Operational Optimization

Reducing Maintenance Costs through Vibration Analysis of Rotating Equipment

Published on March 12, 2025

---

Reactive maintenance generates significant losses in heavy industry. Implementing a vibration monitoring program can reduce total maintenance costs by up to 30%, while extending the lifespan of critical mechanical assets.

By installing accelerometers on main bearings and analyzing the frequency spectrum, technical teams can identify early faults such as imbalances, misalignment, or gear wear. This proactive approach transforms raw data into precise maintenance decisions.

Implementation Methodology

The process begins with a technical audit of the machinery fleet, followed by establishing measurement points and acquisition frequency. Using international standards (ISO 10816), BioExos engineers define customized alarm thresholds for each type of equipment.

• — Identifying assets with high risk of failure
• — Installing sensors and configuring the acquisition system
• — Spectral analysis and monthly trend reporting
• — Planning interventions based on real data

Measurable Results

In a recent project for a cement plant, applying this method led to a 25% reduction in unplanned downtime and annual savings of over €150,000. The sustainability of mechanical assets is directly correlated with the quality of collected data and the timeliness of corrective actions.

---

Related Materials