In this episode of Automation World Gets Your Questions Answered, sponsored by DigiKey and Banner Engineering, Chris McNamara, Automation Group market content director, interviews Steve Kaminski, product manager for condition monitoring sensors at Banner Engineering. 

Kaminski explains that condition monitoring converts machine data into actionable maintenance insights, helping manufacturers keep assets operating efficiently and avoiding failures. He recommends beginning with the most critical, failure-prone, or difficult-to-replace equipment, such as compressors, pumps, and connecting systems.

The discussion highlights Banner’s Snap Signal ecosystem, which connects diverse sensing devices—including vibration, temperature, voltage, current, pressure, and humidity sensors—into a streamlined data network that can incorporate non-Banner products. Vibration, temperature, and power data provide early warnings of mechanical or electrical problems, while differential-pressure monitoring helps optimize filter replacement.

Kaminski says modern systems enable planned maintenance, reduced unplanned downtime, longer asset life, and lower consumable and energy costs. He also describes simpler deployment through overlay networks, wireless options, dashboards, and edge controllers.

Looking ahead, he expects easier-to-use systems that support both basic monitoring and automated maintenance workflows.