Condition-based maintenance software for targeted inspections.
TwinEdge continuously evaluates connected condition signals and shows where telemetry is sufficient, where evidence indicates a focused inspection, and where a physical check is still required. Teams validate the inspection strategy against their assets and risk policy.
Condition-based maintenance software
Use current asset condition to focus inspections and maintenance effort.
TwinEdge condition-based maintenance software evaluates connected asset signals, operating envelopes, physics context, history, and field evidence to identify which assets need attention. Teams can distinguish monitorable conditions from gaps that require a targeted physical inspection.
- Continuous condition assessment
- Track supported telemetry, quality, operating state, thresholds, envelopes, and recent changes against asset context.
- Targeted inspection planning
- Translate evidence gaps and non-normal conditions into a defined inspection question, route, skill, and work scope.
- Mobile evidence capture
- Collect approved observations, photos, guided equipment sound, phone vibration screening, OCR context, and closeout evidence in TwinEdge Field.
- Decision history
- Preserve the signal, review, approval, field finding, maintenance action, and after-work evidence for replay.
Best fit
- Teams replacing blanket inspection intervals with risk- and evidence-informed maintenance while keeping required checks.
- Operations where sensor coverage and physical inspection must work together rather than compete.
Scope and boundaries
- Condition-based maintenance does not remove mandated, safety-critical, or professionally required inspections.
- Mobile-device screening supports maintenance triage and evidence capture; it does not claim certified scientific measurement or final root-cause confirmation.
Buyer questions
Frequently asked questions
What is condition-based maintenance?
Condition-based maintenance schedules inspection or maintenance from current asset condition and operating evidence rather than relying only on elapsed time or usage.
What is the difference between condition-based and predictive maintenance?
Condition-based maintenance responds to observed condition or thresholds. Predictive maintenance additionally estimates future degradation or failure risk. TwinEdge can use both in one reviewed workflow.
Which condition signals can TwinEdge use?
Depending on the asset and deployment, TwinEdge can use industrial telemetry, alarms, operating state, vibration, temperature, pressure, flow, electrical values, model outputs, inspections, and field evidence. Exact signals and adapters are validated for the site.
Does condition-based maintenance replace technicians?
No. It helps technicians and planners focus effort by showing what connected evidence can establish, what remains uncertain, and which physical check is appropriate.
The Three Layers of Condition Assessment
Not everything can be assessed from telemetry alone. The key is knowing what can and what cannot -- and only dispatching technicians for the gaps.
Online Assessment
Continuously evaluates connected signalsTelemetry combined with physics models continuously assess vibration signature, thermal profile, efficiency deviation, and electrical imbalance. If all parameters are within the operating envelope, no inspection is needed.
Targeted Physical Inspection
Covers evidence gaps and physical checksWhen online assessment flags a component but cannot determine root cause from telemetry alone, a targeted work draft is created with specific instructions: "Check coupling alignment on P-3, vibration 2x component elevated."
Visual AI
Adds visual trend evidence where configuredCameras on critical assets analyze corrosion progression, oil color, leak stains, and belt wear. Image analysis triggers or defers visual inspections based on measured change rates rather than calendar schedules.
Traditional vs. Online Condition Assessment
This qualitative comparison shows how calendar-based programs and continuous condition assessment organize work. Validate coverage, latency, cost, and inspection deferral with site data.
| Metric | Traditional (Calendar PM) | TwinEdge Online Assessment |
|---|---|---|
| Asset coverage | Assets visited during the route | Assets with connected, validated signals |
| Assessment frequency | At scheduled visits | Continuous or configured intervals |
| Time from degradation to detection | At the next observation | When validated evidence crosses review logic |
| Inspection priority | Calendar and route | Condition, consequence, and evidence |
| Technician context | Checklist and observed symptoms | Asset, signal, physics, history, and likely cause |
| Root-cause specificity | Observation-dependent | Model- and sensor-dependent evidence |
| Cost model | Labor, travel, and route frequency | Sensors, deployment, models, and targeted work |
| Requires sensor infrastructure | No | Yes (included with TwinEdge) |
What Gets Assessed Online vs. Physical
The goal is not to eliminate all physical inspections. The goal is to eliminate the ones that telemetry can already answer -- and make the remaining ones targeted and justified.
Online (Sensor-Based) -- No Technician Needed
Physical Inspection Still Required For
TwinEdge Visual AI (camera module) can further reduce physical inspections by monitoring corrosion, oil condition, and leak progression. Any inspection deferral remains subject to asset criticality, image quality, engineering review, and the customer's inspection policy.
This Capability Integrates With
Online condition assessment does not work in isolation. It feeds into and is powered by these connected capabilities.
Predictive Maintenance
Condition scores feed degradation models that estimate remaining useful life and draft reviewable work before failure.
Learn more →Operations Intelligence
Reviewed condition findings can become scoped work with evidence, recommended next checks, parts context, and priority.
Learn more →Field Mobile Diagnostics
Technicians capture guided sound, vibration, camera, and OCR evidence, review quality and limitations, and compare the asset after repair.
Learn more →AI & Analytics
Enterprise-wide condition data trains ML models that improve detection accuracy and reduce false positives over time.
Learn more →Switching from another platform?
We'll migrate your data from ANY CMMS or analytics platform — free. Assets, work orders, maintenance history, sensor configurations — everything.
Build a defensible condition-based inspection plan
See how online condition assessment works with your equipment. We will map your asset portfolio and identify which inspections telemetry may support, target, or defer under your engineering policy.