Condition Monitoring

Detect Failures Before They Occur

Monitor vibration, temperature, current, and load in real time. Prevent unplanned breakdowns, reduce maintenance costs, and extend machine life—without disrupting operations.

The Core Problem

Unplanned Breakdowns: The Silent Shopfloor Killer

Most plants still rely on reactive maintenance—waiting for a machine to fail before taking action.
Maintenance logs are often manual, inconsistent, or incomplete.
Technicians receive alerts too late, leading to rushed fixes and higher downtime.
Hidden degradation (bearing wear, temperature rise, motor load) goes unnoticed until it’s too late.
Every hour of stoppage increases cost per part, deadline pressure, and risk of quality defects.

The Solution

S2R2’s Condition Monitoring system provides real-time insights into critical machine parameters like vibration, temperature, current, and load—enabling proactive maintenance and reducing the risk of sudden breakdowns.

Sensor-Based Monitoring

Non-intrusive sensors track vital parameters across machines in real time.

Custom Alert Thresholds

Configure warnings and fault-level alerts based on machine type or failure history.

Health Trend Dashboard

Visualize changes in machine condition over time to spot early signs of wear or imbalance.

Fault History & Maintenance Logs

Record events and link them to preventive actions for future reference.

Mobile + Web Access

Monitor plant health on-the-go with alerts sent directly to engineers and supervisor

The Results Speak for Themselves

Implementing S2R2’s Condition Monitoring solution delivers measurable improvements in machine reliability and operational efficiency.

40% Fewer Emergency Breakdowns

Early detection of anomalies (like vibration surges or temperature spikes) helps prevent costly last-minute stoppages and repairs.

30–50% Drop in Maintenance Cost Overruns

By shifting from reactive fixes to preventive scheduling, plants avoid high-cost emergency part replacements and overtime labor.

Extended Asset Life by 20–25%

Consistent monitoring ensures components are serviced before failure, reducing stress on motors, bearings, and electrical systems.

Audit-Ready Maintenance Logs

Comprehensive digital logs of alerts, events, and interventions help ensure you're always audit-ready—for both internal teams and customer compliance checks.

Condition Monitoring Where It Matters Most

S2R2’s system is built for industries where machine uptime, precision, and preventive care are non-negotiable. Whether it’s a single CNC or a fleet of molding machines, condition monitoring brings tangible ROI across setups.

Heavy Engineering & Fabrication

Monitor high-vibration operations and welding stations to prevent spindle and bearing failures.

Auto Component Manufacturing

Track multi-station machines and ensure reliable performance on long shift cycles.

Injection & Blow Molding

Catch hydraulic system fatigue and temperature inconsistencies before they trigger costly defects or downtime.

Packaging & FMCG

Ensure uninterrupted machine runs, detect motor fatigue early, and reduce unexpected service delays.

What You’ll See

S2R2 Production Monitoring is ideal for

Live Sensor Readings

Real-time vibration (RMS), temperature, current load, and more color-coded by severity.

Custom Alert Logs

Timestamped alerts with categories like Warning, Fault, and Critical.

Health Scores

System-assigned score per machine to prioritize attention and plan servicing.

Trend Graphs

Time-series graphs to identify patterns of degradation across machines or shifts.

Case Study: Proactive Maintenance in Action

See how S2R2’s condition monitoring helped reduce breakdowns and enable faster action—featured in our latest industrial case study.

Case Study

Plant Engineer, Automotive Components Unit, Chennai

S2R2’s condition monitoring gave us real-time visibility into vibration and temperature issues. We now detect faults early, plan maintenance better, and prevent breakdowns before they affect production or quality.

White Paper

–Maintenance Head, Precision Components Manufacturer, Pune

After implementing S2R2’s Condition Monitoring, we reduced unplanned breakdowns by 40% in just 90 days. Our maintenance team now acts on early alerts, not emergency calls.

Result Snapshot

Don’t Let the Next Failure Catch You Off Guard

S2R2’s Condition Monitoring helps you move from reactive firefighting to proactive planning—without expensive system overhauls.