Machine Condition Monitoring Market Size and Outlook 2030

Report Description

Forecast Period	2026-2030
Market Size (2024)	USD 4.14 Billion
CAGR (2025-2030)	8.89%
Fastest Growing Segment	Oil and Gas
Largest Market	North America
Market Size (2030)	USD 6.90 Billion

Market Overview

The Global Machine Condition Monitoring Market, valued at USD 4.14 Billion in 2024, is projected to experience a CAGR of 8.89% to reach USD 6.90 Billion by 2030. Machine Condition Monitoring (MCM) involves the systematic evaluation of equipment parameters such as vibration, temperature, and oil characteristics to detect nascent faults and performance deviations. This enables the implementation of proactive maintenance strategies. The market's expansion is primarily driven by the escalating global demand for enhanced operational efficiency, a critical need to minimize unplanned downtime, and the imperative to extend asset lifespans through predictive insights. Furthermore, the increasing integration of Industry 4.0 principles across manufacturing sectors compels businesses to adopt data-driven approaches to asset management.

A significant challenge impeding market expansion is the substantial initial investment required for deploying and integrating advanced MCM systems into existing industrial infrastructure. This capital expenditure, coupled with the ongoing need for specialized personnel to manage and interpret complex data, represents a notable barrier, particularly for smaller enterprises. According to the International Society of Automation (ISA), in 2023, 58% of organizations utilized automation and artificial intelligence to achieve their sustainability objectives, underscoring the broader trend towards intelligent operational technologies that include condition monitoring applications.

Key Market Drivers

The market for global machine condition monitoring is significantly influenced by the increased adoption of predictive maintenance strategies. Organizations are moving away from time-based or reactive maintenance approaches to minimize unforeseen failures and optimize operational expenditures. This shift is predicated on the ability of condition monitoring systems to provide real-time data and insights into equipment health, enabling timely intervention before catastrophic breakdowns occur. According to an article by SmartDev, in November 2024, a manufacturer reported a 25% improvement in Overall Equipment Effectiveness after integrating AI-driven predictive maintenance, underscoring the benefits driving wider adoption. This proactive stance directly increases the demand for sophisticated sensors, data acquisition systems, and analytical software that constitute the core components of machine condition monitoring solutions.

The integration of artificial intelligence and machine learning for advanced analytics further amplifies this market expansion. AI and machine learning algorithms are pivotal in processing the vast amounts of data generated by condition monitoring sensors, identifying subtle patterns indicative of impending equipment failure, and reducing false positives. These technologies enhance the accuracy of fault diagnosis and prognosis, leading to more effective maintenance planning and resource allocation. For instance, according to an article by SmartDev, in November 2024, a manufacturer achieved a 20% improvement in machine uptime across an entire production line through AI-driven predictive maintenance. Furthermore, the broader industrial landscape continues to see substantial digital infrastructure investments. According to an article in RTInsights, in October 2025, technology investments made by manufacturing companies constituted 30% of their operating budget in 2024, an increase from 23% in 2023, facilitating advanced condition monitoring system upgrades.

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Key Market Challenges

The substantial initial investment required for deploying and integrating advanced Machine Condition Monitoring (MCM) systems presents a direct hindrance to market expansion. This capital outlay encompasses not only the acquisition and installation of sophisticated sensor technology and software but also the necessary modifications to existing industrial infrastructure. Such significant upfront costs deter many businesses, particularly small and medium-sized enterprises, which often operate with tighter budgets and a more cautious approach to large-scale technological upgrades.

Furthermore, the ongoing requirement for specialized personnel to manage, interpret, and act upon complex MCM data adds another layer of financial burden through recruitment, training, and retention expenses. This dual financial challenge limits the accessibility and attractiveness of MCM solutions, thereby constraining broader market adoption. According to PMMI Business Intelligence's 2024 'Trends in Remote Services and Monitoring' report, approximately 60% of end-users consider retrofitting older machinery a barrier to investment in such solutions, underscoring the impact of infrastructure-related costs on technology adoption. This factor directly inhibits the widespread implementation of MCM, slowing the overall growth trajectory of the market.

