The Condition Monitoring Manager leads the development and execution of predictive-maintenance and condition-monitoring programs for rotating and static equipment. This role ensures early detection of mechanical issues, maximizes asset availability, and drives continuous improvement in reliability and maintenance strategies across the plant.
Program Leadership & Strategy
Design, implement and continuously improve a comprehensive condition-monitoring program (vibration, thermography, lubricant analysis, ultrasound, etc.).
Define KPIs and success metrics (e.g., percentage of predictive vs. reactive work, reduction in unplanned downtime).
Team Management & Development
Lead, mentor, and develop a team of vibration analysts, thermographers, and reliability technicians.
Establish training plans, competency matrices, and certification goals (ISO 18436, OEM-specific).
Data Collection & Analysis Oversight
Ensure accurate route creation and execution for data collection on critical assets (turbines, compressors, pumps, gearboxes).
Supervise data validation, trending, and initial fault diagnosis; escalate complex issues to engineering.
Cross-Functional Coordination
Work closely with Maintenance Planning, Operations, and Engineering to translate condition findings into actionable work orders.
Coordinate shutdown inspections and verify corrective actions post-repair.
Technology & Tool Management
Evaluate, procure, and maintain condition-monitoring equipment and software (e.g., handheld analyzers, online monitoring systems, CMMS/APM integration).
Drive digital enhancement—integrate real-time sensors, dashboards, and predictive‐analytics platforms.
Reporting & Continuous Improvement
Deliver regular reliability reports, trend analyses, and recommendations to senior management.
Lead root-cause analysis for repeat or severe failures and implement corrective/preventive measures.
Budget & Vendor Management
Develop and manage the condition-monitoring budget, including tools, training, and outside‐service contracts.
Manage relationships with third-party specialists, calibration labs, and equipment vendors.
Increase the ratio of predictive (PdM) to reactive maintenance, targeting early fault detection and asset life extension.
Ensure high fidelity in data collection—route coverage, sensor health, calibration—and accuracy in initial diagnostics.
Seamlessly convert monitoring insights into maintenance work packages, minimizing lead time from detection to repair.
Pilot and deploy advanced monitoring technologies (wireless sensors, AI/ML analytics, digital twins) to elevate program maturity.
Foster a reliability-centered culture through ongoing training, knowledge sharing, and clear career progression for monitoring staff.
Education: Bachelor’s Degree in Mechanical, Electrical, or Reliability Engineering (or related)
Experience: 8–12 years in condition monitoring or reliability engineering; at least 3 years in a leadership role
Certifications: ISO 18436-2 Category II/III (or equivalent), Certified Maintenance & Reliability Professional (CMRP) preferred
Deep knowledge of vibration analysis, thermography, oil analysis, ultrasound, and tribology
Proficient with CMMS/APM systems and condition-monitoring software (e.g., Bently Nevada, SKF @ptitude, Emerson CSI)
Strong analytical and problem-solving skills; adept at root-cause analysis
Excellent leadership, communication, and stakeholder-management abilities
Familiarity with API, ISO, and OEM standards for equipment condition monitoring
Onsite role in industrial plant environments (turbine halls, compressor rooms, pump houses)
Requires walking inspection routes, climbing to access sensors, and wearing full PPE
Shift flexibility or on-call availability during critical monitoring campaigns or outages