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Deploying wireless condition monitoring in manufacturing
Written By Stephen Howes
October 29, 2026
Manufacturing facilities depend on the reliable operation of pumps, motors, conveyors, fans and other mechanical assets. When equipment deteriorates unnoticed, the consequences can include unplanned downtime, production disruption, additional maintenance costs and pressure on engineering teams.
Traditional maintenance programmes remain essential, but scheduled inspections may not always provide a clear picture of equipment condition between visits. Wireless condition monitoring offers another source of information, helping maintenance teams identify changes in asset behaviour and investigate potential problems before they develop into more serious failures.
IMI TWTG NEON non-Ex sensors provide a way to introduce additional monitoring points in suitable industrial areas without necessarily installing new signal cabling or external power supplies. The key to a successful deployment is to select the right assets, confirm technical suitability and establish a clear process for acting on the data.
1. Identify the assets that matter most
The first step is not to install sensors across an entire production facility. It is to identify where additional condition information could make the greatest operational difference.
A useful starting point is an asset criticality assessment. This should consider:
The effect of equipment failure on production output.
Previous breakdowns and recurring maintenance problems.
The availability of standby or redundant equipment.
The cost and time associated with inspection.
The consequences of a failure for product quality, personnel safety or the environment.
Whether existing monitoring already provides sufficient information.
Rotating equipment is often a logical starting point. Pumps, electric motors, conveyor drives and fans may be suitable candidates for vibration monitoring, provided the selected sensor can measure the relevant condition and can be installed appropriately.
Temperature monitoring may help investigate bearing housings, gearboxes, motor casings or other locations where changes in temperature provide useful diagnostic information. Pressure monitoring may be relevant to selected process or utility systems.
The measurement must match the problem. Vibration data can help identify changes in mechanical behaviour, but it does not directly measure every failure mode. Temperature and pressure readings likewise need to be interpreted in the context of the equipment and process.
The IMI TWTG NEON Vibration Sensor (Non-Ex) is designed for continuous vibration monitoring of rotating and mechanical assets. Its published capabilities include three-axis vibration measurements and spectral analysis.
2. Plan the deployment around a defined problem
Once priority assets have been identified, establish a baseline against which the deployment can be assessed.
Record existing maintenance practices, known failure patterns, inspection frequency and relevant operational measures. Where available, review historical work orders, downtime records and previous condition-monitoring results.
The team should then define a specific objective. For example, the aim might be to improve visibility of the condition of a group of pumps that receives infrequent inspection, or to investigate recurring vibration-related maintenance on a production line.
A limited pilot helps test the approach before it is expanded.
During planning, assess:
The physical location and accessibility of each proposed sensor.
The asset's operating speed, duty cycle and expected operating conditions.
Suitable mounting positions and the manufacturer's installation requirements.
Temperature, dust, moisture, vibration and other environmental factors.
Wireless coverage and the availability of appropriate network infrastructure.
How data will be displayed, reviewed and passed to maintenance personnel.
Any site permits, isolation requirements or installation restrictions.
A wireless device does not automatically eliminate the need for safe access or an approved installation procedure. Work must follow site rules and manufacturer instructions.
3. Select the appropriate NEON sensor
Different measurements address different operational questions.
The NEON vibration sensor provides insight into changes in the vibration behaviour of suitable mechanical assets. According to its product information, it features local data processing, configurable algorithms, and both event-driven and scheduled data transmission. Together, these capabilities help maintenance teams identify significant changes and focus their attention on conditions that may require further investigation.
The NEON Temperature Transmitter (Non-Ex) supports temperature measurement using compatible thermocouples or resistance temperature detectors (RTDs). The correct probe, measurement range and installation arrangement depend on the application.
For pressure-related applications, the NEON Pressure Sensor (Non-Ex) provides a further option where its available range, accuracy and connection arrangements match the requirement.
Sensor selection should be based on the failure modes to be detected, the measurement range required and the quality of information needed to support maintenance decisions. The product datasheet and installation manual should be checked before a model is specified.
An important consideration is that the non-Ex variant is not approved for installation in hazardous areas requiring ATEX or IECEx certification. A site assessment should always be carried out to determine whether a suitably certified alternative is required.
The NEON vibration sensor also offers a simpler wireless deployment approach. Unlike some wireless monitoring strategies, it does not depend on line-of-sight communications or expensive mesh network infrastructure, helping to reduce installation complexity and cost.
IMI TWTG NEON non-Ex sensors provide an effective way to introduce additional monitoring points in manufacturing facilities
4. Install, commission and verify the system
Deployment should follow a documented sequence.
First, confirm the asset identification and installation point. The sensor must be mounted in a position that provides useful measurements and is suitable for the device's mounting method and operating limits.
For vibration monitoring, the mounting surface and position are particularly important. Poor mechanical coupling, an unsuitable mounting location or inconsistent installation can affect the usefulness of the measurements. Follow the manufacturer's instructions rather than selecting a location solely for convenience.
Next, configure the device and establish communications. NEON devices use LoRaWAN, a low-power wireless networking technology. The implementation must provide suitable coverage and an agreed route for transmitting, receiving and presenting the data.
Commissioning should include checks that:
The sensor is securely installed and correctly identified.
Measurements are plausible for the asset and its operating state.
Communications and data collection operate as intended.
Alerts and responsibilities for reviewing them have been agreed.
Relevant maintenance records and procedures have been updated.
Involve maintenance, reliability, operations and automation or IT/OT personnel as appropriate. Their responsibilities should be clear before the system enters routine use.
5. Turn condition data into maintenance decisions
Monitoring creates value only when information leads to an appropriate response.
A baseline helps establish the normal behaviour of an asset. Subsequent measurements can then be reviewed for changes, while accounting for operating speed, load, process conditions and normal variation.
An alert should prompt investigation, not automatically trigger a repair or prove that a component has failed. Engineers should consider the measurement alongside operating history, inspection findings and other available evidence.
Condition monitoring should complement established maintenance and safety procedures, not replace them.
6. Measure the results before expanding
Evaluate the pilot against its original objectives. Suitable measures may include:
Unplanned downtime on monitored assets.
Number and type of maintenance interventions.
Time spent on routine inspections.
Time between identifying a potential issue and investigating it.
Equipment availability and recurring failure rates.
The proportion of alerts that lead to useful maintenance action.
Consider the baseline period, the number of monitored assets and other changes introduced during the trial. A short pilot may demonstrate that the monitoring approach works technically, but it may not be long enough to prove an effect on infrequent failures.
Once the results have been reviewed, prioritise additional assets according to operational value and suitability. This creates a repeatable deployment process rather than an indiscriminate rollout.
Practical deployment checklist
Identify critical assets and recurring failure modes.
Define the measurement and the operational objective.
Verify the selected sensor's specifications and environmental suitability.
Confirm the location does not require hazardous-area certification for which the non-Ex variant is unsuitable.
Assess mounting, communications and data integration.
Assign responsibility for alerts and follow-up actions.
Evaluate the pilot against agreed KPIs before scaling up.
Conclusion
Wireless condition monitoring can extend visibility of equipment condition across a manufacturing facility, particularly where conventional monitoring is limited by access, wiring or the number of assets involved.
The best starting point is a clearly defined maintenance problem, a suitable NEON non-Ex sensor and a controlled pilot. By combining reliable measurements with engineering judgement and an established maintenance workflow, manufacturers can assess where additional condition information can support more effective asset management.
Stephen Howes is Product Manager, Connected Devices, at IMI
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