Key Market Trends

Two highly significant trends shaping the Global Machine Condition Monitoring Market are the increasing adoption of wireless and cloud-based monitoring solutions and the diversification of these technologies across emerging industrial sectors. These trends are distinct, addressing different facets of market evolution and expansion.

Wireless and cloud-based monitoring solutions are transforming how industries approach asset management by offering enhanced flexibility and accessibility. These systems eliminate the need for extensive cabling, simplifying installation and enabling deployment in remote or hazardous environments. The cloud infrastructure facilitates scalable data storage, advanced analytics processing, and real-time access to equipment health data from any location. This shift allows for more agile maintenance strategies and reduces the upfront costs associated with traditional wired systems. According to a PMMI Business Intelligence's 2024 "Trends in Remote Services & Monitoring" report, approximately 60% of end-users consider retrofitting older machinery a barrier to investment in such solutions, underscoring the demand for easily deployable, less intrusive monitoring options. Furthermore, in September 2023, Rockwell Automation partnered with Everactive to offer wireless and batteryless condition monitoring solutions, providing customers with actionable insights from rotating equipment assets without interruption for battery replacement. This type of collaboration highlights the industry's move towards seamless, low-maintenance monitoring.

The diversification of machine condition monitoring into emerging industrial sectors represents another crucial growth trajectory. Historically concentrated in heavy industries, these monitoring solutions are now finding widespread application in areas such as renewable energy, food and beverage, and smart infrastructure. This expansion is driven by the universal need for operational efficiency, asset longevity, and predictive maintenance across various industrial landscapes. For instance, the Association for Advancing Automation (A3) reported in 2024 that robot orders in North American food and consumer goods increased by 60%, and in life sciences, pharmaceuticals, and biomedical by 43%, indicating significant automation growth in these non-traditional sectors. This robust automation growth often necessitates integrated condition monitoring to ensure the reliability and performance of new equipment. Additionally, SKF's 2024 Annual Report indicated that demand for its offerings was increasingly driven by emerging applications in renewable energy, electric vehicles, and smart infrastructure, demonstrating a clear market shift beyond conventional segments.

Segmental Insights

The Oil and Gas segment is a significant growth driver in the Global Machine Condition Monitoring Market. This rapid expansion is primarily attributed to the sector's inherently process-intensive operations and the substantial financial implications associated with equipment failure, leading to significant capital loss and costly unplanned downtime. The imperative to enhance overall operational efficiency and ensure asset longevity, coupled with stringent regulatory requirements for safety and environmental protection, compels companies to adopt advanced monitoring solutions. These systems enable proactive maintenance strategies, critical for detecting potential issues early and maintaining continuous, reliable operation in challenging environments.

Regional Insights

North America leads the global Machine Condition Monitoring Market due to a combination of factors promoting advanced industrial practices. The region demonstrates a strong emphasis on optimal asset utilization across diverse sectors such as oil and gas, power generation, and aerospace. This is further supported by stringent government regulations concerning workplace safety and personnel protection, alongside rigorous quality control standards in key industries. The early adoption of Industry 4.0 initiatives and smart factory deployments also drives demand for sophisticated monitoring solutions. Furthermore, the presence of major market participants significantly contributes to North America's dominance in developing and implementing machine condition monitoring technologies.

Recent Developments

In October 2025, it was reported that Honeywell's Ensemble health monitoring service for business jet engines was experiencing increased adoption. This service, initially launched in 2024, was specifically developed to detect, analyze, and predict potential maintenance issues in aircraft engines before they could cause flight disruptions. The Ensemble system utilized a Wi-Fi-enabled engine data gateway to securely transmit operational data to Honeywell's cloud-based platform for advanced analytical processing. This offering provided near real-time health monitoring, marking a significant development in predictive maintenance for critical aerospace assets within the Global Machine Condition Monitoring Market.

