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Machvory Digital Engineering
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OPTIMUS · CONDITION MONITORING

Watch critical machines before a fault turns into a breakdown

Vibration, temperature, current, and other condition parameters tracked continuously on critical assets, with thresholds, trends, and tiered alarms.

See the screens

Platform: OPTIMUS · Asset Reliability

OPTIMUS Monitoring page with live charts from CT sensors and kWh meters per area, showing current and total power for each device
Captured from a running system, not an illustration.

The problem

Machine condition is only known at the scheduled inspection

A routine inspection gives you a snapshot of one moment. Whatever changes between two inspections goes unseen, and damage is often found only once you can clearly hear it or feel it.

Signs we usually find

  • Vibration is measured by hand, and not often
  • Readings are stored in separate places and hard to compare
  • Nothing warns you automatically when condition gets worse
  • Faults are found by noise or heat, not by data

Used by

  • Maintenance Manager
  • Reliability Engineer
  • Predictive Maintenance Technician
  • Plant Manager

Data it reads

  • Vibration and temperature sensors on rotating equipment
  • Motor current from a power meter or current transformer
  • Asset nameplate data and reference thresholds (e.g. ISO 10816-3)
  • Area, asset, and device hierarchy
A condition sensor mounted on a gearbox body on the production floor
A condition sensor mounted on a gearbox body on the production floor

How it works

From the machine to a decision

  1. 01

    Sensors

    Vibration, temperature, current

  2. 02

    Telemetry

    Continuous data to the platform

  3. 03

    Thresholds

    Normal limits per asset

  4. 04

    Alarms

    Warning & critical

The system

What it looks like on screen

OPTIMUS Telemetry page with sensor parameter trends per device for condition analysis
OPTIMUS Telemetry page with sensor parameter trends per device for condition analysis

Capabilities

What you can do with it

  • Continuous telemetry

    Condition is read around the clock, not only at the scheduled inspection.

  • Multi-axis vibration

    RMS and peak values per axis, so you can tell which direction the fault is coming from.

  • Temperature & current

    Supporting parameters read alongside vibration to back up the diagnosis.

  • Thresholds per asset

    Normal limits set for each machine’s class and rating, not one number for everything.

  • Tiered alarms

    Warning and critical kept apart, so it is clear what gets handled first.

  • Historical trends

    A change in condition shows up as a direction over time, not a single reading.

  • Asset hierarchy

    Plant, area, asset, and device arranged so condition can be read at every level.

  • Notifications

    Alarms can be forwarded to the responsible team by email and WhatsApp.

On the floor

How it is used day to day

  1. 01

    Condition changes

    Picked up by the sensor

  2. 02

    Threshold crossed

    Warning or critical

  3. 03

    Notify

    The right team is alerted

  4. 04

    Diagnose

    Trend & history reviewed

  5. 05

    Act

    Inspection or work order

Impact

Why it matters

01

Time to plan the job

Catching a condition change early leaves room to get spare parts ready and schedule the repair when it disrupts production the least.

02

Inspections go to the assets that actually changed

Instead of checking every machine on the same interval, the team can focus on the assets whose data shows a change.

03

A condition history you can trace

Every maintenance decision has data behind it, which helps when reviewing the work and when filing a warranty claim.

Start with this alone

Condition monitoring usually starts on a few of the most critical rotating machines. Once condition data is flowing, predictive maintenance, asset health, and CMMS in OPTIMUS can be added step by step.

In practice

Across different kinds of plants

Rotating Equipment
Monitor critical motors, pumps, and fans continuously, with no manual rounds.
Utility
Keep watch on compressors and chillers that run nonstop.
Oil & Gas
Track the condition of gas compressors and process equipment in hard-to-reach areas.
Manufacturing
Watch gearboxes and bearings on machines that are expensive to stop.

Integration

It connects to what you already have

No PLC, meter, or ERP needs replacing. Machvory reads from the equipment already installed in your plant.

  1. 01

    PLCs, sensors, meters

    Data at the machine

  2. 02

    Edge gateway

    Acquisition and buffering

  3. 03

    Machvory integration layer

    Modbus, OPC UA, MQTT

  4. 04

    TNS / OPTIMUS

    Analytics and workflow

  5. 05

    ERP, SAP, BI

    Enterprise reporting

  • Siemens, Mitsubishi, Omron, Allen-Bradley PLCs
  • Modbus TCP and Modbus RTU
  • OPC UA
  • MQTT
  • Power and energy meters
  • Vibration, temperature, current sensors
  • Existing SCADA and HMI
  • ERP and SAP
  • REST API and SQL

Next steps

What usually comes next

Start with one need and add the rest when you actually need it.

optimus · Asset ReliabilityPredictive MaintenanceCondition trends, anomaly detection, and maintenance history combined into recommended actions, so the maintenance schedule follows asset condition and not just the calendar.Learn moreoptimus · Asset ReliabilityAsset Health MonitoringA health score per asset, a ranking based on condition and criticality, and a watchlist of critical assets that makes the order of work clear.Learn moreoptimus · MaintenanceCMMSPreventive and corrective maintenance, scheduling, work orders, checksheets, spare parts, and work history all tied to the same asset.Learn moreoptimus · Operations & VisualizationOPTIMUS Digital TwinEvery object in the 3D plant model is bound to the real asset and carries its operating status, condition, active alarms, running hours, and open work orders.Learn more

See the whole platform OPTIMUS

FAQ

Questions we get a lot

Do we have to put sensors on every machine?

No. Condition monitoring pays off most on assets where a stop is costly or a repair takes a long time. Picking those critical assets is usually the first part of the assessment.

Do the sensors have to come from Machvory?

Not necessarily. Third-party sensors can be integrated as long as their data is reachable over Modbus, MQTT, OPC UA, or another open protocol. Machvory also supplies acquisition hardware where it is needed.

Does this guarantee every failure gets predicted?

No, and we do not claim it does. What the system does is watch condition continuously, flag changes and anomalies early, and give enough context for the maintenance team to decide on an action before things turn critical. The final call stays with the engineer.

Do we have to replace our existing PLCs or machines?

No. Machvory reads from what is already installed over Modbus, OPC UA, MQTT, or a power meter. Where a machine does not expose the data point we need, we add a sensor or gateway to that machine alone rather than touching its controls.

Can it run on-premise, with no cloud?

Yes. It can run entirely on a server inside the plant, in the cloud, or split between the two. The choice usually comes down to your IT/OT policy and what the plant network can carry.

How long does the first implementation take?

It depends on how ready the data points are and how many machines are involved. We normally start with a pilot on one line or a few critical assets to prove out data quality and the workflow, then widen once it holds up on the floor.

Further reading

Assess the Risk on Your Critical Machines

Our engineers look at your machines and the data you already have, then scope a pilot that is realistic to run.

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