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Condition Monitoring and Predictive Maintenance Chapter 1 The Challenge of Unplanned Downtime In a busy manufacturing plant, a critical 400 kW air compressor runs non-stop, powering the production line. When Analog Devices' smart motor sensor detects subtle, early- stage vibrations signaling a bearing fault, maintenance teams quickly intervene. Catching the problem long before any visible or audible signs appear, the plant avoids costly downtime, demonstrating how advanced condition monitoring transforms maintenance from reactive repairs into proactive problem-solving. Smart manufacturing is undergoing a transformation as automation technologies become increasingly prevalent in the industry. However, unplanned downtime remains a significant challenge, accounting for 24% of total production costs. Despite the implementation of maintenance programs, 82% of companies still struggle with unexpected equipment failures. This issue is further exacerbated by the impending retirement of experienced workers, resulting in a critical shortage of machine expertise. Forward-thinking manufacturers are embracing advanced solutions like condition monitoring and predictive maintenance to tackle these challenges and maintain competitiveness. These proactive approaches utilize real-time data from various sensors to identify early warning signs of potential issues, allowing companies to resolve problems before they lead to costly downtime. While traditional wired monitoring systems can be expensive and difficult to implement, the industry is transitioning toward more flexible and scalable battery-powered wireless tools. Environmental Impact and Sustainability Benefits The benefits of predictive maintenance go beyond merely minimizing downtime. By proactively identifying and addressing faults, such as inefficient motors, manufacturers can significantly lower energy consumption and CO2 emissions. This not only saves costs but also aids in achieving sustainability goals, making condition monitoring an essential part of the future smart factory. Defining Condition Monitoring vs. Predictive Maintenance At its core, condition monitoring involves consistently tracking machine health using real-time data from sensors that measure key indicators such as vibration, 4 Engineering Reliable Industrial Automation With Sensor Fusion