In June 2025, Alfa Laval launched Clariot™, an advanced AI-based condition monitoring solution engineered specifically for hygienic process equipment. This new generation system was developed to deliver more precise analysis and operational support for critical machinery in sensitive industrial settings. Clariot™ continuously monitors equipment and processes, providing actionable insights intended to maximize uptime and optimize resource efficiency. The introduction of this solution represented a significant advancement in predictive maintenance strategies for industries with strict hygiene requirements, contributing to the broader Global Machine Condition Monitoring Market by helping to minimize unplanned downtime and product loss.

In July 2024, SKF collaborated with Luleå University of Technology on a research project focused on integrating generative artificial intelligence into machine reliability practices. This initiative aimed to advance machine condition monitoring by leveraging AI to analyze complex sensor data from industrial machinery. The research sought to automate the detection of anomalies and the forecasting of equipment failures, particularly in challenging operational environments. This breakthrough was intended to reduce the intensive requirement for highly experienced human analysts for initial fault identification, thereby enhancing the efficiency and accessibility of predictive maintenance solutions in the Global Machine Condition Monitoring Market.

In January 2024, MachineMetrics introduced new product features aimed at enhancing its condition monitoring workflow. These releases focused on improving machine performance and operational efficiency for manufacturing clients. The updates provided expanded data accessibility and an enhanced user experience, incorporating advanced predictive maintenance tools, real-time analytics, and broader integration capabilities with existing factory systems. These innovations were designed to offer manufacturers deeper insights into equipment health, thereby optimizing decision-making and automating production processes within the Global Machine Condition Monitoring Market.

Key Market Players

Siemens AG
Honeywell International Inc.
Schneider Electric SE
Rockwell Automation Inc.
Emerson Electric Co.
General Electric Company
ABB Ltd.
Yokogawa Electric Corporation
Hitachi Ltd.
Parker Hannifin Corporation

By Monitoring Technique	By Offering	By Deployment Type	By Monitoring Process	By End User	By Region
Vibration Monitoring Thermography Oil Analysis Corrosion Monitoring Ultrasound Emission Motor Current Analysis	Hardware Software	On-premises Cloud	Online Condition Monitoring Portable Condition Monitoring	Oil and Gas Power Generation Metals and Mining Chemicals Automotive Aerospace and Defense Food and Beverages Marine Others	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Machine Condition Monitoring Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

Machine Condition Monitoring Market, By Monitoring Technique:

o Vibration Monitoring

o Thermography

o Oil Analysis

o Corrosion Monitoring

o Ultrasound Emission

o Motor Current Analysis

Machine Condition Monitoring Market, By Offering:

o Hardware

o Software

Machine Condition Monitoring Market, By Deployment Type:

o On-premises

o Cloud

Machine Condition Monitoring Market, By Monitoring Process:

o Online Condition Monitoring

o Portable Condition Monitoring

Machine Condition Monitoring Market, By End User:

o Oil and Gas

o Power Generation

o Metals and Mining

o Chemicals

o Automotive

o Aerospace and Defense

o Food and Beverages

o Marine

o Others

Machine Condition Monitoring Market, By Region:

o North America

§ United States

§ Canada

§ Mexico

o Europe

§ France

§ United Kingdom

§ Italy

§ Germany

§ Spain

o Asia Pacific

§ China

§ India

§ Japan

§ Australia

§ South Korea

o South America

§ Brazil

§ Argentina

§ Colombia

o Middle East & Africa

§ South Africa

§ Saudi Arabia

§ UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies presents in the Global Machine Condition Monitoring Market.

Available Customizations:

Global Machine Condition Monitoring Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

Detailed analysis and profiling of additional market players (up to five).

