IIoT, SCADA & Edge Connectivity calculator
Condition Monitoring Coverage Calculator
Estimate condition monitoring coverage. Enter the count of critical assets with active condition monitoring (vibration, temperature, current, oil), the total critical assets in the criticality register, and the program coverage target. The calculator returns the coverage rate and the gap to target.
What this calculator does
- Estimate the share of critical assets with active condition monitoring (vibration, temperature, current, oil) from the count of critical assets monitored against the total critical assets in the criticality register, against the program target.
- Use it when a reliability lead is reporting condition monitoring deployment progress against a criticality-based target on the reliability dashboard.
- It returns the share of critical assets covered by active condition monitoring and the gap to the reliability program target.
Formula used
- Condition monitoring coverage = monitored critical assets ÷ total critical assets × 100
- Coverage gap to target = target coverage - actual coverage
Inputs explained
- Critical assets with active condition monitoring: Use the count of critical assets with at least one active vibration, temperature, current, oil, or ultrasonic monitoring point delivering data.
- Total critical assets: Use the count of critical assets from the criticality register (typically class A and class B equipment).
- Condition monitoring coverage target: Use the program target (typical 90 to 100 percent for class A, 60 to 80 percent for class B).
How to use the result
- Use it on the reliability dashboard, before the next sensor capital request, and when an asset failure post-mortem asks whether monitoring should have caught the failure.
- Coverage does not equal alarm response. A monitored asset with an unread vibration alarm is a process gap; pair with the alarm rationalization workload calculator.
Common questions
- What counts as monitored? An asset with at least one active vibration, temperature, current, oil, or ultrasonic monitoring point delivering data and assigned to a reliability rule.
- Why scope to critical assets? Monitoring every motor in the plant is rarely cost-justified. Scope to class A and B per the criticality register so the rate matches your reliability strategy.
- What target is realistic? 90 to 100 percent for class A, 60 to 80 percent for class B. World-class programs target 100 percent class A and 80 percent class B.
- How do I model a partial sensor (only vibration, no temperature)? Treat the asset as monitored for this calculator. If you need a fully-instrumented view, define what fully-instrumented means and run a stricter version of this calculator with that bar.
Last reviewed 2026-05-12.