Strategic Monitoring for Sustainable Success

Beyond the Blanket: Why a Strategic Approach to Condition Monitoring Outperforms “One-Size-Fits-All” Wireless

In today’s fast-moving industrial world, real-time data and easy-to-deploy technologies are hard to ignore. It’s why so many teams lean toward a “one size fits all” approach to condition monitoring, often relying heavily on plant-wide wireless sensor networks. While wireless has clear benefits, blanketing your facility with sensors without a strategy can create its own set of problems and miss the mark when it comes to true operational excellence. A better approach? Criticality-based strategic approach, the use of a combination of data collection methods to get lasting results.

Temptation of Wide-Scale Wireless Monitoring

It’s easy to see why so many plants are drawn to wide-scale wireless monitoring: 

• Ease of Deployment:

  Wireless sensors reduce installation time and cost by removing the need for extensive cabling, especially in remote or hard-to-reach areas.

• Accessibility of Data:

  Getting automatic, consistent data from multiple assets gives teams faster insight into what’s really happening on the floor.

• Built-In Flexibility:

  Wireless solutions can be moved or reconfigured with minimal hassle, which comes in handy for shifting layouts or temporary monitoring needs. 

That said, while the benefits are significant, leaning too hard on a wireless-only approach, without factoring in the needs and criticality of each asset, can lead to more headaches than value. A smart strategy goes beyond convenience and looks at what each machine truly requires. 

The Downside of an Unstrategic Wireless-Only Approach

Wireless technology is an invaluable component of modern condition monitoring, but going all-in without a solid strategy or considering asset criticality can create more problems than it solves:

1. Too Much Data, Not Enough Clarity:

   When you monitor every single asset, regardless of its importance to production, you end up buried in data. That kind of “noise” makes it hard for teams to spot what really matters. Alarm fatigue sets in, and real threats can get missed in the mix.

2. Wasted Resources Where It Matters Less: 

   • Extra Maintenance Load: Battery-powered sensors need regular upkeep like battery swaps, calibrations, and troubleshooting connectivity issues. That’s time your technicians could be spending on proactive work for your most critical machines. 
   • Infrastructure Costs Add Up: Sure, you save on wiring, but now you’ve got to manage all that data, meaning recurring costs on software, data storage, and analytics tools.
   • Investment Misses the Mark: Pouring money into nonstop monitoring of low-priority machines doesn’t always pay off. In many cases, a simpler, periodic approach would do just fine and would free up budget for the assets that really need it.

3. Some Machines Need More Than Wireless Can Deliver:

   For highly critical assets or complex machinery, you may need sharper, faster data, things like high-frequency sampling or real-time analysis. In those cases, wireless might not cut it. Hardwired or continuous systems still tend to deliver the best reliability.

4. Integration Complexities:

   A sprawling, unstructured wireless network can introduce complexities in cybersecurity, network management, and seamless integration with broader operational systems if not meticulously planned and managed.

Combining Monitoring Methodologies with Criticality in Mind

Instead of covering every asset with the same kind of monitoring, a smarter approach is to tailor your setup based on how critical each asset is and how it fits into your operation. That means combining different data collection methods to match real-world needs:

1. Start with a Criticality Assessment:

   Before you do anything, rank your assets based on their importance. That means looking at:

   • Impact on Production: What is the financial and operational impact of an asset failure (e.g., downtime, lost production, quality issues)?
   • Safety Risks: Does an asset failure pose a risk to personnel or the environment?
   • Regulatory Compliance: Are there legal or compliance reasons to monitor certain machines more closely? 
   • Maintenance History and Failure Modes: Which assets have a history of frequent failures or pose unique maintenance challenges?

2. Build a Tiered Monitoring Plan with the Right Tools:

   Once you’ve sorted assets by importance, apply the right tools to the right jobs. 

   • Tier 1 (Highly Critical Assets): These are the backbone of your plant. They usually need continuous online monitoring, either hardwired for top-level accuracy or high-performance wireless systems where appropriate, to catch issues early and keep production running. This will help provide real-time, high-resolution data for advanced diagnostics and predictive insights.
   • Tier 2 (Semi-Critical Assets): These assets contribute significantly to production but might have some redundancy or less immediate impact. Here, strategically deployed wireless sensors can be highly effective for continuous or periodic condition monitoring, providing early warnings of potential issues, especially in remote or difficult-to-access locations.
   • Tier 3 (Low or Non-Critical Assets): For these assets, periodic manual inspections or portable data collectors used during routine rounds might suffice, offering cost-effective monitoring without over-investing resources.
     

