various sources such as sensors, IoT devices, production databases and external data sources. They include information about the condition, performance, environment and interactions of the real object.

    Which KPIs are most important in the manufacturing industry?

    In the manufacturing industry, there are a variety of KPIs (Key Performance Indicators) that can be used to measure the performance and efficiency of production processes. These include KPIs such as OEE (Overall Equipment Effectiveness), throughput time, scrap rate, capacity utilisation, productivity per employee, return on investment, uptime, maintenance costs and many more. The selection of relevant KPIs depends on the specific goals and requirements of a company.

    How can KPIs be used effectively in production to improve performance?

    The effective use of KPIs requires regular monitoring and analysis of performance indicators and the implementation of appropriate measures for improvement. By continuously monitoring their KPIs and analysing relevant data, companies can identify potential bottlenecks and issues and proactively take action to optimise performance.

    How can companies ensure that their KPIs provide meaningful and relevant information?

    To ensure that KPIs provide meaningful and relevant information, it is important to select the right performance indicators that match the organisation's goals and requirements. Organisations should regularly review their KPIs and adjust them where necessary to ensure they meet current requirements and provide meaningful insights into the performance and efficiency of production processes.

    Get in touch with us

    For more information about our condition monitoring and associated KPIs and how we can support your business, please contact us for a personalised consultation.

    Richard Stegmann

    Manager Digital Solutions
    Richard Stegmann