How Condition Monitoring Solutions Reduce Downtime and Enhance Longevity

In an exclusive interview with Industry Outlook magazine, Seshan Iyer, President of Bearings & Industrial Solutions at Schaeffler India, shares his insights on how companies can boost operational efficiency while tackling the challenge of unpredictable downtimes. He brings over 31 years of leadership experience in industrial application businesses. He has steered industrial sales verticals for Bonfiglioli Transmission India, Dalmia Refractories Limited, TDW India Limited and Cooper Roller Bearings Company. With his in-depth knowledge of the target markets, he is driving Schaeffler’s intelligent, efficient and sustainable products and services to advance Industry 4.0 motion technology.

According to him, companies can reduce unplanned downtime by,

-Periodically ensuring the health and reliability of machinery.

-Integrating advanced sensors in existing and new machinery.

-Gather meaningful insights via data analytics to schedule maintenance

Condition monitoring solutions are increasingly being adopted in Indian manufacturing to enhance operational efficiency. What specific benefits are companies experiencing from this adoption?

Condition monitoring is a broad and essential aspect of industrial operations, ensuring the health and reliability of machinery. In industries like Schaeffler’s, where components such as bearings are critical, monitoring their condition is vital because bearings inevitably wear out over time. The key challenge is predicting when a bearing is likely to fail so that maintenance can be scheduled proactively, avoiding costly unplanned downtime.

To address this, vibration sensors are installed on equipment where bearings are assembled. These sensors continuously monitor vibration patterns, detect anomalies, and transmit data to the cloud. The collected data is then analyzed in a digital ecosystem, allowing for real-time condition assessments and predictive maintenance.

For example, in a paper manufacturing plant, where machinery operates continuously, unexpected breakdowns can have severe financial and operational consequences. Vibration sensors installed on rotating elements communicate critical machine health information to a remote control room, enabling maintenance teams to intervene before failures occur.

Beyond vibration analysis, lubrication monitoring is another crucial factor in ensuring machine longevity. Schaeffler has developed innovative solutions for analyzing lubrication conditions, such as the Grease Check system. This advanced sensor technology is installed in machines that require periodic grease replenishment. It continuously measures grease viscosity, detects contamination, and identifies foreign particles caused by wear. By performing wear debris analysis, it provides valuable insights into the overall health of the machine.

Advanced sensors are significantly reducing unplanned downtime in the automotive sector. How are these sensors integrated into existing maintenance workflows to maximize their effectiveness?

There are two key approaches to integrating condition monitoring solutions for industrial machinery, depending on whether the equipment is new or already in operation. 

For newly manufactured machines, we work directly with Original Equipment Manufacturers (OEMs) to integrate sensors into their products, such as gearboxes. These OEMs supply industrial machinery to major end users like Tata Steel, SR Steel, and others. By embedding vibration sensors in the gearbox during manufacturing, the end user can start capturing and analyzing condition data from day one. This proactive approach ensures that predictive maintenance capabilities are built into the equipment from the outset. 

For older machines already in use, we collaborate with end users to assess machine criticality and recommend the most suitable condition-monitoring solutions. The selection process considers factors such as operational importance, failure risks, and maintenance needs. 

In addition to supplying condition monitoring products, we provide comprehensive services to support implementation. This includes annual condition monitoring contracts, where trained specialists are deployed to the customer’s plant to conduct continuous monitoring and diagnostics. Remote monitoring and data analysis are also offered, where vibration data is collected from sensors, transmitted to centralized monitoring centers (such as in Pune, India), and used to generate real-time reports for customers.

Data analytics plays a crucial role in improving the effectiveness of condition monitoring systems. What specific metrics are most valuable for manufacturers to track?

Data analytics in condition monitoring is a broad and critical domain, aimed at capturing and interpreting process-related data to ensure machine reliability and efficiency. The goal is to gather meaningful insights that can help predict potential failures and optimize maintenance schedules. 

For instance, in the case of a pump, its primary function is to build pressure and deliver flow. If the pump is driven by an electric motor that starts malfunctioning, it will fail to meet the required flow or pressure. Data analytics helps monitor such process parameters, identifying deviations that may indicate underlying issues. If an electric motor begins to deteriorate, the failure could be due to problems with the bearing, rotor, or stator. By fitting vibration sensors on the motor, these issues can be detected early. The collected signals allow analysts to assess the motor’s performance at different RPM levels, track trends, and predict potential failures before they occur. 

A key metric in this analysis is the Mean Time Between Failure (MTBF). Every asset owner aims to maximize this interval, as a longer MTBF signifies stable and controlled operations. When deviations occur from expected metrics, it can indicate problems related to maintenance, lubrication, assembly, or other process-related factors. 

Different industries have specific performance metrics based on their operational requirements. A paper plant, cement plant, or steel plant will each have unique parameters, but the fundamental priorities remain the same—ensuring reliability and 24/7 equipment availability. Data analytics enables real-time monitoring and predictive maintenance, allowing businesses to maintain smooth operations and minimize unplanned downtime.

