Integrating sensors with your CMMS gives you tighter production control, smarter resource usage, more efficient maintenance, and a bigger bottom‑line impact.
In modern operations, data is the new oil. With growing demands for predictive maintenance and continuous equipment monitoring, sensor–CMMS integration is the powerhouse behind your maintenance strategy.
Read more: What Is Predictive Maintenance? (Definition, Examples, IoT Solutions)
This applies to all sensor types, especially those that record cumulative operating data (like hour meters, flow meters, and runtime counters). These directly fuel condition-based maintenance based on actual usage.
El‑Watch offers direct integrations between Neuron and EG Maintenance CMMS. Staying true to Neuron’s core principle of “Simplicity,” all unnecessary complexity is removed—while key functionality is preserved and enhanced.
Also worth reading: In five months, Rygene-Smith & Thommesen saved 70,000 EUR with Neuron Sensors from El-Watch!
What Is CMMS, and Why Add Sensors?
A CMMS (Computerized Maintenance Management System) is software that plans, documents, and tracks maintenance activities. It helps with:
- Work orders
- Spare part inventories
- Maintenance schedules
- Historical data and reporting
By capturing real-time sensor data, a CMMS can automatically assess equipment condition and trigger work orders—without human intervention. That’s a major leap toward automation and Industry 4.0.
Read more: How wireless sensors enable a sustainable manufacturing industry
Popular CMMS Solutions
Several CMMS platforms are tailored to support sensor integration for advanced maintenance. Key examples include:
- EG Maintenance – widely used by various businesses and municipalities, now featuring seamless integration with El‑Watch Neuron.
- SAP PM (Plant Maintenance) – part of SAP’s ERP system, common in large industrial settings; supports sensor integration and predictive analytics via open APIs and IoT modules.
- Fiix (Rockwell Automation) – a cloud-native tool with an open API for smooth IoT/sensor integration.
- IBM Maximo Application Suite – Enterprise-grade asset management with built-in IoT and AI-powered analytics for predictive maintenance. Suitable for energy, utilities, manufacturing, and more.
- UpKeep – User-friendly mobile-first CMMS used globally. Offers IoT sensor integrations and is ideal for fast deployment in smaller teams or remote operations.
- MaintainX – Focuses on mobile operations with real-time work order tracking and sensor integrations. Rapidly growing user base across industries.
- eMaint (Fluke) – Part of the Fluke reliability ecosystem. Supports predictive maintenance and sensor integration via cloud or hybrid installations.
When selecting a CMMS, your company should look for open APIs and documented sensor support—either built-in or via platforms like El‑Watch Neuron.
Read more: Neuron Sensor System—A Sixth Sense for IoT Monitoring
How Sensor–CMMS Integration Works
1. Data Collection
Mount Neuron sensors on or near equipment to monitor variables such as:
- Cumulative counts (e.g., fluid flow, operational hours)
- Vibration
- Temperature
- Pressure
Data is transmitted to the Neuron platform via a local gateway.
2. Data Processing
The Neuron platform filters, normalizes, and analyzes the data. Automated alarms and checks run continuously to detect anomalies.
3. API-Driven Work Orders
When a threshold is crossed (e.g., a motor overheats), a work order is created instantly in the CMMS. Additionally, the CMMS can auto-generate orders when counters hit set levels.
Customer Story Video: Reduced downtime and significant savings for Norwegian timber company
Why Cumulative-Count Sensors Shine
Sensors that track cumulative data—with direct ties to real usage—offer high ROI:
- Maintenance aligns precisely with actual wear
- Data is stable, predictable, and straightforward
- Real-time processing isn’t required for effectiveness
Examples:
- Flow meter → trigger job at 10,000 liters
- Runtime counter → schedule service at 1,000 hours
- Cycle meter → plan belt replacement after 50,000 cycles
Other Key Sensor Applications
Beyond counters, various sensors proactively alert the CMMS to potential failures:
- Vibration sensors: early warning signs of imbalance or component wear
- Temperature sensors: detect overheating or overloading
- Pressure sensors: prevent failures in hydraulics and fluid systems
Related articles:
- Complete Wireless IoT Solutions for Multiple Industries
- How does vibration sensor application increase productivity?
- Wireless temperature sensor: A remote control for industrial gains
Business Benefits of Sensor–CMMS Integration
Linking sensors to your CMMS delivers strategic gains that extend well past automation:
- Automated workflows: Eliminate manual data entry—gain accuracy and predictability
- Predictive insight: Reduce downtime with condition-based servicing
- Resource efficiency: Replace parts based on need, not routine
- Full transparency: Logs contain sensor values alongside work history
- Standardization: Open APIs ensure scalable solutions, even across SCADA or other platforms
Integrating sensor data into your CMMS is more than a tech upgrade—it’s a shift from reactive fixes to predictive precision. Specifically, cumulative-count sensors offer an immediate, high-impact return by enabling automated triggers based on real-world asset usage.
This strategic transformation delivers value from day one.
Read more: What are IoT sensors, and why are they a good investment?
Ready to try wireless sensors?
Please contact our CTO for some good advice and a nice sensor- chat.
