Here’s what you need to know:
- Condition-based maintenance, or CBM, is a proactive approach to maintenance triggered by real-time data from the truck.
- It's different from predictive maintenance, which adds algorithms, AI or other data analysis to forecast maintenance needs.
- Dealerships and shops with the proper training can leverage CBM into more efficient workflows.
Trucks, trailers and their ecosystems are the lifeblood of the American economy. Industries and households across the country depend on trucks getting goods to market, manufacture or storage on time and safely.
That, in turn, can only be done with proper maintenance. There are nearly as many theories on what proper maintenance means as there are trucks on the road. But as equipment evolves, so do the ways of keeping it running.
Traditionally, trucks have been maintained on a schedule based on the mileage of the vehicle. To a degree, Volvo’s Magnus Gustafson says, component maintenance intervals are optimized, but no schedule can take into account how specific vehicles are run.
“Many trucks are actually over maintained,” says Gustafson, vice president of connected services for Volvo Group North America, adding companies with multiple trucks often have different makes, models and engines, all with different service intervals. “How do I, as a customer, manage my equipment the easiest way?”
One answer may be condition-based maintenance.
Volvo says its Volvo Connect system brings the advantages of large fleets with in-house service to smaller fleets. Volvo Trucks North America
What is condition-based maintenance?
Condition-based maintenance (CBM) is a proactive approach to maintenance, says Mayank Nayar, principal product manager for Samsara, triggered by the actual condition of the vehicle using real-time data from sensors, telematics and diagnostics. The approach abandons the traditional service intervals in favor of recommending maintenance before a failure but only when it detects signs of wear or the potential for failure.
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It goes by many names in the trucking industry: Predictive maintenance, a more familiar term, generally uses some form of algorithm, AI or other analysis to predict maintenance needs and component failure, dynamic maintenance or adaptive maintenance.
The difference, Nayar says, is in the timing.
“Predictive maintenance uses historical data and algorithms to forecast when a part will likely fail,” he says. “Condition-based maintenance on the other hand, is triggered by current, live data showing actual signs of deterioration or failure.”
Hannah Koke, manager of data and analytics at Geotab, likens CBM to going to the doctor for humans.
“Instead of going to the doctor for a check-up every year just because the calendar says so, you go when you have a symptom, like a fever or a cough,” she says. “Condition-based maintenance is the same idea for your trucks.”
Mack's on-board tire pressure monitoring system. Mack Trucks
How are OEMs reacting to these new systems of maintenance?
As trucks are manufactured, the ingredients for condition-based maintenance are baked into the truck’s design, along with OEM-managed versions of some form of CBM or predictive maintenance or both, depending on how much the customer wants to spend.
Mack’s version is called adaptive maintenance and uses connected vehicle data and AI to dynamically adjust service schedules based on the truck’s usage and condition. The company says this maximizes uptime for the truck and reduces costs for customers.
Volvo uses a similar approach, Gustafson says, looking at the truck as a system.
“We’ve wrapped a service agreement around these assets,” Gustafson says. “You have a fixed price and then, depending on the usage of your vehicle, we will manage this for you.”
[RELATED: Volvo announces new Volvo Blue maintenance plan]
The company offers 24/7 monitoring, remote diagnostics and fleet manager at the dealership level, along with human inspections and input, such as oil sampling, to adjust the maintenance of the truck. Gustafson says the company also looks for opportunities to bundle maintenance, moving some service up, to maximize each maintenance visit.
Daimler Trucks North America says its maintenance systems also vary service intervals based on how the truck is driven. Without it, most customers rely on regular maintenance intervals, says Scott Faris, Detroit Diesel’s field sales engineering manager, national accounts.
“When the truck is not operating, when it’s in a repair shop and not making money, they are not happy about that,” Faris says. “It’s in their best interest to maintain these things.”
Condition-based maintenance can streamline workflows at shops, allowing technicians to be more efficient. Fleetio
Condition-based maintenance on the shop floor
Using CBM and other data-based maintenance products can make the truck work smarter — and the dealership shops too. Having the dealer manage the truck’s maintenance and repair can give smaller fleets and owner-operators the same advantages and big fleets with in-house service, Gustafson says.
“These trucks are obviously a huge investment for our customers,” he says. “We want to make sure our customers understand the capabilities of these trucks and the engineering of these trucks to improve their bottom line.”
Dealership technicians can leverage data-intensive systems to pinpoint exactly what components need attention, prioritize repairs and service, prepare customers for expected maintenance and repairs, and communicate to their customers.
“Instead of a truck showing up with a mysterious problem, the technician already has a heads-up,” Koke says. “They get an alert and a specific fault code so they can diagnose the issue before the vehicle even pulls into the bay. Technicians can get right to work without wasting time on initial diagnostics. This helps them turn vehicles around faster, which is a win for everyone.”
This is, of course, provided technicians are properly trained to download and interpret the boatload of data each one of these trucks carry.
“A CBM program requires a dealer to schedule maintenance based on the actual condition of equipment. To do this effectively, dealerships need to implement a maintenance scheduling system along with the necessary resources to account for performance data and prioritize maintenance tasks accordingly,” Mack Services Director Ashish Sadhu says. “The dealership needs to foster a culture of continuous improvement within its organization, so maintenance personnel are continually encouraged to identify areas for improvement and implement changes based on the results.”
It should also be noted while CBM is effective on many parts, there are some components that still require the old-fashioned service interval. Fleetio recommends low-cost consumables on the truck, such as wiper blades and air filters, stick to a set schedule, as should regular inspections and components that are difficult to sensor, such as certain mechanical or structural parts. Geotab adds there are some components a manufacturer says must be replaced for safety reasons by a certain number of hours or miles, and those should be obeyed regardless of condition.
“The key is knowing where CBM adds real value versus where fixed schedules still make sense,” Daneri says.
