Eliminate 73% of Scheduled Inspections. Assess Equipment in Real Time.
Most condition assessment happens on a calendar -- a technician walks the floor every 30 days, checks 5 assets, and finds 4 of them perfectly healthy. TwinEdge scores equipment condition 24/7 from telemetry data. Physical inspections only when sensors cannot see.
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
Eliminates ~70% of inspectionsTelemetry 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
Handles ~25% of assessmentsWhen online assessment flags a component but cannot determine root cause from telemetry alone, a targeted work order is created with specific instructions: "Check coupling alignment on P-3, vibration 2x component elevated."
Visual AI
Eliminates another ~5%Cameras 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
Side-by-side comparison of calendar-based inspection programs versus continuous telemetry-driven condition assessment.
| Metric | Traditional (Calendar PM) | TwinEdge Online Assessment |
|---|---|---|
| Asset coverage at any moment | 3-5% | 100% |
| Assessment frequency | Every 30-90 days | Continuous (every second) |
| Time from degradation to detection | 15-45 days (next scheduled visit) | 2-8 hours |
| Unnecessary inspections | 60-80% (healthy equipment inspected) | 0% (only flagged assets) |
| Technician utilization | 35% reactive, 40% wasted PM | 85% targeted, planned work |
| Root cause specificity | "Sounds rough" (subjective) | "Bearing inner race 12.4x BPFI" (objective) |
| Cost per asset per year | $2,400 | $380 |
| 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 -- converting another 5-10% of physical inspections into automated assessments.
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 predict remaining useful life and auto-create work orders before failure.
Learn more →Operations Intelligence
Targeted work orders land directly in Operations Intelligence with specific diagnosis, parts list, and priority -- no manual triage.
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.
Eliminate 73% of Scheduled Inspections
See how online condition assessment works with your equipment. We will map your asset portfolio and show you exactly which inspections telemetry can replace.