Condition Monitoring Platform Shifts Manufacturing Maintenance from Reactive to Proactive

For manufacturing operations, unplanned downtime remains one of the costliest challenges. As a result, much of the focus of Internet of Things and AI analytics technologies for industry have focused on this area.

As part of this industry-wide push to reduce downtime, Regal Rexnord developed its Perceptiv platform. This technology aims to shift maintenance strategies from reactive responses to proactive interventions through intelligent condition monitoring and predictive analytics.

At Pack Expo 2025, Automation World spoke with Moataz Khalil and Mike Mersberger with Regal Rexnord to learn more about the Perceptiv technology.

A platform for equipment health

"With Perceptiv, not only do we have the expertise in being able to understand how the sensors are communicating and, ultimately, the data that we're receiving from them, but also the ability to analyze the information coming out of the equipment that we're monitoring," said Khalil.

The platform uses in-field sensors and gateways to continuously track equipment performance across multiple areas, such as vibration analysis, motor current and temperature readings. At Pack Expo 2025, the demonstration featured Perceptiv technology installed on motors powering a conveyor. 

This multi-modal approach creates what Khalil describes as "a true reliability overview of your equipment," enabling comprehensive insights into machine health.

Scalability across operations with flexible analysis options

One of Perceptiv's key advantages is its scalability. Mersberger pointed out that the technology can accommodate operations of virtually any size. "We can do anything from a single conveyor up to more than a hundred conveyors," he said. 

The platform's architecture supports this scalability through its Universal Gateway, which provides both wired and wireless connections to multiple sensor types. This flexible infrastructure allows manufacturers to start with critical equipment and expand coverage as needed, creating implementations tailored to specific operational requirements.

Every conveyor leaving Regal Rexnord now comes equipped with Perceptiv vibration and temperature sensors that communicate with the platform's gateway system, Mersberger added.

Manufacturers can choose to self-manage data analysis from Perceptiv or rely on Regal Rexnord's reliability engineers for expert interpretation. 

This dual-path approach accommodates different organizational capabilities and preferences. For manufacturers with internal reliability teams, the platform provides direct access to equipment data through on-premises systems or the Perceptiv Web Platform, which serves as a centralized viewing and analysis interface, built on the Microsoft Azure infrastructure. 

For those seeking external expertise, Regal Rexnord's reliability engineers analyze the data and provide actionable recommendations on extending equipment life and preventing failures.

Perceptiv’s open approach

Unlike closed monitoring systems, Perceptiv can integrate with existing manufacturing infrastructure. The platform connects to programmable logic controllers (PLCs) and third-party cloud platforms, allowing data to flow into customers' preferred systems. 

Regal Rexnord says this interoperability allows manufacturers to incorporate condition monitoring data into their broader operational analytics and decision-making processes.

From reactive to proactive maintenance

The fundamental value proposition of Perceptiv centers on downtime reduction. "Perceptiv is really about one thing: Reduction in downtime for the equipment critical to your operation," Khalil stressed. 

The platform achieves this by identifying potential equipment failures before they occur, enabling maintenance teams to address issues during planned downtime rather than responding to unexpected breakdowns.

Reactive maintenance typically carries significant costs associated with emergency repairs, production losses and expedited parts procurement. In contrast, proactive maintenance based on condition monitoring data allows manufacturers to schedule repairs, secure parts in advance and minimize production disruptions.

According to Regal Rexnord, the platform's predictive capabilities can help reduce unexpected failures by up to 55% and increase machine life by as much as 40%. These improvements translate to substantial cost savings, with the potential to save operations an average of $250,000 annually.

In the video below, Moataz and Mike cover the highlights of the Perceptiv platform.

• Predictive Maintenance Success with MES 
• From Reactive to Proactive: Implementing Condition Monitoring for Predictive Maintenance Success
• Preventative Maintenance for Robots in the Field