Global Machine Condition Monitoring Market is an upcoming report to be released soon. If you wish an early delivery of this report or want to confirm the date of release, please contact us at [email protected]

Table of content

1. Product Overview

1.1. Market Definition

1.2. Scope of the Market

1.2.1. Markets Covered

1.2.2. Years Considered for Study

1.2.3. Key Market Segmentations

2. Research Methodology

2.1. Objective of the Study

2.2. Baseline Methodology

2.3. Key Industry Partners

2.4. Major Association and Secondary Sources

2.5. Forecasting Methodology

2.6. Data Triangulation & Validation

2.7. Assumptions and Limitations

3. Executive Summary

3.1. Overview of the Market

3.2. Overview of Key Market Segmentations

3.3. Overview of Key Market Players

3.4. Overview of Key Regions/Countries

3.5. Overview of Market Drivers, Challenges, Trends

4. Voice of Customer

5. Global Machine Condition Monitoring Market Outlook

5.1. Market Size & Forecast

5.1.1. By Value

5.2. Market Share & Forecast

5.2.1. By Monitoring Technique (Vibration Monitoring, Thermography, Oil Analysis, Corrosion Monitoring, Ultrasound Emission, Motor Current Analysis)

5.2.2. By Offering (Hardware, Software)

5.2.3. By Deployment Type (On-premises, Cloud)

5.2.4. By Monitoring Process (Online Condition Monitoring, Portable Condition Monitoring)

5.2.5. By End User (Oil and Gas, Power Generation, Metals and Mining, Chemicals, Automotive, Aerospace and Defense, Food and Beverages, Marine, Others)

