Checklist

Condition-Based Maintenance Pilot Checklist

Interactive checklist and pilot plan to design, run, verify, and operationalize a condition-based maintenance (CBM) pilot. Guides teams through defining failure modes, collecting baselines, sensor and data plans, model targets, alerting and operator responses, verification, and acceptance criteria.

Interactive Tool

Condition-Based Maintenance Pilot Checklist

Use this interactive checklist to plan, run, and verify a condition‑based maintenance pilot that replaces calendar‑based work with need‑driven actions. Complete required fields, capture measurable targets, and record checkboxes so operational teams can execute reliably and review pilot results.

Short descriptive name (e.g., 'Compressor CBM Pilot - Plant A')
Name and role or email of the person accountable for running the pilot
Identify the specific line, asset, or equipment scope for the pilot
Use YYYY-MM-DD format
How long will you run this pilot before review?
Be specific and measurable (e.g., detect bearing wear >48h before failure; reduce false alarms to <5% of daily alerts)
List failure modes the pilot should detect. One per line. Example: 'Bearing wear leading to seizure', 'Shaft misalignment', 'Lubrication starvation'
Existing metrics (MTBF, MTTR, current preventative schedule, current alarm rates, downtime minutes/week)
Select all sensor types you plan to use, and describe specifics in 'sensorPlanDetails'
Where sensors will be placed, vendor/part numbers if known, wiring or wireless connectivity, sampling rate
How will you validate data completeness, integrity, time synchronization, and missing data handling?
Specify concrete, testable targets (e.g., detection lead time >= 48 hours, false positive rate <= 5% of alerts, precision >= 0.85 at target lead time)
Which historical data will you use, how will you split train/validation/test, and what metrics will you report?
Define threshold values, severity (informational, action required, urgent), and examples of expected alerts
Do you have step‑by‑step operator actions for each alert type?
If yes, describe the playbook steps, who executes, required tools/locks, and escalation rules
Who is notified at each severity, SLA to respond, and how tickets are created or routed
How often will you run verification and calibration checks during the pilot
Concrete tests to verify model predictions (e.g., controlled failures, seeded anomalies, cross‑validation against inspections)
Clear numeric or qualitative criteria the team will use to decide whether to scale, iterate, or stop
Who owns the data, how long it is retained, who may access it, and any regulatory/privacy constraints
Describe training sessions, materials, and validation of readiness
Technical, operational, safety, or business risks and how you will mitigate them
Who must sign off at pilot milestones (operations, reliability, safety, IT, finance)
Freeform: links to diagrams, vendor docs, or ticket IDs
Have the failure modes been documented and agreed?
Are baseline metrics collected and stored?
Are sensors installed, connected, and producing valid data?
Has a model been trained and passed initial validation tests?
Are alerts routed to the right channels with thresholds set?
Are playbooks accessible at point of work?
Is a verification cadence scheduled in the calendar?
Have necessary personnel been trained?
What will you present at review (metrics, evidence, recommendations)
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