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Condition Monitoring – Practical Examples
for monitoring your
Machines. Equipment. Plants. Silos. Filters.

Find out how other companies in our network are gaining more transparency by monitoring conditions – for information that previously only existed on paper or in the heads of employees. In which areas would you like to see more transparency?

over
1700 + Projects

Companies that successfully implement IoT/IIoT applications

Companies from our community that are already successfully implementing IoT and IIoT applications in practice.

Solution Examples > Condition Monitoring

Your use case has already
been successfully implemented.

Find out how other companies in our network successfully implement Condition Monitoring. Our validated use cases showcase the technologies and solutions in use, as well as the partners who can support you. Where would you like to see more transparency?

Boosting Delivery Reliability with Real-Time Applications.

Boosting Delivery Reliability with Real-Time Applications.

Hermes Schleifmittel GmbH, founded in 1927, is a family-owned company headquartered in Hamburg. As a leading p...

Chemicals and Resources Mechanical and Plant Engineering Production

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13. February 2025

Efficient process data visualization for the industry

Efficient process data visualization for the industry

Process data visualization is essential in modern production environments. With the IoT platform ALD EXPERT GR...

Automotive Production

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06. February 2025

Documentation and traceability in metallurgy

Documentation and traceability in metallurgy

Melt review sheets enable the precise recording and tracing of all process data in metallurgy. Real-time monitoring, automated documentation and integration into ERP and MES s...

Metals and Electronics Production

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23. January 2025

Proven Use Cases for Condition Monitoring

Condition Monitoring is a hot topic. You want to get started but aren’t sure where? Or are you looking for inspiration? We present proven use cases from the field – and perhaps even ones your competitors have already successfully implemented.

Vibration Monitoring

Optimization Through Real-Time Sensors. With modern sensors for vibration monitoring, companies can detect damage early and prevent costly downtime. These sensors provide real-time feedback, enable data-driven maintenance decisions, and improve the reliability of equipment.

  • Early Damage Prevention
  • Reduction of Unplanned Downtimes
  • Improved Operational Efficiency

Filter Monitoring

Efficient Maintenance of Filtration Systems. Monitoring pump and fan systems helps anticipate and streamline maintenance needs. Sensors detect the condition of filter mats or wear data, allowing for well-planned and timely service operations.

  • Extended Lifespan of Filtration Systems
  • Reduction of Energy Consumption
  • Stabilization of Production Processes

Temperature Measurement

Digital temperature monitoring for extreme conditions!
In our network, we implement IoT-supported temperature measurements for steam pipes – with, for example LoRaWAN or mioty® sensors that detect temperatures and operate maintenance-free for over 10 years.

  • Longevity – sensors operate maintenance-free for 10 years
  • Reliability – measurement at up to 700°C and at high pressure
  • Efficiency – no pipeline shutdown thanks to smart measurement method

Groundwater Level Measurement

Precise level measurement without maintenance!
Battery-operated sensors are used to automatically detect groundwater levels, for example – even in areas that are difficult to access. The maintenance-free technology enables efficient and reliable data acquisition.

  • Autonomous – battery-operated and maintenance-free
  • Connected – simple transmission for seamless integration
  • Flexible – Can be used in boreholes up to 15 m deep

Vibration Monitoring

Precise diagnosis through vibration analysis. Monitoring bearings or heat treatment furnaces provides early warning signals for temperature deviations or mechanical irregularities. This ensures production quality and prevents damage.

  • Improved Production Quality
  • Early Planning of Repairs
  • Reduction of Maintenance Costs

Acoustic Monitoring

Detect anomalies through sound patterns. Acoustic sensors diagnose wear and malfunctions in machines based on sound patterns. This precise method reduces unplanned downtime and ensures efficient maintenance planning.

  • Precise Error Analysis
  • Prevention of Major Damage
  • More Efficient Maintenance Measures

Control Cabinet Monitoring

Safety Monitoring for Digital Systems. Open control cabinets can cause serious malfunctions due to temperature fluctuations, humidity or dust. IoT technologies network OT and IT systems to minimize these risks and increase operational reliability.

  • Protection from environmental influences
  • Prevention of Downtime
  • Improved Safety Standards

Wear Monitoring

Process Safety Through Timely Diagnosis. Monitoring production processes such as conveyor belts or grinding machines enables early detection of wear. Faulty parts can be automatically sorted and documented.

Benefits:

  • Planned Maintenance Measures
  • Prevention of Production Downtime
  • Improved Product Quality

Conveyor System Monitoring

Reliability for Material Flows. Companies use IoT technologies to monitor their conveyor systems and detect irregularities at an early stage. This ensures smooth operation and increases the availability of the systems.

