Unplanned downtime and high maintenance costs in rotating assets like pumps, fans, and motors often stem from a lack of real-time health data. When these critical components fail unexpectedly, the resulting production losses can be catastrophic. Our wireless Condition-Based Monitoring (CBM) solution bridges this gap by collecting high-fidelity data—including 3-axis vibration, temperature, and FFT spectrums. This system provides automated early-stage fault diagnostics, enabling maintenance teams to transition from reactive repairs to a truly proactive, data-driven strategy
Automated early-stage fault detection for rotating assets like motors, fans, and gearboxes
High-fidelity data collection including 3-axis vibration, temperature, and FFT waveforms
Proactive maintenance workflows that eliminate the costs associated with unexpected failures
Measurable improvements in reliability, uptime, and maintenance effectiveness
Reduced Unplanned Downtimes
Prevent sudden mechanical failures and costly production halts by identifying internal asset wear before it leads to a trip
Improved Asset Lifecycle Cost
Lower total ownership costs by extending component life and optimizing repair schedules based on actual health data
Minimized Manual Inspections
Eliminate the need for labor-intensive manual vibration audits with 24/7 automated digital health tracking and alerts
Reduced Production Losses
Maximize plant throughput by ensuring critical machinery stays operational and avoiding downtime during peak production
Solution Highlights
Key capabilities enabling early fault detection and condition-based maintenance
One-Stop Dashboard
Integrated interface for viewing real-time diagnostics, alerts, and actionable repair recommendations
AI-Based Problem Detection
Automatically identifies 40+ specific faults including misalignment, unbalance, and bearing degradation
Standalone Infrastructure
Operates on an independent wireless network, removing the need to interface with existing plant IT
Vast Asset Coverage
Engineered to monitor a wide range of rotating equipment, from centrifugal pumps to complex gearboxes
Expert SME Analytics
Comprehensive reports and diagnostic support provided by industry experts to guide maintenance decisions
Rugged Plug-and-Play Sensors
Durable, high-precision sensors designed for rapid deployment with an industry-leading 3-year warranty
Why Faclon Labs
Core strengths behind scalable and proven condition monitoring deployments
AI Features & Agent Studio
Use AI SDKs and ChatGPT-style chat tools to query asset health data instantly
Unified Maintenance Software
A single software platform to manage multiple predictive maintenance use cases
Proven Large-Scale Success
Multiple successful deployments across demanding power plants and chemical units
Customer Success Dedicated
Rapid support and expert guidance to ensure long-term system adoption and ROI
End-to-End Implementation
We manage everything from sensor installation to final analytical data delivery
Tailored System Customization
Custom features and dashboards developed to meet your specific site requirements
CASE STUDY - CONDITION-BASED MONITORING
Driving Power Plant Availability: Large-Scale CBM Implementation
We implemented a large-scale CBM network across five power plants, deploying over 1,000 sensors to monitor 400+ critical rotating assets. This digital transformation replaced periodic manual vibration checks with a 24/7 diagnostic hub, providing the maintenance team with real-time health scores for every motor and pump. The system identifies specific mechanical faults early, allowing for planned interventions during scheduled shutdowns rather than emergency repairs
ROI Achieved in < 1 Year through the prevention of high-value equipment failures and unplanned downtime
Increased Asset Availability by 5% by maximizing the operational window of critical rotating machinery
Increased Asset Availability by 5% by maximizing the operational window of critical rotating machinery
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