Transform Plant‑Floor Data Into Decisions That Matter
ProAlert™ is a single-database, single-login operations platform for asset-intensive manufacturers. Maintenance, quality, production, compliance and the shop floor all run in the one database, so what happens at a machine flows straight into the work order, the parts request, the quality record and the shift review... with no integration project to buy first.
Your Data is Talking… Are You Listening?
Watch How ProAlert Transforms Your Shop Floor
ProAlert is already deployed at Reyes Hayashi Automotive and Reyes Hayashi Mexico... Hayashi Telempu joint-venture facilities in North America.
Give every level of your organization
the visibility to act... right now.
ProAlert is a single-database, single-login operations platform for asset-intensive manufacturers, built so that information normally scattered across separate systems is already connected. Maintenance with its parts purchasing, quality, asset compliance, daily management, workforce, production planning, analytics, video, industrial IoT and shop-floor response share one database behind one login, so information flows from one job to the next instead of being re-entered, exported or reconciled, and nobody is deciding on a partial picture. ProAlert is not an ERP (Enterprise Resource Planning) or MRP (Material Requirements Planning) system. The only procurement in ProAlert is the purchasing side of its CMMS (Computerized Maintenance Management System): the spare parts, consumables and tooling that work orders and preventive maintenance schedules call for, bought from the same records the maintenance team works in. It does not run finance, sales orders or production material requirements planning. The ERP keeps those jobs, and ProAlert exchanges data with it through a documented REST API.
The distinguishing property is not any one of those disciplines. It is that they were never separate. A failure recorded at a press is the same record the maintenance planner schedules against, the quality engineer classifies, the buyer orders parts for, and the plant manager sees in the shift review. Nothing is exported, mapped or reconciled to make that happen.
View moreFrom machine event to the right person's screen
Operational disciplines on one database
Reyes Hayashi Automotive... Hayashi Telempu joint-venture facilities... running ProAlert across North America.
OEE sustained at world-class level over multiple years
Scrap reduction from 2023 baseline to 2026
First-pass quality rate sustained
Downtime calls reduced from 2024 peak to 2026
Based on ProAlert deployment data... Reyes Hayashi Automotive
What Control Looks Like After Go-Live
“We reduced scrap, rework, and downtime within weeks of going live. ProAlert didn’t just give us data... it gave us control.”
The lean floor management discipline, automated.
FMDS (Floor Management Development System) is the proven lean approach to running a shop floor: surface gaps, own them, fix them, repeat. The discipline is sound. The problem is it depends on the right leader being present and consistent every shift. ProAlert's A-FMDS automates the discipline itself... so the system holds whether it's a Tuesday morning with a full team or a holiday weekend with a skeleton crew.
Every threshold breach, sensor alarm, and missed schedule becomes a tracked gap the moment it occurs... without anyone writing it on a board.
Gaps promote to Problems with an owner, a due date, and a tracked lifecycle. Escalation fires automatically if nothing moves... the system holds people accountable.
Target → Gap → Problem → Action → Verified. A-FMDS runs that loop continuously... not just on mornings when the lean champion happens to be on the floor.
What Sets ProAlert Apart
Most manufacturing software gives you operational information the next day when a report is run. ProAlert delivers operational truth in real time... so you fix today's problems today, not read about them tomorrow.
Fourteen Operational Disciplines, One Database
A plant normally buys maintenance with its parts purchasing, quality, daily management and video from four or five vendors, then pays to wire them together. ProAlert ships all of it as one product, so there is nothing to wire.
- Maintenance with its parts purchasing, quality and asset compliance in one record set
- One organizational graph across machines, lines, plants and legal entities
- One audit trail, written automatically on every auditable record
- No integration layer, because the systems were never separate
Everything a Plant Runs On, In One System
Every one of these is shipping today, on the same database. Maintenance comes first because it is what most plants buy first. Shop-floor response coordination comes last because it is one discipline of fourteen, not the product.
