The oil and gas industry, marked by its intricate infrastructure and dependence on equipment reliability, progressively embraces Industry 4.0 (I4.0) technologies to drive operational excellence. This study presents a comprehensive framework for integrating I4.0 principles with Condition-Based Maintenance (CBM) strategies aimed at revolutionising maintenance practices in the sector. The research addresses recurring industry challenges, including equipment failures, production disruptions, and rising maintenance costs. It leverages a rigorous literature review, empirical data, and Delphi study to develop an innovative I4.0-based CBM framework designed to harness real-time diagnostics and predictive analytics. This framework provides a systematic, actionable roadmap for organisations looking to enhance equipment reliability, reduce downtime, and optimise maintenance expenditures. As part of the I4.0-based CBM framework, the study introduces an I4.0 Maturity Model and an online assessment tool, enabling maintenance professionals to gauge their readiness and progress in adopting I4.0-enabled CBM practices. The research culminates in the real-world application of the developed framework within an operational oil and gas organisation in Nigeria. This application demonstrates tangible enhancements in equipment reliability, production efficiency, and maintenance strategy optimisation. Insights from empirical deployment showcases the transformative potential of I4.0-enabled CBM in driving operational efficiency.

This research significantly contributes to the field of industrial operations management, offering a practical guide for organisations in the oil and gas sector and beyond. It presents a blueprint for leveraging I4.0 technologies to redefine maintenance paradigms, foster innovation, and enhance operational efficiency, paving the way for a sustainable and competitive future in the oil and gas industry.