Machine Condition Monitoring Market Report 2025

This Machine Condition Monitoring market report covers market characteristics, size and growth, segmentation, regional and country breakdowns, competitive landscape, market shares, trends and strategies for this market. It traces the market’s historic and forecast market growth by geography.

The machine condition monitoring market size has grown strongly in recent years. It will grow from $3.14 billion in 2024 to $3.37 billion in 2025 at a compound annual growth rate (CAGR) of 7.6%. The growth in the historic period can be attributed to growth in industrial automation and manufacturing activities, increased emphasis on equipment reliability and asset performance, demand for predictive maintenance in process industries, focus on cost savings and operational efficiency in industries, regulatory compliance and safety standards in manufacturing.

The machine condition monitoring market size is expected to see strong growth in the next few years. It will grow to $4.6 billion in 2029 at a compound annual growth rate (CAGR) of 8.1%. The growth in the forecast period can be attributed to adoption of wireless and iot-enabled condition monitoring solutions, integration of artificial intelligence (ai) and machine learning (ml) in predictive maintenance, rising importance of remote monitoring for distributed assets, research and development in advanced sensor technologies and data interpretation. Major trends in the forecast period include predictive analytics for early fault detection, vibration analysis for machinery health assessment, integration of digital twins for asset performance monitoring, incorporation of wireless and iot sensors, ultrasound and acoustic emission for non-destructive testing.

The rise of wireless communication in machine condition monitoring is playing a significant role in the expansion of the machine condition monitoring market. Wireless communication refers to the transmission of information from one point to another without the use of connections such as wires, cables, or any physical medium. This technology facilitates the easy and rapid deployment of machine condition monitoring, minimizing gaps in the data stream and preventing any adverse effects on system reliability. For example, in September 2024, a report published by The WorldData.info, a US-based information group, revealed that in 2023, there were a total of 473.99 million connections, including 386.0 million mobile phones, averaging 1.2 mobile phones per person. This average of 1.2 mobile phones per person is also consistent in the EU. Therefore, the growing demand for wireless communications is expected to propel the growth of the machine condition monitoring market.

The growth of the automotive industry is anticipated to drive the machine condition monitoring market further. The automotive industry, covering vehicle design, development, manufacturing, marketing, and sales, benefits significantly from machine condition monitoring as a powerful tool for efficiency improvement, quality enhancement, cost reduction, safety improvement, and product quality improvement. In May 2023, the global production of motor vehicles reached 85.4 million units, reflecting a notable 5.7% increase from 2021, as reported by the European Automobile Manufacturers Association. Additionally, in February 2022, the automobile sector achieved approximately 78 million unit sales, marking a substantial 10% increase, according to Brand Finance plc. Thus, the expanding automotive industry is a key driver for the growth of the machine condition monitoring market.

Major companies in the machine condition monitoring market are concentrating on developing advanced motor condition monitoring devices to enhance predictive maintenance, reduce downtime, improve operational efficiency, and lower maintenance costs by delivering real-time insights into machine health and performance. These advanced motor condition monitoring devices are sophisticated tools designed to continuously evaluate the performance and condition of electric motors and related equipment. They enable local monitoring without the need for complicated installations or cloud systems, making them easier to integrate into existing setups. For example, in February 2023, OMRON Corporation, a Japan-based company, launched the K7DD-PQ Series, an advanced motor condition monitoring device aimed at improving predictive maintenance in manufacturing environments. The K7DD-PQ can measure both voltage and current, or solely current, from power lines that drive motors and other equipment. It can identify multiple failure modes across various load conditions and analyzes over 400 types of feature values derived from current and voltage measurements.

Major companies in the machine condition monitoring market are focusing on innovative products, such as the K7TM condition monitor, to boost their revenues. The new OMRON K7TM allows for automatic assessment of the heater's proper resistance value while in use, displaying the heater's trend toward deterioration. For example, in April 2022, Omron Corporation, a Japan-based company, introduced the K7TM condition monitor for heating equipment, primarily used in the automotive and FMCG industries. This product aids in achieving a carbon-free society by visualizing deterioration trends to enable predictive maintenance. It reduces production downtime by scheduling maintenance tasks based on compiled rate-of-change data on resistance values for every heater, contributing to energy efficiency by minimizing thermal energy required for restarts.

In October 2023, Emerson Electric Co., a US-based company, acquired National Instruments Corporation for $8.2 billion. This acquisition enables Emerson to enhance its portfolio by integrating National Instruments' expertise in machine condition monitoring solutions. National Instruments Corporation is a US-based firm that specializes in providing machine condition monitoring solutions.

Major companies operating in the machine condition monitoring market include ALS Limited, Bruel & Kjaer, Emerson Electric Co., Teledyne FLIR LLC, Fluke Corporation, Baker Hughes Company, General Electric, Honeywell International Inc, Meggitt PLC, National Instruments Corp, PARKER HANNIFIN CORP, Rockwell Automation Inc., Schaeffler India Limited, SKF Condition Monitoring Inc, Symphony Industrial AI, Wilcoxon Sensing Technologies Inc., Azima DLI Corporation, AB SKF (Swedish: Svenska Kullagerfabriken), Emerson Electric Co., Ifm Electronic Gmbh, Schaeffler AG & Co., Baker Hughes Company, Analog Devices Inc., RoadBotics Inc., Litmus Automation Inc., Amphenol Inc., Brüel & Kjaer Vibro, FLIR Systems Inc., Nippon Avionics Co. Ltd., Thermo Fisher Scientific Inc., Perkin Elmer Inc., PCB Piezotronics Inc., SPM Instrument AB, KCF Technologies Inc., Monnit Corporation.

North America was the largest region in the machine condition monitoring market share in 2024. Asia-Pacific is expected to be the fastest-growing market in the machine condition monitoring market. The regions covered in the global machine condition monitoring industry report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, and Africa. The countries covered in the machine condition monitoring market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, and USA.

Machine condition monitoring is the practice of continuously tracking a machine's status over time, encompassing factors like efficiency to detect potential deeper issues. Its purpose is to minimize and eliminate unexpected machine downtime, enhance equipment health and performance, improve product quality, reduce scrap, and optimize maintenance schedules using precise machine data. Additionally, it enables real-time automation based on the machine's current state.

The primary types of machine condition monitoring include hardware, software, and services. Hardware refers to the actual components of a computer and related devices, both internal (e.g., motherboards, hard drives, RAM) and external (e.g., monitors, keyboards, mouse, printers, scanners). Machine condition monitoring can be deployed on-premise or in the cloud, and various techniques such as vibration monitoring, thermography, oil analysis, corrosion monitoring, ultrasound emission, and motor current analysis are utilized. Industries benefiting from machine condition monitoring span oil and gas, power generation, metals and mining, chemicals, automotive, aerospace and defense, food and beverages, and marine.

The machine condition monitoring market research report is one of a series of new reports that provides machine condition monitoring market statistics, including machine condition monitoring industry global market size, regional shares, competitors with a machine condition monitoring market share, detailed machine condition monitoring market segments, market trends and opportunities, and any further data you may need to thrive in the machine condition monitoring industry. This machine condition monitoring market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenario of the industry.

The machine condition monitoring market includes revenues earned by entities by providing identification of appropriate machine condition monitoring technique and selection of available technologies. The market value includes the value of related goods sold by the service provider or included within the service offering. Only goods and services traded between entities or sold to end consumers are included. The machine condition monitoring market also includes sales of image sensor, microelectronics, complementary metal oxide semiconductor, which are used in machine condition monitoring. Values in this market are ‘factory gate’ values, that is the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

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