5.2.6. By Region

5.2.7. By Company (2024)

5.3. Market Map

6. North America Machine Condition Monitoring Market Outlook

6.1. Market Size & Forecast

6.1.1. By Value

6.2. Market Share & Forecast

6.2.1. By Monitoring Technique

6.2.2. By Offering

6.2.3. By Deployment Type

6.2.4. By Monitoring Process

6.2.5. By End User

6.2.6. By Country

6.3. North America: Country Analysis

6.3.1. United States Machine Condition Monitoring Market Outlook

6.3.1.1. Market Size & Forecast

6.3.1.1.1. By Value

6.3.1.2. Market Share & Forecast

6.3.1.2.1. By Monitoring Technique

6.3.1.2.2. By Offering

6.3.1.2.3. By Deployment Type

6.3.1.2.4. By Monitoring Process

6.3.1.2.5. By End User

6.3.2. Canada Machine Condition Monitoring Market Outlook

6.3.2.1. Market Size & Forecast

6.3.2.1.1. By Value

6.3.2.2. Market Share & Forecast

6.3.2.2.1. By Monitoring Technique

6.3.2.2.2. By Offering

6.3.2.2.3. By Deployment Type

6.3.2.2.4. By Monitoring Process

6.3.2.2.5. By End User

6.3.3. Mexico Machine Condition Monitoring Market Outlook

6.3.3.1. Market Size & Forecast

6.3.3.1.1. By Value

6.3.3.2. Market Share & Forecast

6.3.3.2.1. By Monitoring Technique

6.3.3.2.2. By Offering

6.3.3.2.3. By Deployment Type

6.3.3.2.4. By Monitoring Process

6.3.3.2.5. By End User

7. Europe Machine Condition Monitoring Market Outlook

7.1. Market Size & Forecast

7.1.1. By Value

7.2. Market Share & Forecast

7.2.1. By Monitoring Technique

7.2.2. By Offering

7.2.3. By Deployment Type

7.2.4. By Monitoring Process

7.2.5. By End User

7.2.6. By Country

7.3. Europe: Country Analysis

7.3.1. Germany Machine Condition Monitoring Market Outlook

7.3.1.1. Market Size & Forecast

7.3.1.1.1. By Value

7.3.1.2. Market Share & Forecast

7.3.1.2.1. By Monitoring Technique

7.3.1.2.2. By Offering

7.3.1.2.3. By Deployment Type

7.3.1.2.4. By Monitoring Process

7.3.1.2.5. By End User

7.3.2. France Machine Condition Monitoring Market Outlook

7.3.2.1. Market Size & Forecast

7.3.2.1.1. By Value

7.3.2.2. Market Share & Forecast

7.3.2.2.1. By Monitoring Technique

7.3.2.2.2. By Offering

7.3.2.2.3. By Deployment Type

7.3.2.2.4. By Monitoring Process

7.3.2.2.5. By End User

7.3.3. United Kingdom Machine Condition Monitoring Market Outlook

7.3.3.1. Market Size & Forecast

7.3.3.1.1. By Value

7.3.3.2. Market Share & Forecast

7.3.3.2.1. By Monitoring Technique

7.3.3.2.2. By Offering

7.3.3.2.3. By Deployment Type

7.3.3.2.4. By Monitoring Process

7.3.3.2.5. By End User

7.3.4. Italy Machine Condition Monitoring Market Outlook

7.3.4.1. Market Size & Forecast

7.3.4.1.1. By Value

7.3.4.2. Market Share & Forecast

7.3.4.2.1. By Monitoring Technique

7.3.4.2.2. By Offering

7.3.4.2.3. By Deployment Type

7.3.4.2.4. By Monitoring Process

7.3.4.2.5. By End User

7.3.5. Spain Machine Condition Monitoring Market Outlook

7.3.5.1. Market Size & Forecast

7.3.5.1.1. By Value

7.3.5.2. Market Share & Forecast

7.3.5.2.1. By Monitoring Technique

7.3.5.2.2. By Offering

7.3.5.2.3. By Deployment Type

7.3.5.2.4. By Monitoring Process

7.3.5.2.5. By End User

8. Asia Pacific Machine Condition Monitoring Market Outlook

8.1. Market Size & Forecast

8.1.1. By Value

8.2. Market Share & Forecast

8.2.1. By Monitoring Technique

8.2.2. By Offering

8.2.3. By Deployment Type

8.2.4. By Monitoring Process

8.2.5. By End User

8.2.6. By Country

8.3. Asia Pacific: Country Analysis

8.3.1. China Machine Condition Monitoring Market Outlook

8.3.1.1. Market Size & Forecast

8.3.1.1.1. By Value

8.3.1.2. Market Share & Forecast

8.3.1.2.1. By Monitoring Technique

8.3.1.2.2. By Offering

8.3.1.2.3. By Deployment Type

8.3.1.2.4. By Monitoring Process

8.3.1.2.5. By End User

8.3.2. India Machine Condition Monitoring Market Outlook

8.3.2.1. Market Size & Forecast

8.3.2.1.1. By Value

8.3.2.2. Market Share & Forecast

8.3.2.2.1. By Monitoring Technique

8.3.2.2.2. By Offering

8.3.2.2.3. By Deployment Type

8.3.2.2.4. By Monitoring Process

8.3.2.2.5. By End User

8.3.3. Japan Machine Condition Monitoring Market Outlook

8.3.3.1. Market Size & Forecast

8.3.3.1.1. By Value

8.3.3.2. Market Share & Forecast

8.3.3.2.1. By Monitoring Technique

8.3.3.2.2. By Offering

8.3.3.2.3. By Deployment Type

