Industrial Machine Health Monitoring: Opportunities & Forecasts Through 2029

Inside this Report

As industrial organizations increasingly embrace the data-driven strategies enabled by the Industrial Internet of Things (IIoT), many have prioritized investments in solutions that monitor the health of their operational equipment. By continuously monitoring the status and performance of compressors, gear boxes, motors, pumps, and other industrial machinery, manufacturers and other industrial operators can develop and manage maintenance strategies that help maximize production uptime and output. As such, industrial machine health monitoring solutions - which combine sensing hardware, real-time monitoring capabilities, and advanced analytics (e.g., predictive modeling) within a complete, end-to-end solution - have emerged as critical tools in these organizations' pursuit of operational efficiency and optimization. This report covers the global market for industrial machine health monitoring solutions, including segmentations and forecasts by geographic region, channel, and industry.

What Questions are Addressed?

• How large is the market for industrial machine health solutions?
• Which regions and industries will drive growth over the next five years?
• How is the convergence of OT, IT, and IoT shaping this market?
• Which industrial automation suppliers have been most aggressive in supporting machine health initiatives?
• How have cybersecurity concerns affected the adoption and implementation of these solutions?

Who Should Read this Report?

This report is intended for those making critical decisions regarding product development, partnerships, go-to- market planning, and competitive strategy and tactics. It is written for executives, senior managers, and other decision-makers involved in the development, deployment, marketing, management, or sales of industrial machine health solutions, including those in the following roles:

Vendors Listed in this Report:

Executive Summary

The continued maturation of sensing technologies has been a foundational growth driver throughout the early stages of this market. Moving forward, the emergence and maturation of industrial artificial intelligence will be among the most critical technological drivers for this market.

This market is populated by a diverse mix of machine health startups, established industrial technology vendors, industrial component suppliers, and global industrial automation giants. Through the early stages of this market, dedicated machine health providers such as Augury, I-care, and KCF Technologies have been the most successful in generating demand due to their laser focus on this sector. From a solution perspective, competitors in this market generally fit into one of several categories: companies that sell sensors, companies that sell sensors and provide manual diagnostics and recommendations via service engagements, and companies that sell sensors and provide automated diagnostics and recommendations leveraging AI. Beyond the leading vendors, the competitive landscape is further populated by variety of niche competitors that serve select geographies, industries, or machine health monitoring applications.

The food and beverage industry was the leading sources of industrial machine health monitoring revenue in 2024 due, in large part, to the high volume of machinery present in facilities within this space. Operating environments within the food and beverage industry are generally less complex to monitor, allowing for straightforward deployments and easily demonstrable cost savings. The energy and power generation sector will be the fastest- growing industry segment through 2029 as corporate environmental, societal, and governance (ESG) goals drive operators to address mounting requirements such as those around carbon emissions or energy management. Automotive manufacturers and component suppliers will also drive significant growth through the end of the forecast period.

Key Findings:

• The maturation of industrial artificial intelligence will be a critical growth driver for this market.
• Requirements around openness and interoperability have intensified as industrial organizations continue gaining access to new operational data sources.
• Competitors whose deployments rely on professional services will find it increasingly difficult to scale their services capacity as their install base grows.
• The Asia-Pacific region will attain the highest growth rate through the end of the forecast period.
• Vendors overwhelmingly rely on direct sales to engage with customers.

Monitoring Technique Segmentation and Forecast

Overview

Vibration monitoring - either via dedicated vibration sensors or multi-function sensors also including temperature and other measurements - generated the overwhelming majority of industrial machine health monitoring revenue in 2024. Due to its ability to identify abnormal behavior in common industrial equipment such as compressors, generators, fans, motors, pumps, and turbines, vibration monitoring is the de facto starting point for any industrial organization looking to prevent failures before they occur. The addition of temperature measurement allows multi-function sensors to provide a more comprehensive understanding of machine performance. Multi-function sensors from Augury, I-care, and other market leaders commonly include additional measurement parameters, such as impact and magnetic flux. The expanded coverage afforded by these additional measurement parameters will allow the growth rate of this segment to outpace that of the single- parameter vibration segment. Moving forward, vibration and multi-function sensors will continue to comprise the vast majority of this market through the end of the forecast period, however, alternative techniques such as corrosion monitoring, electrical monitoring, and oil analysis will grow at the greatest rate (nearly 16% per year through the end of the forecast period) as organizations begin to target non-rotating equipment such as drums, pipes, and tanks. Sensors measuring magnetic flux will become particularly attractive due to their ability to measure energy consumption and help organizations meet their ESG objectives.

Alternative Techniques Hindered by Limited Machine Knowledge

Even before the emergence of this IIoT-enabled market segment, vibration monitoring has long been at the forefront of industrial organizations' condition monitoring efforts. As such, solution providers have access to tremendous volumes of reference data detailing common failure points and fault conditions for most types of rotating industrial equipment. Used in conjunction with vendors' machine learning algorithms and AI capabilities, this reference data is a foundational element of the machine health market. Unfortunately, reference data for non- rotating, discrete machinery such as cranes and robots is comparatively scarce. Without a sufficient body of knowledge as to how these machines break and how they are fixed, vendors in this space have been hesitant to offer coverage in this area. To effectively cover assets with critical, non-rotating components, solution providers must amass not only sufficient reference data around each new class of machinery, but also sufficient in-house expertise to deliver value-adding advice to customers.