- Maintenance Management (CMMS)
- CMMS-Connected Procurement
- Quality and Nonconformance
- Asset Lifecycle and Compliance
- A-FMDS Daily Management
- Workforce Operations
- Production Planning and Scheduling
- Performance Analytics and Executive Dashboards
- Video Management (VMS)
- EdgeSense Industrial IoT
- ProAlert Mobile (PAM)
- Safety and Emergency Broadcast
- Platform Foundation
- Response Coordination
Precision Data Capture. Zero Guesswork.
ProAlert's architecture connects directly to your existing equipment signals... no rip-and-replace required. Our lightweight edge devices and LAN-based server platform turn raw machine data into structured, actionable intelligence that stays on your network.
Edge Data Capture
Connect to PLCs, sensors, and I/O signals without replacing existing equipment.
LAN-First Architecture
Runs on your plant's local network. Your data stays on your infrastructure, under your control, with no internet dependency.
Escalation & Dispatch
Notification chains and escalation paths routed through your actual organizational structure.
OEE Analytics
Automated OEE scoring with trend analysis, loss-reason breakdowns, and benchmarking.
Flexible Configuration
Map data to your naming conventions, shift structures, and reporting hierarchies.
System Integration
API-ready connections to ERP, MES, CMMS, and BI tools you already use.
One Organizational Graph, From Cell to Corporate
Every plant runs differently. ProAlert lets you define how data is structured... mapping machines to lines, lines to departments, departments to plants... so your reports always reflect the way your business actually operates.
- Custom hierarchy mapping per facility
- Shift-aware reporting and aggregation
- Multi-plant roll-up views for corporate reporting
Built for Discrete Manufacturing
ProAlert is purpose-built for manufacturers where uptime and throughput drive the bottom line.
Automotive & Tier Suppliers
Monitor stamping, welding, assembly, and sub-assembly lines. Track JIS/JIT compliance and Andon pull events in real time.
Metal Fabrication
Capture press cycle times, tool change events, and shift OEE across every cell and line.
Plastics & Injection Molding
Detect short shots, cycle deviations, and mold-change downtime the moment they occur.
Multi-Plant Operations
Unify OEE and Andon data from multiple facilities into a single corporate dashboard.
Straight Answers About the Platform
What is ProAlert?
ProAlert is a single-database, single-login operations platform for asset-intensive manufacturers. Maintenance, quality, production, compliance and the shop floor all run in the one database, so information that is normally scattered across four or five separate systems, and connected only if you buy an integration project on top of them, is already connected: what happens at a machine flows straight into the work order, the parts request, the quality record and the shift review without anyone re-entering it. It covers fourteen operational disciplines: maintenance management, CMMS-connected procurement for maintenance parts only, quality and nonconformance, asset lifecycle and regulatory compliance, A-FMDS daily management, workforce operations, production planning and scheduling, performance analytics, video management, industrial IoT, mobile, safety broadcast, platform foundation, and shop-floor response coordination. Because every one of them reads and writes the same database, nobody in the plant is making a decision on a partial picture. ProAlert is not an ERP (Enterprise Resource Planning) or MRP (Material Requirements Planning) system. The only procurement in ProAlert is the purchasing side of its CMMS (Computerized Maintenance Management System): the spare parts, consumables and tooling that work orders and preventive maintenance schedules call for, bought from the same records the maintenance team works in. It does not run finance, sales orders or production material requirements planning. The ERP keeps those jobs, and ProAlert exchanges data with it through a documented REST API.
Is ProAlert an ERP or MRP system?
No. ProAlert is not an ERP (Enterprise Resource Planning) or MRP (Material Requirements Planning) system. The only procurement in ProAlert is the purchasing side of its CMMS (Computerized Maintenance Management System): the spare parts, consumables and tooling that work orders and preventive maintenance schedules call for, bought from the same records the maintenance team works in. It does not run finance, sales orders or production material requirements planning. The ERP keeps those jobs, and ProAlert exchanges data with it through a documented REST API. Most plants keep production material purchasing in the ERP and use ProAlert for the maintenance side, where the demand signal comes from the CMMS work orders and preventive maintenance schedule rather than from a sales forecast. See what the purchasing discipline covers.