8.3.3.2.4. By Monitoring Process

8.3.3.2.5. By End User

8.3.4. South Korea Machine Condition Monitoring Market Outlook

8.3.4.1. Market Size & Forecast

8.3.4.1.1. By Value

8.3.4.2. Market Share & Forecast

8.3.4.2.1. By Monitoring Technique

8.3.4.2.2. By Offering

8.3.4.2.3. By Deployment Type

8.3.4.2.4. By Monitoring Process

8.3.4.2.5. By End User

8.3.5. Australia Machine Condition Monitoring Market Outlook

8.3.5.1. Market Size & Forecast

8.3.5.1.1. By Value

8.3.5.2. Market Share & Forecast

8.3.5.2.1. By Monitoring Technique

8.3.5.2.2. By Offering

8.3.5.2.3. By Deployment Type

8.3.5.2.4. By Monitoring Process

8.3.5.2.5. By End User

9. Middle East & Africa Machine Condition Monitoring Market Outlook

9.1. Market Size & Forecast

9.1.1. By Value

9.2. Market Share & Forecast

9.2.1. By Monitoring Technique

9.2.2. By Offering

9.2.3. By Deployment Type

9.2.4. By Monitoring Process

9.2.5. By End User

9.2.6. By Country

9.3. Middle East & Africa: Country Analysis

9.3.1. Saudi Arabia Machine Condition Monitoring Market Outlook

9.3.1.1. Market Size & Forecast

9.3.1.1.1. By Value

9.3.1.2. Market Share & Forecast

9.3.1.2.1. By Monitoring Technique

9.3.1.2.2. By Offering

9.3.1.2.3. By Deployment Type

9.3.1.2.4. By Monitoring Process

9.3.1.2.5. By End User

9.3.2. UAE Machine Condition Monitoring Market Outlook

9.3.2.1. Market Size & Forecast

9.3.2.1.1. By Value

9.3.2.2. Market Share & Forecast

9.3.2.2.1. By Monitoring Technique

9.3.2.2.2. By Offering

9.3.2.2.3. By Deployment Type

9.3.2.2.4. By Monitoring Process

9.3.2.2.5. By End User

9.3.3. South Africa Machine Condition Monitoring Market Outlook

9.3.3.1. Market Size & Forecast

9.3.3.1.1. By Value

9.3.3.2. Market Share & Forecast

9.3.3.2.1. By Monitoring Technique

9.3.3.2.2. By Offering

9.3.3.2.3. By Deployment Type

9.3.3.2.4. By Monitoring Process

9.3.3.2.5. By End User

10. South America Machine Condition Monitoring Market Outlook

10.1. Market Size & Forecast

10.1.1. By Value

10.2. Market Share & Forecast

10.2.1. By Monitoring Technique

10.2.2. By Offering

10.2.3. By Deployment Type

10.2.4. By Monitoring Process

10.2.5. By End User

10.2.6. By Country

10.3. South America: Country Analysis

10.3.1. Brazil Machine Condition Monitoring Market Outlook

10.3.1.1. Market Size & Forecast

10.3.1.1.1. By Value

10.3.1.2. Market Share & Forecast

10.3.1.2.1. By Monitoring Technique

10.3.1.2.2. By Offering

10.3.1.2.3. By Deployment Type

10.3.1.2.4. By Monitoring Process

10.3.1.2.5. By End User

10.3.2. Colombia Machine Condition Monitoring Market Outlook

10.3.2.1. Market Size & Forecast

10.3.2.1.1. By Value

10.3.2.2. Market Share & Forecast

10.3.2.2.1. By Monitoring Technique

10.3.2.2.2. By Offering

10.3.2.2.3. By Deployment Type

10.3.2.2.4. By Monitoring Process

10.3.2.2.5. By End User

10.3.3. Argentina Machine Condition Monitoring Market Outlook

10.3.3.1. Market Size & Forecast

10.3.3.1.1. By Value

10.3.3.2. Market Share & Forecast

10.3.3.2.1. By Monitoring Technique

10.3.3.2.2. By Offering

10.3.3.2.3. By Deployment Type

10.3.3.2.4. By Monitoring Process

10.3.3.2.5. By End User

11. Market Dynamics

11.1. Drivers

11.2. Challenges

12. Market Trends & Developments

12.1. Merger & Acquisition (If Any)

12.2. Product Launches (If Any)

12.3. Recent Developments

13. Global Machine Condition Monitoring Market: SWOT Analysis

14. Porter's Five Forces Analysis

14.1. Competition in the Industry

14.2. Potential of New Entrants

14.3. Power of Suppliers

14.4. Power of Customers

14.5. Threat of Substitute Products

15. Competitive Landscape

15.1. Siemens AG

15.1.1. Business Overview

15.1.2. Products & Services

15.1.3. Recent Developments

15.1.4. Key Personnel

15.1.5. SWOT Analysis

15.2. Honeywell International Inc.

15.3. Schneider Electric SE

15.4. Rockwell Automation Inc.

15.5. Emerson Electric Co.

15.6. General Electric Company

15.7. ABB Ltd.

15.8. Yokogawa Electric Corporation

15.9. Hitachi Ltd.

15.10. Parker Hannifin Corporation

16. Strategic Recommendations

17. About Us & Disclaimer

Report Description

Table of content

Figures and Tables

Frequently asked questions

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