CONDITION MONITORING

Condition Monitoring Solutions for Discrete Manufacturing

Most equipment failures do not happen without warning. They develop over time through changes in alarm patterns, signal behavior, drive temperatures, and other measurable indicators that precede the failure itself. Give your operation the continuous, standardized machine data it needs to see equipment health clearly and act before problems compound.

CAPTURE DEEP MACHINE DATA 

Go beyond basic machine states with access to signals like load, alarms, feed rates, and overrides, configured to the data that matters to your operation.

SEE CHANGES, NOT JUST STOPS

Understand shifts in operating conditions in real time, not just when a machine goes down, so you can respond earlier and keep production running smoothly.

REDUCT UNPLANNED DOWNTIME

Catch issues earlier and respond before they disrupt production with real-time data when evaluating machine health and performance

THE GAP

The Cost of Operating Without Condition Monitoring

Without continuous visibility into how your equipment is actually performing, maintenance decisions default to two options: respond to failures after they happen, or service equipment on a fixed schedule regardless of its actual condition. Both approaches carry costs that condition monitoring systems are specifically designed to reduce.

Unplanned failures are expensive

When equipment fails without warning, the costs compound quickly. Emergency service calls, overtime and weekend labor rates, expedited parts procurement, idle downstream equipment, and missed production targets all arrive at once. In a multi-process production environment, a single unplanned failure can stop an entire line. The repair itself is rarely the largest expense. The cascading production losses are.

Maintenance without data wastes resources

Time-based preventive maintenance schedules service equipment on a calendar rather than on true condition. Parts get replaced before they need to be. Maintenance labor gets spent on assets that do not yet require attention while developing issues on other machines go undetected between intervals. Without continuous signal and alarm monitoring across every asset, the maintenance schedule is an estimate, not a plan.

Manual monitoring won’t scale the shop floor

An operator can directly observe one machine. A supervisor can walk the floor periodically. Neither approach generates the continuous, standardized equipment data that effective condition monitoring requires. In discrete manufacturing environments running even 20 machines, manual monitoring leaves critical gaps that only become visible when something goes wrong.

OUR APPROACH

How Juxtum Delivers Condition Monitoring Across Your Operation

Juxtum’s software adapters collect a broad range of data directly from your manufacturing equipment, including axis positions, spindle loads, feed rates, drive temperatures, overrides, and block and line numbers, all standardized using the MTConnect ANSI standard format. Once connected, Juxtum View monitors alarm patterns and signal behavior across every asset in real time.

Deviations from normal operating conditions surface as alerts before they become failures. Maintenance teams gain earlier visibility into equipment health so repairs can be scheduled strategically, at a planned time, with the right resources in place, rather than in response to an unplanned stoppage.

Condition monitoring systems are only as effective as the data feeding them. Juxtum’s patented adapter software automatically discovers each machine’s unique configuration without interrupting production. For most CNC machines, data is flowing within approximately ten minutes of deployment. No downtime. No manual configuration.

The same connectivity extends to PLCs, robots, and other assets across the shop floor, including legacy equipment and control types that competing solutions cannot reach. Juxtum is the only provider with dedicated adapters for Siemens 840D and Sinumeric controls, giving manufacturers access to machine data other platforms leave on the table.

For assets where additional physical monitoring strengthens the condition picture, Juxtum supports supplementary sensor data collection as a layer on top of native machine data. Vibration analysis, temperature monitoring, and other condition signals can be incorporated into the same standardized data stream without requiring a separate system or data silo.

Juxtum View delivers condition monitoring data through real-time dashboards, alarm reports, downtime reports, and utilization analytics, deployable in the cloud or on-premises. Alerts reach the right people when equipment behavior changes, giving maintenance teams and operations leadership a shared, accurate view of shop floor performance without waiting on manual reports or shift summaries.

THE IMPACT

What Condition Monitoring Makes Possible

Effective condition monitoring does not just reduce maintenance costs. It changes how your operation runs. When alarm patterns and signal trends are visible continuously, maintenance decisions can be based on actual equipment condition rather than elapsed time or failure events. Repairs get scheduled at planned intervals, with the right parts on hand, at a time that minimizes production impact. The result is lower maintenance costs, better resource allocation across your maintenance team, and a production schedule that is not regularly interrupted by equipment failures.

One manufacturer connected through Juxtum discovered that machines scheduled to run for seven hours were averaging six hours and fifteen minutes of actual production time. That forty-five-minute gap represented recoverable capacity that required no additional capital investment to address. Identifying and reducing unplanned downtime through condition monitoring is one of the most direct paths to increased throughput in a facility you are already running.

The same data layer that supports condition monitoring today can support more advanced predictive maintenance software analytics as your operation’s digital maturity grows. Juxtum Connect provides the clean, structured, real-time shop floor data those initiatives require. The foundation does not need to be replaced as your ambitions expand.

$50,000 IN SAVINGS IDENTIFIED JUST MINUTES AFTER DEPLOYMENT

An aircraft engine manufacturer deployed condition-based monitoring on critical equipment using Juxtum. Almost immediately, the team uncovered serious issues that traditional maintenance methods would have missed

OUR EDGE

Why Manufacturers Choose Juxtum for Condition Monitoring

Connection across entire asset base

Our patented automatic discovery technology connects to any manufacturing asset, regardless of age, brand, or control type. Where competitor solutions leave legacy equipment unconnected and create gaps in condition monitoring coverage, Juxtum gives you a complete picture across every machine on your floor.

Cloud or on-premise deployment

Deploy in the cloud for rapid time-to-value, or on-premises for manufacturers with strict data security requirements. This is a critical distinction for aerospace and defense facilities where production data must stay within facility boundaries. Most monitoring solutions offer cloud-only. Juxtum gives operations teams the choice.

Integration with the systems you already have

Juxtum is not an ERP or MES. It fills the machine data gap those systems cannot address and delivers standardized equipment data to the platforms your team already relies on, including ERP systems, MES platforms, databases, Power BI, and third-party analytics tools.

“We’ve moved from reacting to identifying problems before they impacted production. Juxtum made our maintenance approach more proactive without adding burden to the team.”

– Mark R., Maintenance Manager, Wichita, KS 

See Your Equipment Health in Real Time

The manufacturers with the clearest picture of what is happening on their shop floors are the ones best positioned to act on it. If your maintenance decisions are still driven by schedules, assumptions, or the last failure event, the opportunity to change that is within reach, using the equipment you already own.

Condition Monitoring FAQs

Condition monitoring is the continuous tracking of machine health indicators such as alarm patterns, signal behavior, and drive temperatures to identify early signs of equipment issues before failure occurs.

It enhances maintenance planning by adding real-time equipment visibility, helping teams make more informed decisions about when and where maintenance is actually needed.

By identifying early warning signs, manufacturers can address issues before they escalate into machine failures, reducing the likelihood of unplanned stoppages.

When early indicators are missed, issues can compound until they result in unplanned downtime, often leading to higher operational and repair costs.

Not always. Many machines can be connected directly through existing controls. Additional sensors are used only where they add value or where machine data access is limited.

Get More From Your Shop Floor

The data you need is already in your machines. Juxtum makes it actionable so you can turn production into performance that moves your operations forward.