  • Minimization of Transport Disruptions
  • Higher System Availability
  • Optimization of Material Flows

Fill Level Measurement


Efficiency in Warehousing and Production.
Real-time monitoring of fill levels in tanks or silos enables precise control of production processes. Automatic notifications facilitate reordering and prevent overflows or bottlenecks.

  • Efficient Inventory Management
  • Optimization of Production Planning
  • Avoiding Material Waste

Intelligent Cable and Screw Monitoring

Making Hidden Problems Visible. Sensors monitor cables and screws for wear or defects. Problems are detected in time before they cause significant damage, enhancing operational safety.

  • Preventive Maintenance
  • Increased Service Life of Components
  • Improved Safety

How do other companies
successfully implement Condition Monitoring?

Have you decided to implement a specific use case for condition monitoring or are you already in the planning phase? But you lack the solid foundation and the right building blocks to avoid costly mistakes that waste time and money? Condition monitoring requires the perfect interplay of multiple components – tailored to your industry and specific requirements.

Data Acquisition

The basis of every IoT and IIoT project lies in data acquisition and pre-processing (EDGE). The data from the field and control level can be transmitted either directly by wire or wirelessly. Operational parameters such as temperature, pressure, force, or production data in real time are captured – and made available for any use case.

Data Transmission

A seamless transfer of captured data is essential. Many companies combine wireless and wired solutions depending on the use case – for secure data transmission to the cloud or locally. Suitable networks for distance, data load and environments as well as high security standards are crucial in order to avoid downtimes.

Device Management

Efficient device management for IIoT devices enables companies in our community to centrally manage the entire life cycle, including automated updates and certificate management. Our partners are working on solutions to reduce operating costs through automation, minimize downtimes and achieve high efficiency through scalable solutions and optimized interfaces.

Data Integration

Data only becomes valuable when it is seamlessly integrated into existing IT and OT systems. A strong connection between machine level, MES, ERP systems and other business solutions enables efficient processes and consolidated insights. Keywords: Data Warehousing, Data Lake and Database (storage)

Data Standard (Communication)

Many companies do not have standardized access to machine and device data right through to their IT systems. Standards such as OPC UA, LoRaWAN and mioty enable seamless integration from the edge to the cloud. OPC UA, for example, connects OT and IT by transferring data via edge gateways to cloud services such as Azure Event Hubs or Kafka and tools such as Grafana or Power BI. Our partners ensure that these standards can be used efficiently.

Data Standard (Master Data)

Master data for products and services is often not uniformly classified and is available in data silos. When implementing use cases such as traceability, digital type plates, the digital product passport (DPP) or the product carbon footprint, this leads to high costs in data engineering due to duplication of work and inefficient processing. Uniform data formats, standardized product descriptions and technical concepts such as the Asset Administration Shell (AAS) are therefore crucial.

Data Visualization

The visualization of IoT data makes it possible to display complex information such as alarm trends, golden batch or process dashboards in intuitive reports. Customizable dashboards on standard tools help to analyze real-time data, identify trends and make informed decisions. Low-code solutions are also available.

Data Analysis and Evaluation

IoT/IIoT data analysis provides real-time insights into processes through, for example, data event-driven apps, real-time analytics, and root cause analytics. Tools such as MVDA, OEE, process KPIs and Predictive Maintenance can be used to identify anomalies and optimize processes. Low-code solutions also facilitate rapid implementation.

Data Security

Protection against unauthorized access, theft or manipulation is an issue for every company in our network. Our partners are working on solutions for the optimal use of digital identities and encryption technologies for secure access and communication of your devices, machines and systems.

Services

The services of our partners support companies from our network in the implementation and optimization of IoT solutions. This includes consulting, individual customization, training and technical support. The aim is to make processes more efficient, integrate systems seamlessly and derive maximum benefit from IoT/IIoT data.

Our partners with tried-and-tested IoT/IIoT solutions

Providers from our network whose IoT and IIoT solutions have been tried and tested in practice.

Explore proven solutions from our network for your Condition Monitoring projects.

Imagine having direct access to proven technologies and best practices that have demonstrated their effectiveness in real-world applications. No theory, no guesswork – just solutions that have already been successfully implemented.

Industry challenges – do these sound familiar to you?

  • How do I find the right sensors and technologies that truly fit?
  • How do I integrate condition monitoring into my existing systems without disrupting operations?
  • How do I find partners who have proven their ability to solve these challenges?

