Managing condition‐based maintenance technology

TLDR

Condition‑based maintenance diagnoses component failure or predicts time to failure, yet most research has focused on mathematical models, with limited attention to industrial practice; this study is among the first in‑depth empirical investigations of actual maintenance practice. The paper aims to summarize eight literature‑derived postulates on condition‑based maintenance and compare them with industrial practice. The authors formulated postulates across technical, managerial, and workforce dimensions and tested them through a multiple‑case study of five large process‑industry firms. Empirical evidence supports some postulates, while others—such as prognostics, dedicated software, procedures, training, and knowledge management—receive limited or no support, highlighting gaps between literature and practice and offering practitioners a framework to benchmark their maintenance strategies.

Abstract

Purpose Condition‐based maintenance is the diagnosis of component failure or a prognosis of a component's time to failure. The aim of this paper is twofold: a summary of the main assumptions regarding condition‐based maintenance found in the literature into eight postulates, and a comparison of the postulates against industrial practice. The postulates were formulated regarding the technical system, the managerial system and workforce knowledge. Design/methodology/approach The postulates were examined in a multiple case study of five large firms in the process industry. Findings The results indicate that some postulates were supported with empirical findings. Limited or no support was found for postulates concerning the application of prognostic activities, use of dedicated software, use of procedures, use of training, and the active management of domain‐related knowledge availability. Practical implications Practitioners can use the eight postulates as key elements in the management of condition‐based maintenance technology, and for the comparison of their current condition‐based maintenance practices with what literature generally proposes. Originality/value Other researchers have reported on condition‐based maintenance, but most publications focus on applied mathematics and new monitoring and simulation models. Only limited attention was paid to industrial practice so far. The study is one of the first in‐depth empirical studies into actual condition‐based maintenance practice.