3. Use Each Method Where It Makes the Most Sense: 

   • Wireless Sensors are great for: Hard-to-access areas, mobile machines, temporary projects, or when ultra-precise data isn’t required.
   • Portable Analyzers work best for: Route-based collection, in-depth troubleshooting of specific issues, or covering more ground with less hardware or permanent installations. 
   • Continuous Online Systems (wired or high-performance wireless) are ideal for: Assets with rapid failure modes, critical machines, or any situations requiring immediate and precise diagnostics tied to automation or shutdown.

4. Tie Everything Together:

   No matter what you use, make sure your data talks to your SCADA, PLC, and CMMS systems. That’s how you get the full picture and make better decisions across maintenance, operations, and management.

5. Focus on What You Can Act On:

   The goal is to turn that data into clear, useful insights that let you plan ahead, fix problems before they grow, and boost plant performance. That means using strong analytics, good visualization, and tools that can pull everything together in one place.

Bringing Strategy to Life with the Acoem NEST Ecosystem

To see what a smart, strategic approach to condition monitoring looks like, take a look at the Acoem NEST Ecosystem. Acoem gets that it’s not about throwing one type of sensor on every asset, it’s about turning the right data into real insights, especially on the machines that matter most.

The NEST Ecosystem, which includes NEST i4.0 software plus tools like the Sparrow and Eagle wireless sensors, Falcon portable analyzers, and the MV-x real-time monitoring system, is built around that principle:

• Data That Works Together:

  NEST i4.0 pulls in data from different sources and brings it into one platform. That includes the Sparrow and Eagle wireless sensors (great for regular checks on general assets), Falcon portable analyzer (perfect for in-depth, route-based analysis), and the MV-x system (continuous, real-time monitoring for your most critical machines). No data silos, just a full view of asset health, no matter the source.

• Smart, Targeted Diagnostics with Accurex™ AI:

  Acoem’s Accurex™ AI engine is a real differentiator. It automatically analyzes vibration data from all sources, flags known issues like unbalance or bearing faults, and gives clear, confident diagnoses with ratings. It helps cut through the noise so maintenance teams can focus where it really counts.

• From One Machine to Full Plant View:

  The Machine Health Matrix in NEST i4.0 gives a quick visual on which machines need attention, while NEST Vision steps it up with a plant-wide, web-based view. It helps pinpoint problem assets over time and connects vibration data with other sources like ultrasound, oil analysis, and even visual checks. That big-picture view helps prioritize work based on urgency and real risk.

• Built for Techs, Not Just Analysts:

  NEST Vision is designed to be user-friendly, so that you don’t need to be a vibration expert to use it. With tools like the guided setup, drag-and-drop machine builder, and intuitive dashboards, maintenance teams can get the system running and interpret results quickly without needing a specialist. This enhances the efficiency of condition monitoring programs across all criticality tiers, regardless of the data source.

• Open Data Platform for Enterprise Integration:

  Acoem’s commitment to an open data platform (supporting standards like OPC UA and CSV export) ensures that asset health information from the NEST Ecosystem can be seamlessly integrated with broader enterprise systems like CMMS, PLCs, and SCADA. That means you’re not just collecting data, you’re feeding it directly into smarter maintenance planning and resource allocation. 

Conclusion: Smarter Monitoring for Sustainable Success

The appeal of real-time data and simplified deployment is hard to ignore, and wireless technology has become a powerful part of modern condition monitoring. But to really get the most out of it, along with other tried-and-true methods, you need a strategy based on asset criticality. That means mixing portable, wireless, and continuous monitoring tools based on what each machine actually needs. Solutions like the Acoem NEST Ecosystem show how you can bring all that data together, no matter where it comes from, and turn it into clear, actionable insights. That’s what drives smarter maintenance, better performance, and fewer unexpected failures. The future of condition monitoring isn’t about picking one technology over another; it’s about using the right mix of tools in the right places, with a focus on what really matters.

Whether you’re building a condition-based maintenance program from the ground up or strengthening an existing one, Acoem is here to help. As the Reliability Partner, our team has the expertise and tools to help you drive a culture of reliability and resilience across your organization.

Get in touch with us today — let’s start building your path to greater reliability.