Our platform is your shortcut to the solution.

We guide you step by step, showing how other companies have overcome the same challenges. Along the way, we connect you directly with the right technologies and partners to help you achieve your goals faster – safely and efficiently.

Benefits of Condition Monitoring:
Increase efficiency, avoid downtime

Early Detection of Problems


Condition Monitoring detects anomalies such as vibrations, overheating, or pressure fluctuations in real-time. Issues are identified before they escalate, preventing costly repairs and unexpected downtime.

Reduction of Energy Consumption

Through continuous monitoring of machines, inefficient processes can be identified and corrected. This not only leads to cost savings but also results in a significant reduction in energy consumption and CO2 emissions.

Extension of Machine Lifespan

Through continuous monitoring of wear parts and critical components, targeted actions can be initiated. This extends the lifespan of your machines and reduces long-term investment costs.

Higher Customer Satisfaction


Companies that use Condition Monitoring consistently deliver high quality and reliable products. This not only strengthens customer loyalty but also positions the brand as a trusted provider in the market.

Control over Costs

Condition Monitoring not only reduces unplanned downtime and repair costs but also ensures faster amortization of investments through optimized processes.

Improvement of Resource Planning

With Condition Monitoring, companies can plan the use of machines, personnel, and materials more efficiently. Resource waste is minimized, and production processes run more smoothly.

Optimization of the Maintenance Strategy


Instead of rigid maintenance schedules, Condition Monitoring enables a predictive approach. Maintenance is planned based on real-time data, so actions are only taken when they are truly necessary.

Increase in Operational Efficiency

Condition Monitoring helps identify and optimize inefficient processes. This minimizes energy consumption and resource waste, while sustainably increasing production performance.

From manufacturer to solution provider

Are you a machine and plant manufacturer working on digital solutions in your company? You know it too: Digitalization brings new challenges that you’d like to discuss with an experienced partner. We help you make your machines future-ready, build the right infrastructure, and develop innovative business models. Together with you and our strong partners, we find tailored solutions that optimize your processes and create new added value.

Centralized customer portal for Condition Monitoring

Offer your customers a powerful portal for accessing master data, technical documentation, and contact information. The integration of shift logs and data-sharing functions enhances transparency and increases the efficiency of your services.

Maintenance calendar with self-service features

Make maintenance planning easier for your customers with digital manuals and clear troubleshooting options. The maintenance calendar ensures that maintenance measures are carried out efficiently and without delays.

Seamless ecosystem integration for greater flexibility

Seamlessly integrate knowledge and data into a comprehensive ecosystem. With API interfaces and export options, you can provide your customers with a connected and flexible solution.

Smart plant integration and seamless commissioning

Support your customers in the efficient commissioning of new plants. With digitally supported processes, system integration and production starts are smoothly executed.

Optimized user integration and feedback tools

Give your customers the opportunity to better understand their end users. Through feedback management and customer traffic analysis, services can be tailored and optimized.

Predictive Maintenance

Help your customers act proactively rather than reactively. Predictive Maintenance enables data-driven maintenance planning, reduces downtime, and increases machine availability.

Intelligent recipe management for production lines

Digitize your customers' recipe management to make production processes more efficient. Changes and synchronization can be implemented across locations to save time and resources.

Transparent reports and compliance made easy

Provide your customers with solutions for comprehensive reporting that covers warranties and legal compliance. Transparent processes build trust and foster long-term partnerships.

Centralized customer portal for Condition Monitoring

Offer your customers a powerful portal for accessing master data, technical documentation, and contact information. The integration of shift logs and data-sharing functions enhances transparency and increases the efficiency of your services.

Maintenance calendar with self-service features

Make maintenance planning easier for your customers with digital manuals and clear troubleshooting options. The maintenance calendar ensures that maintenance measures are carried out efficiently and without delays.

A partner who understands your challenges

IoT Use Case is more than a network – we are your trusted advisor with a focus on trust, integrity and added value. Regardless of whether you want to implement a use case or are looking for the right entry point:

Our expertise and our network support you in making well-founded decisions based on practical experience that achieve your goals. With our experience from over 1,700 projects, we understand the hurdles, pitfalls and opportunities – and help you to overcome them.

Tried and tested solutions
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IoT Use Case – Your community for implementing IIoT

Join our IoT community and learn how other companies have successfully implemented Condition Monitoring. We provide you with a platform to discover best practices and find the right IoT solutions for your challenges.

Share and expand experiences

Exchange ideas and approaches on IIoT use cases such as Predictive Quality or Digital Service.

