This paper describes a novel approach, named Initial Optimisation Procedure (IOP), which is implemented to design enhanced condition monitoring systems. The IOP method is designed to evaluate the most sensitive location for a sensor for the detection of machine or process faults. The vibration data of a milling process is used in an experimental work to demonstrate the suggested methodology. Fourier Transformation and Wavelet are used for data analysis. The results show that the suggested approach is most suitable for vibration and acoustic emission sensors to improve the reliability and the capability of condition monitoring systems.

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