What does ProAlert replace?
The stack of separate systems a plant would otherwise buy and integrate: a maintenance management system, a maintenance parts purchasing and inventory system, a quality and nonconformance system, an asset governance and compliance system, a daily management system, a workforce system, a production planning tool, a video management system, an industrial IoT gateway, and a shop-floor response tool. Plants normally buy those from four or five vendors and pay an integration bill to connect them. See what that stack actually costs.
Is ProAlert a CMMS?
Maintenance management is one of the fourteen disciplines, and it is a full one: work orders with SLA tracking, preventive maintenance triggered by time, meter reading, condition or event, inspections with reusable templates, parts inventory across multiple storerooms, 5-Why root cause analysis, ISO 14224 (Equipment Reliability Data Standard) failure taxonomies, and FMEA (Failure Mode and Effects Analysis) worksheets. The difference from a standalone CMMS (Computerized Maintenance Management System) is that it shares a database with quality, maintenance parts purchasing, production planning and asset compliance, so a work order carries the full operational context of what the line was doing when the failure occurred.
What are the fourteen operational disciplines ProAlert covers?
1. Maintenance Management (CMMS). 2. CMMS-Connected Procurement, covering maintenance parts only. 3. Quality and Nonconformance. 4. Asset Lifecycle and Compliance, including ISO 55001 and FAA Airworthiness Directive tracking. 5. A-FMDS Daily Management. 6. Workforce Operations. 7. Production Planning and Scheduling. 8. Performance Analytics and Executive Dashboards. 9. Video Management. 10. EdgeSense Industrial IoT. 11. ProAlert Mobile. 12. Safety and Emergency Broadcast. 13. Platform Foundation, covering licensing, multi-site, audit, API and four shipped languages. 14. Response Coordination for shop-floor calls.
Does ProAlert track material lots and genealogy?
Yes. Lot traceability runs end to end: a material lot register with a running balance and a transaction ledger, the lot captured at pick, delivery of staged material to the line, the lot an operator declares loaded at the machine, and a production lot whose genealogy lists every material lot that fed it. From there you can trace a material lot forward to every production lot it reached, or a production lot back to its inputs, and print a lot label as PDF or ZPL (Zebra Programming Language). Materials is a separately licensed module. Materials and inventory.
How does ProAlert control work instructions and other documents?
Controlled documents live in ProAlert and are linked to what they govern: a product, a component, a route step, a machine, a work order or a whole plant node. A document is reviewed and released through an approval queue, and the author cannot release their own document unless an administrator turns that off in document control settings. Acknowledgements are pinned to a specific version and revision, so a revision invalidates them. The production start gate then refuses to start a run when a required document is missing or unacknowledged, and names the one that is blocking. Document control.
How does ProAlert connect to existing plant equipment?
Through ProAlert EdgeSense, a .NET 8 edge client on Raspberry Pi hardware that speaks Modbus TCP/RTU natively, reads GPIO and digital I/O, counts cycles, detects production state, and buffers locally when the network drops. It costs approximately $500 per unit against industrial middleware that typically runs $20,000 or more per line. A visual workflow rule builder lets a customer define edge behaviour without writing code.
Does ProAlert require replacing existing machines or infrastructure?
No. ProAlert connects to your existing machines through EdgeSense devices and standard RTSP (Real Time Streaming Protocol) IP cameras. There is no rip-and-replace, and the platform runs on your plant's local network.
What industries does ProAlert serve?
Asset-intensive discrete manufacturers, including automotive stamping, metal fabrication, plastics injection molding, electronics assembly, medical device manufacturing, aerospace and defense, and food and beverage production. FAA Airworthiness Directive tracking in the asset compliance module extends it into regulated aviation maintenance.
Ready to see ProAlert in action?
Book a 30-minute live demo... we'll walk through your specific plant-floor challenges.