The integration of predictive maintenance strategies is becoming essential for enhancing machine longevity. What challenges do companies face when transitioning from reactive to predictive maintenance?

Predictive maintenance is increasingly being adopted by companies as a key strategy to enhance operational efficiency and prevent unplanned downtime. However, several challenges arise in its implementation, particularly when integrating older machines with Industry 4.0 technologies. Many companies aspire to upgrade their infrastructure to enable seamless machine-to-machine communication, but this often encounters compatibility issues. Older machines may operate on different platforms that do not inherently communicate with one another, creating a significant bottleneck in achieving a unified Industry 4.0 ecosystem.

Another major challenge is the investment required for Industry 4.0 deployment. Organizations differ in their priorities—some may seek to sensorize thousands of rotating equipment points, while others may focus on a select few critical machines. Without aligning with the company’s specific priorities and budget constraints, a comprehensive predictive maintenance strategy cannot be effectively deployed.

Data ownership and security present additional hurdles. When condition monitoring sensors are installed on a company’s machinery, the data must be transmitted to a remote location or the cloud for analysis. This introduces several concerns, including data transmission reliability, bandwidth availability, and security measures to protect sensitive information. Many companies prefer to keep their data local to mitigate cybersecurity risks, but this approach increases manpower requirements. For example, if each of India’s 1,500 long product mills requires on-site personnel to monitor data, or if every cement plant with hundreds of rotating machines demands dedicated staff, the scalability of such a system becomes impractical.

Ultimately, the industry is still evolving in terms of trust and maturity when it comes to outsourcing predictive maintenance and data management. Many organizations remain hesitant to fully rely on service providers for real-time remote monitoring, fearing data breaches or loss of control over critical operational insights. Overcoming these challenges will require a combination of technological advancements, improved security frameworks, and a shift in mindset toward trusting external predictive maintenance solutions.

What is the primary objective and purpose behind Schaeffler India’s participation in IMTEX 2025?

At IMTEX 2025, visitors will witness a wide range of advancements in machine tools, automation, and robotics. Schaeffler India, as a leading provider of both products and service solutions, is actively participating in the event to showcase its latest innovations and reinforce its commitment to its customers. The company is demonstrating cutting-edge technologies that will shape the future of the industry, offering solutions that can enhance efficiency and performance for manufacturers and end users alike. 

At Schaeffler India's exhibition stall, visitors can explore several innovative solutions, including advanced sensorization technology, state-of-the-art lubrication systems, and high-performance metallurgy coatings. The display also features ceramic rollers and ceramic ball bearings, which offer superior durability and efficiency. Additionally, the company is showcasing its precision planetary gearbox, a crucial component in Automated Guided Vehicles (AGVs), collaborative robots (Cobots), and other robotic applications. 

Beyond products, Schaeffler India is emphasizing its comprehensive service offerings. The company provides a range of lubrication solutions, including single-point and multi-point lubrication systems designed to optimize machine performance and longevity. By offering a holistic approach that combines high-quality components with reliable service support, Schaeffler India positions itself as a single-window solution provider for customers participating in IMTEX 2025.

How do you see the industrial sector evolve in India in the coming years, what are the trends you foresee that will drive the change?

The wind energy sector has seen significant advancements, moving from 1.2 MW turbines two decades ago to 5 MW today, with potential growth up to 11 MW, especially with India's investment in offshore wind farms. This shift demands larger, high-performance bearings—up to 2 meters in diameter—along with specialized coatings for minimal friction and long-term lubrication solutions for efficient operation.

With India's focus on high-speed trains like the Vande Bharat and infrastructure projects such as the high-speed freight corridor and metro expansions, there is an increasing need for high-performance traction motors, tapered roller bearings (Terrol) for freight applications, and insulated bearings for electric locomotives. Schaeffler India is well-positioned to support these advancements with cutting-edge bearing and coating technologies.

The machine tool industry is transitioning from conventional speeds of 15,000-20,000 rpm to 40,000 rpm, requiring advanced lubrication, high-grade steel, and low-friction bearing solutions that can operate efficiently at high speeds.

With the rise of EVs, electric motors are replacing traditional combustion engines. High-speed ball bearings with low friction coatings are essential for maximizing efficiency and minimizing heat generation. Schaeffler is actively innovating in this space to support the transition to electric mobility.

Efficiency is the key driver in heavy industries, with a trend towards downsized but highly efficient machines. This requires robust, long-lasting bearings that enhance productivity and reliability while reducing maintenance costs.

The next 5 to 10 years will be crucial for industrial transformation. With a focus on sustainability, efficiency, and advanced engineering, Schaeffler India is poised to play a pivotal role in shaping the future of multiple industrial segments through cutting-edge bearing solutions, coatings, lubrication technologies, and automation innovations.