Develop use cases further

Share tips and best practices across functions and inspire other companies.

Discuss trends and challenges

Learn how others use IIoT technologies to solve challenges and identify trends early on.

Get inspired or find targeted solutions
– Your IIoT use cases at a glance.

Discover proven approaches for real-time monitoring of machines and facilities. Minimize downtime and ensure the availability of your processes.

React efficiently when it matters. Reduce downtime and keep your production running.

Plan maintenance work smarter and data-driven. Prevent failures with solutions that identify problems before they occur.

Track materials and products across the entire supply chain. Meet regulatory requirements and build trust through transparency.

Increase the efficiency of your facilities. Optimize operations, maintenance, and management with innovative technologies.

Reduce energy costs and optimize consumption. Use real-time data to make sustainable decisions.

Ensure your product quality with state-of-the-art technologies. Avoid rejects and identify sources of errors early.

Simplify your processes with paperless workflows. Benefit from centralized access and efficient data management.

Protect your assets and processes. Smart technologies help detect and minimize risks early.

Manage vehicle fleets efficiently and smartly. Optimize routes, reduce costs, and improve operational safety.

Protect your employees with innovative IoT solutions. From contaminant detection to emergency communication – ensure maximum safety.

Opt for eco-friendly and sustainable solutions. Monitor emissions and optimize resource consumption.

Implementation Support

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Use our free beta network database until 31.12.2025 to find practice-proven IoT solutions. Simply register and get direct access to tried and tested solutions from real projects, provided by trusted partners and companies. Benefit from the latest information, success stories and a preview of use cases that will drive your projects forward.

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FAQ

Ihre Fragen - unsere Antwort

Hinterlassen Sie Ihre Kontaktdaten und eine Nachricht zu Ihrem Anliegen. Wir vereinbaren einen Termin und schauen gemeinsam in die Datenbank.

Im Termin besprechen wir gemeinsam Ihre spezifischen Herausforderungen und Ziele. Anschließend präsentieren wir Ihnen entweder im Termin oder im Nachgang per Liste passende praxisgeprüfte Lösungen aus der Datenbank, die auf Ihre Bedürfnisse zugeschnitten sind. Der Termin dauert in der Regel 30 bis 60 Minuten.

Unsere Datenbank ist nach Branchen, Use Cases, Funktionsbereichen, Asset-Types und Technologien strukturiert. Je nach den Eigenschaften Ihres Use Cases schauen wir gemeinsam in die Datenbank und finden die für Sie relevanten Lösungen.

Ja, die Nutzung der Beta-Version ist bis zum 31.12.2025 kostenlos. Es gibt keine versteckten Kosten.

Der Zugang ist kostenlos, weil wir uns in der Beta-Phase unserer Plattform befinden. Ziel dieser Phase ist es, Feedback von Nutzern wie Ihnen zu sammeln, um unsere Netzwerk-Datenbank optimal auf die Bedürfnisse der Community anzupassen. Gleichzeitig möchten wir Ihnen die Möglichkeit geben, die Vorteile praxisbewährter Lösungen aus erster Hand zu erleben und Ihre IoT-Projekte erfolgreich voranzutreiben.

Unser Interesse bei IoT Use Case ist es, praxisbewährte IIoT-Lösungen zugänglich zu machen, die Unternehmen dabei unterstützen, ihre Digitalisierungsprojekte erfolgreich umzusetzen. Mit unserer Plattform und den zugehörigen Services schaffen wir eine vertrauenswürdige Umgebung, in der Best Practices und konkrete Anwendungsbeispiele im Mittelpunkt stehen.

Nach dem Termin erhalten Sie eine Zusammenfassung der präsentierten Lösungen sowie Zugang zu weiterführenden Informationen und Ansprechpartnern.

Die Lösungen in unserer Datenbank stammen von vertrauenswürdigen Partnern und Unternehmen aus unserer Community, die erfolgreich IoT-Projekte in der Praxis umgesetzt haben. Jede Lösung basiert auf realen Anwendungsfällen und wurde unter realen Bedingungen von mindestens einem Kunden oder Anwender getestet.

Die Inhalte werden täglich mit aktuellen Lösungen, Referenzen und neuen Use Cases aktualisiert.

Ja, wir freuen uns über neue Lösungen. Wenn Ihre Lösung bereits in der Praxis erfolgreich eingesetzt wurde, können Sie diese in die Community-Datenbank einbringen. Sprechen Sie uns dazu einfach über unseren Kontaktbereich an oder senden Sie uns einfach eine Nachricht mit den Details Ihrer Lösung an:

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