# Condition Monitoring Program Readiness Checklist > Source: https://netray.co/tools/condition-monitoring-program-readiness-checklist > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer A practical checklist for starting or auditing a condition monitoring program, from asset selection to closing the loop in the work order system. ## Category maintenance ## Industry Discrete Manufacturing ## Audience - Reliability engineer - Maintenance manager - Plant manager ## Tool **Kind:** checklist **Groups:** #### Scope and asset selection **Items:** **Text:** Asset criticality ranking is complete and agreed with operations **Critical:** true **Text:** Failure modes for the top assets are listed (FMEA or RCM output) **Critical:** true Each failure mode has a detection technique matched to it **Text:** P-F interval is estimated for each chosen technique **Critical:** true Inspection interval is set shorter than half the P-F interval Run-to-failure assets are listed on purpose, not by omission Assets are in the CMMS or ERP with unique tags #### Measurement and data **Items:** Measurement points are defined, marked and photographed **Text:** Sensor mounting method is consistent between surveys **Critical:** true Machine speed and load are recorded with every reading **Text:** Baseline readings were taken on healthy machines **Critical:** true Units and measurement types are standard across all tools Route order and frequency are documented Instrument calibration is tracked and in date Data is stored centrally, not on a single laptop #### Alarms and diagnosis **Items:** **Text:** Alert and danger limits are set per point, with a documented basis **Critical:** true Analysts are trained and their category or competence is recorded Findings use a standard severity scale A second technique is used to confirm high severity calls Lubrication and oil sampling points are on the route Infrared scans for electrical equipment are scheduled #### Work flow and follow up **Items:** **Text:** Every confirmed finding creates a work request in the CMMS or ERP **Critical:** true **Text:** A named planner owns the finding to work order step **Critical:** true Spare parts for common failures are stocked or have known lead times Repair outcome is recorded: what was found when opened Post-repair readings confirm the fix False alarms and missed failures are logged and reviewed #### Review and value **Items:** Monthly review meeting covers new findings and overdue actions **Text:** Avoided failures are recorded with an estimate of the saving **Critical:** true Coverage percent of critical assets is a tracked KPI Program cost is tracked: instruments, licences, labour Alarm limits are reviewed at least once a year Management receives a short summary each quarter **Scoring Note:** Count the items you can tick. Under 50 percent: build the foundations (criticality, baselines, work flow) before buying more sensors. 50 to 80 percent: the program exists, focus on closing the loop. Over 80 percent: tune limits and prove value. ## Content **Intro:** Most condition monitoring programs fail not because of sensors but because findings never become work. This checklist walks through scope, data, alarms, work flow and review so you can build or audit a program in a structured way. **Sections:** #### How to use the checklist **Body:** Work through each group with the reliability engineer, the planner and a technician in the room. Tick only what you can show evidence for, such as a document, a screen or a report. Items marked critical are the ones that most often explain why a program does not deliver. Export the list with your answers to PDF or Excel, then turn the unticked items into actions with owners and dates. #### Why scope comes first **Body:** Monitoring everything is expensive and dilutes attention. Start with the assets whose failure is costly or dangerous and for which a failure mode gives warning. Condition monitoring only works when there is a P-F interval, meaning a period between the first detectable sign and functional failure. If a failure has no warning, such as a sudden electronic fault, monitoring will not help and a different strategy is needed. #### Closing the loop **Body:** The value is created when a finding becomes a planned job. That needs a named owner, a link from the finding to a work request in the CMMS or ERP, and parts and time to act. Review overdue findings monthly. Also record what was found during the repair, because that feedback is how analysts improve their calls and how you prove the savings. #### Common mistakes **Body:** Buying instruments before ranking assets, taking readings with no baseline, using one set of limits for every machine, and reporting findings by email with no work request are the common failures. Another is measuring on a fixed interval longer than the P-F interval, which guarantees missed failures. **Cta:** If your ERP or CMMS holds the asset and work order history, we can help connect findings to requests and report coverage automatically. Ask for an expert review. **Faq:** #### Where should I start with condition monitoring? **Answer:** Start with a criticality ranking and the failure modes of the top assets. Then pick the cheapest technique that detects each failure mode early enough, set baselines, and make sure a named person turns findings into work requests. #### How many assets should be on a route? **Answer:** It depends on the techniques and staff. A common start is the top 10 to 20 percent of assets by criticality. Expand only when findings are being closed on time and the data quality is good. #### Do I need online sensors or are manual routes enough? **Answer:** Manual routes are enough for many slow-developing faults with a long P-F interval. Online sensors suit critical, fast-developing or hard-to-reach assets, or sites with few skilled staff. Many programs use both. #### How do I show the program is worth the cost? **Answer:** Record each avoided failure with the downtime hours, repair cost difference and any scrap or safety impact avoided. Compare the total with the program cost over the same period. Use only confirmed catches. ## Search terms condition monitoring program checklist, predictive maintenance implementation checklist, condition based maintenance setup, start a vibration monitoring program, condition monitoring audit, predictive maintenance readiness, cbm program steps, reliability program checklist --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json