How to Fix Condition Monitoring Mistakes and Prevent Downtime

What We Learned in the GraceSense™ Webinar on Improving Condition Monitoring

In our recent webinar, Business Development & Training Coordinator Nick Augustine and Field Application Engineer Jake Wistinghausen explored some of the most common condition monitoring mistakes and practical ways to fix them. Their message was clear: you can’t build a reliable predictive maintenance program without first investing in better machine health monitoring.

If you missed the live session, you can watch it anytime on‑demand here.

Common Pitfalls in Condition Monitoring

Many facilities still rely on route-based inspections or monthly vibration readings, leaving blind spots that can turn into expensive surprises. Nick opened with a familiar scenario: a machine shows subtle changes in vibration, but no one sees it until a major failure occurs.

That’s why GraceSense™ was designed to deliver continuous real-time asset monitoring—with alerts that put actionable data in front of your team right away.

Automated alarms via email and text ensure you never miss critical asset health updates.

Why Catching Faults Early Matters

Jake walked through the well-known D-I-P-F curve, showing how equipment moves from design and precision phases into failure if problems aren’t caught early. Repairs get more costly and disruptive the farther you move down the curve.

GraceSense™ Machine Health Monitoring keeps you on the left side of that curve—detecting potential failure early so you can plan interventions instead of reacting to emergencies.

The D-I-P-F Curve shows why detecting issues early is key to cost‑effective predictive maintenance.

Trending Data Over Time

One of the most valuable parts of the webinar was seeing real examples of vibration trends from actual deployments. With wireless vibration monitoring and temperature tracking, GraceSense™ provides clear trend lines that reveal issues developing over days or weeks.

Instead of reacting to a single reading, you can see the story of your asset’s health over time.

Continuous monitoring reveals patterns that periodic checks can miss.

Defect Classification Without an Analyst

Traditionally, interpreting vibration data required a certified vibration analyst. GraceSense™ changes that by automatically matching sensor data to 19 fault models, from bearing wear to imbalance.

Jake demonstrated how the Maintenance Hub dashboard visualizes this data in simple charts rather than raw FFT plots, so anyone on your team can understand what’s happening and take action.

Maintenance Hub fault classification displays clear, actionable data without requiring a vibration analyst.

Scalable Predictive Maintenance That Works

With GraceSense™, scaling your program doesn’t mean adding headcount. Each sensor integrates quickly, and gateways support both plant networks and cloud connectivity. Nick and Jake shared stories of plants installing dozens of sensors in just a few hours and cutting unplanned downtime dramatically within months.

Whether you’re monitoring a single motor or hundreds across multiple sites, GraceSense™ makes condition monitoring implementation fast and repeatable.

Ready to Improve Your Condition Monitoring?

If your predictive maintenance strategy isn’t delivering results, start with better data. GraceSense™ gives you the real-time insights you need to catch faults early, plan smarter maintenance, and avoid costly surprises.

✅ Learn more about GraceSense™
✅ Watch the on-demand webinar
✅ Request a demo or pilot kit

You don’t need a team of vibration experts—you just need the right tools. GraceSense™ helps you avoid predictive maintenance mistakes and keep your operations running strong.