SmartCBM® Critical Catches
Real-world examples of equipment issues identified through condition monitoring before they became larger reliability, safety, or production problems.
CRITICAL CATCHES
Find Developing Equipment Issues Before They Escalate
A Critical Catch is a documented equipment issue identified through condition monitoring, SmartCBM®, or reliability analysis that required action before failure occurred. These examples show how early detection, expert review, and practical recommendations help maintenance teams prioritize corrective work, reduce downtime risk, and protect critical assets.
HOW IT WORKS
From Detection to Corrective Action
Each Critical Catch summarizes the asset involved, the condition monitoring technology used, the abnormal condition detected, and the corrective action or operational impact when available.
Asset Monitored
The equipment involved and its role in the operation.
Issue Detected
The abnormal condition identified through monitoring, testing, or analysis.
Recommended Action
The next step advised by Allied Reliability’s analysts or reliability team.
Corrective Action / Result
What maintenance found, repaired, validated, or prevented when available.
Case Study: Featured Critical CatcH
Process Oil Pump Resonance Confirmed Through Vibration Testing
| Industry: | Tire Manufacturing |
| Customer: | Goodyear Mexico (El Salto) |
| Technology: | Vibration |
| Asset: | Process oil pump |
Issue Detected
Spectral analysis showed a peak at 2X operating frequency in the vertical direction, with amplitude changes during data collection. A bump test identified natural frequencies at 19.55 Hz and 23.01 Hz, confirming resonance in the system.
Recommended Action
Increase system rigidity to shift the natural frequencies. Add a steel beam in the middle of the equipment base.
Corrective Action / Result
The base structure was reinforced with a steel beam. After installation of the supports, vibration amplitudes decreased.
Operational Impact
The corrective action reduced vibration associated with resonance and supported more reliable pump operation.
6-8
Hours Saved
from Downtime
$3,150
Cost Savings
Case Study: Featured Critical CatcH
Dryer Gear Bearing Wear Identified Through Vibration Analysis
| Industry: | Packaging and Containers Manufacturing |
| Customer: | Graphic Packaging International |
| Technology: | Vibration |
| Asset: | Dryer gear / gearbox |
Issue Detected
Vibration analysis showed an increase in gear mesh and gearbox bearing frequency, indicating bearing wear.
Recommended Action
Inspect and replace bearings. Inspect the gear for damage.
Corrective Action / Result
Bearings and the idler gear were replaced. The stub shaft for the gear was broken, and an issue with the dryer bearing caused the dryer to drop, shifting the weight of the dryer onto the gear.
Operational Impact
The finding helped identify a developing mechanical issue before the gear and supporting components experienced more severe damage.
6-8
Hours Saved
from Downtime
1.9M
Cost Savings
COMMON ISSUES IDENTIFIED
The Failure Modes Critical Catches Help Surface
Critical Catches often begin as subtle changes in condition data. When reviewed by experienced analysts, those changes can indicate equipment conditions that require planned maintenance before the equipment fails. Below are examples of some common failure modes:
Bearing wear and developing gearbox defects
Fan imbalance, belt issues, and elevated vibration amplitudes
Resonance and structural flexibility problems
Electrical insulation deficiencies, arcing, and ground leakage
Lubrication restrictions and abnormal gearbox temperatures
Packing leakage, rattling, and pump condition changes
Structural cracking in critical weld areas
SERVICES
Explore Condition Monitoring and Reliability Support
Condition Monitoring
Identify developing equipment issues through vibration, infrared, ultrasound, oil analysis, and other predictive technologies.
Equipment Health Assurance
Assess asset condition and build a more proactive maintenance strategy around critical equipment.
Reliability Consulting
Translate findings into practical reliability improvements, maintenance planning, and asset performance actions.
