Methodology · Online Condition Monitoring System
Execution Methodology
The engagement unfolds in seven phases, from scoping to steady-state operation.
10 · Phases
From the measurement plan to sustainable condition-based maintenance
| Phase | Objective | Outcome |
|---|---|---|
| 1. Scoping & criticality | Define what and where to measure (fit-for-purpose). | Justified measurement plan + machine criticality ranking. |
| 2. Instrumentation & baseline | Deploy the online CMS and establish reference signatures. | Operational system + baseline signatures (ISO 20816). |
| 3. Acquisition & initial diagnosis | Collect data and detect the first faults. | Vibration database + initial diagnosis (quick win). |
| 4. Signature analysis | Deepen and correlate faults / spectra. | Detailed diagnosis of the equipment. |
| 5. Training & coaching | Transfer the method by working alongside the field teams. | Autonomous engineers / technicians. |
| 6. Capitalization | Formalize (charts, thresholds, FR/EN procedures). | The "Tongon Method". |
| 7. Steady state | Move to data / OT monitoring and governance. | Sustainable condition-based maintenance. |
1
Scoping & criticality
Objective: Define what and where to measure (fit-for-purpose).
Outcome: Justified measurement plan + machine criticality ranking.
2
Instrumentation & baseline
Objective: Deploy the online CMS and establish reference signatures.
Outcome: Operational system + baseline signatures (ISO 20816).
3
Acquisition & initial diagnosis
Objective: Collect data and detect the first faults.
Outcome: Vibration database + initial diagnosis (quick win).
4
Signature analysis
Objective: Deepen and correlate faults / spectra.
Outcome: Detailed diagnosis of the equipment.
5
Training & coaching
Objective: Transfer the method by working alongside the field teams.
Outcome: Autonomous engineers / technicians.
6
Capitalization
Objective: Formalize (charts, thresholds, FR/EN procedures).
Outcome: The "Tongon Method".
7
Steady state
Objective: Move to data / OT monitoring and governance.
Outcome: Sustainable condition-based maintenance.
10.1 · Application
A phased deployment
This method first applies to the scope of Option 1 (ball mills and cyclone feed pumps), then is replicated identically on the crushers under Option 2 — ensuring consistent execution regardless of the scope selected.