[et_pb_section fb_built=”1″ admin_label=”section” module_class=”fpb0 table_of_content_sec” _builder_version=”4.27.4″ locked=”off” global_colors_info=”{}”][et_pb_row admin_label=”row” module_class=”fpt0 fpb0″ _builder_version=”4.27.4″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_code _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_code][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”1″ module_id=”sectionscrollid1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
In industrial production, efficient maintenance strategies are crucial to productivity, quality and competitiveness. While fixed maintenance intervals used to be the standard, modern companies are increasingly relying on flexible, data-based procedures. <\/p>\n
Condition-based maintenance (CBM) is one of the central concepts here. It uses measured values, sensors and digital systems to precisely monitor the current condition of a system. On this basis, maintenance work is only carried out when it is actually necessary. <\/p>\n
In this way, CBM not only helps to reduce downtimes, but also to sustainably extend the service life of your machines and devices. In combination with digital solutions such as tepcon’s “instructor”, this creates intelligent maintenance management that makes operations more efficient, transparent and safe. <\/p>\n
Let’s take a closer look at this concept in the following article: For example, how does it differ from the concept of “predictive maintenance”, what can its use bring to your business and your team, and what problems might arise?[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/11\/Zustandsabhaengige-Instandhaltung-2.avif” alt=”Industrial machine with sensors for condition-based maintenance” module_class=”img__radius” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”2″ module_id=”sectionscrollid2″ module_class=”checkmrk_list anchor_link_class ” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
The world of maintenance is complex – numerous terms describe different strategies, approaches and types of maintenance.<\/p>\n
Here is a quick overview of the most important maintenance strategies<\/a>, which offer very different solutions:<\/p>\n These different maintenance models show: Modern maintenance is no longer a reactive process; the right choice is a strategic success factor.[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ admin_label=”Common_CTA” module_class=”wissen_cta_section” _builder_version=”4.27.4″ _module_preset=”default” use_background_color_gradient=”on” background_color_gradient_direction=”90deg” background_color_gradient_stops=”#2c333a 0%|#2c333a 52%|#532d3b 75%|#b61f3f 100%” background_image=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/10\/bg-element-3.svg” background_position=”top_center” collapsed=”off” global_colors_info=”{}”][et_pb_row column_structure=”2_3,1_3″ module_class=”vam_a980″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”2_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text module_class=”h2_class white_text anchor_link_class” _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n [\/et_pb_text][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_button button_url=”https:\/\/tepcon.de\/en\/contact\/” button_text=”Contact us” button_alignment=”right” module_class=”secondary_btn” _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_button][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”3″ module_id=”sectionscrollid3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Condition-based maintenance CBM is a sub-form of preventive maintenance and aims to carry out maintenance measures exactly when they are necessary. The current condition of machines or systems is monitored continuously or at intervals. <\/p>\n Typical measured variables used to monitor machines and systems include temperature, vibrations, pressure, flow or energy consumption. As soon as defined threshold values are exceeded, maintenance is initiated. <\/p>\n CBM therefore uses data to make informed decisions – a clear advance over time-based maintenance, which intervenes at fixed intervals regardless of actual wear.<\/p>\n The principle:<\/strong> If sensors report a decrease in performance or unusual values, an intervention is planned before a failure occurs. This minimizes downtimes and increases the availability of production systems. <\/p>\n CBM increases efficiency and reduces costs across the entire operation. Your teams can tackle maintenance jobs as soon as the condition requires it, avoiding unnecessary downtime or over-maintenance.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”3″ module_id=”sectionscrollid4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Whereas with reactive maintenance, action is only taken when a malfunction or failure occurs, CBM acts proactively.<\/p>\n Reactive means that a machine breaks down and repairs only begin afterwards. This leads to longer downtimes, increased maintenance costs and potential consequential damage. <\/p>\n Condition-based, on the other hand: Continuous monitoring and analysis of sensors and data enables the optimum maintenance time to be identified. Interventions are targeted before problems arise. Digitalization is fundamentally changing maintenance. Today’s industrial plants are complex, networked and highly automated – one error or unplanned downtime can cost millions. <\/p>\n This is where the value of condition-based maintenance becomes apparent: it enables the efficient use of resources, extends the service life of critical components and reduces the risk of unplanned downtime.<\/p>\n In conjunction with modern maintenance strategies, IoT technologies and software solutions such as the “instructor”, condition monitoring can be seamlessly integrated into existing processes. This gives companies a real-time view of their systems – a decisive advantage in the age of Industry 4.0.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/11\/Zustandsabhaengige-Instandhaltung-4.avif” alt=”Employees monitor production data on a digital dashboard” module_class=”img__radius” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”7″ module_id=”sectionscrollid6″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Another important building block for efficient, digital maintenance processes is the close cooperation with our partner Transaction-Network<\/strong>. In combination with tepcon’s “instructor”<\/strong>, this creates a strong synergy potential: digital work and test instructions become part of a networked overall system that makes maintenance measures even faster, safer and more transparent.<\/p>\n [\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”7″ module_id=”sectionscrollid7″ module_class=”anchor_link_class ” _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n The basic principle of the CBM strategy is simple: maintenance is only carried out when indicators point to an imminent reduction in performance. The recorded status data is analyzed continuously or at defined intervals. If the system detects deviations, maintenance work is triggered automatically. <\/p>\n In contrast to preventive maintenance, which is based on fixed intervals, CBM reduces maintenance costs because interventions are only carried out when necessary. In addition to the reduced maintenance effort, this also lowers costs and increases the availability of the systems. If you would like to know how we optimize both condition-based and predictive maintenance and servicing with our software, simply ask us directly<\/a>![\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ admin_label=”Common_CTA” module_class=”wissen_cta_section” _builder_version=”4.27.4″ _module_preset=”default” use_background_color_gradient=”on” background_color_gradient_direction=”90deg” background_color_gradient_stops=”#2c333a 0%|#2c333a 52%|#532d3b 75%|#b61f3f 100%” background_image=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/10\/bg-element-3.svg” background_position=”top_center” collapsed=”off” global_colors_info=”{}”][et_pb_row column_structure=”2_3,1_3″ module_class=”vam_a980″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”2_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text module_class=”h2_class white_text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n [\/et_pb_text][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_button button_url=”https:\/\/tepcon.de\/en\/contact\/” button_text=”Contact us” button_alignment=”right” module_class=”secondary_btn” _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_button][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_class=”checkmrk_list anchor_link_class” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”8″ module_id=”sectionscrollid8″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n International standards play an important role in the implementation of condition-based maintenance. DIN EN 13306, which sets out the basic terms and definitions of maintenance, is particularly relevant. <\/p>\n It describes the different types of maintenance, including preventive, corrective and condition-based procedures, thus creating a common language for operators, manufacturers and service providers.<\/p>\n In many industries, further standards, safety guidelines and documentation requirements must also be observed – the “instructor” offers an efficient way of documenting processes in an audit-proof manner.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”9″ module_id=”sectionscrollid9″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n [\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”10″ module_id=”sectionscrollid10″ module_class=”anchor_link_class” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Although both strategies are based on the collection of status data, there are clear differences:<\/p>\n With condition-based maintenance, the current status of your systems is monitored in order to detect problems immediately. Predictive maintenance goes one step further: it combines sensor data, historical information and AI algorithms to accurately predict the optimal time for the next maintenance. <\/p>\n In a system with a predictive approach, for example, cavitation in a pump system can be detected at an early stage – based on vibrations, temperature and ambient data. Both approaches complement each other and often form the basis of a sustainable maintenance strategy.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/11\/Zustandsabhaengige-Instandhaltung-5.jpg” alt=”Condition-based maintenance software analyzes machine data” module_class=”img__radius” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row module_class=”checkmrk_list ” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”11″ module_id=”sectionscrollid11″ module_class=”anchor_link_class” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Condition-based maintenance offers a number of advantages – especially for manufacturing companies that require high plant availability:<\/p>\n With CBM, teams not only increase efficiency, but also create transparency throughout the entire operation.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”11″ module_id=”sectionscrollid12″ module_class=”anchor_link_class” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Despite all the advantages, CBM also entails requirements and problems: Technical challenges also play a role: some sensors cannot withstand harsh operating environments, older systems are difficult to retrofit, and even wear and tear cannot always be clearly measured.<\/p>\n CBM is therefore not a sure-fire success – it requires a clear approach, modern technologies and well-trained teams.<\/p>\n This is where the “instructor”<\/i> helps to digitally standardize work processes, maintenance measures and test steps.<\/p>\n\n
Are you in a hurry? Click here to go directly to our product<\/a>, the tepcon instructor! <\/h4>\n
Definition of condition-based maintenance<\/h2>\n
Difference between reactive and condition-based maintenance<\/h2>\n
\nThe result: lower costs, predictable processes and greater reliability – albeit at a higher cost for sensors and data analysis.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”3″ module_id=”sectionscrollid5″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”]<\/p>\nImportance of condition-based maintenance for the manufacturing industry<\/h2>\n
Digital instructions as part of the networked service ecosystem of Transaction-Network<\/h2>\n
Transaction-Network is a cross-industry, industrial service ecosystem in real time – manufacturer-neutral and cloud-based. It connects operators, machine manufacturers and material suppliers on a single platform and ensures that machine downtimes are avoided by identifying critical situations at an early stage and automatically integrating all relevant partners. <\/p>\nHow does condition-based maintenance work?<\/h2>\n
\nThe inspection is carried out using measuring systems, sensors and data acquisition devices that monitor parameters such as vibrations, temperature or pressure in real time.<\/p>\nBook your personal demo and experience the benefits directly!<\/h4>\n
Excursus: Standards and legal requirements<\/h2>\n
Different types of maintenance<\/h2>\n
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Predictive maintenance vs. condition-based maintenance<\/h2>\n
\nThe advantage: even more precise planning, fewer failures, higher uptime.<\/p>\nAdvantages of condition-based maintenance<\/h2>\n
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The challenges of condition-based maintenance<\/h2>\n
\nThe installation of sensors and monitoring devices can result in high initial costs. Analyzing large amounts of data requires trained personnel and powerful software. <\/p>\n