The bottom line: A standalone CMMS is a ticketing system. ProAlert's CMMS is a reliability program. Because it shares a database with production, quality, procurement and asset compliance, your work orders arrive with full operational context: what failed, when it failed, what the line was producing, and what the OEE was at the moment of failure. That context transforms maintenance from reactive to predictive.

The Integration Tax Most Plants Are Paying

Most manufacturers today source their maintenance management software, OEE system, and shop-floor response tools from different vendors. The individual systems work in isolation. The cost is not just the software licenses.

ProAlert CMMS dashboard showing work order counts with a four hour average work order duration, temporary fix ages, 91.4 percent preventive maintenance compliance against 3346 expected tasks, $18,378 of inventory with four parts below reorder point, failure analysis with 66 failures, 117.3 hours of downtime and a 1.8 hour mean time to repair, top failure modes, and 28 continuous improvement ideas worth an estimated $115,800 — **One module, one screen, no integration project.** Work orders, temporary fixes, preventive maintenance compliance, spare parts inventory, failure analysis and continuous improvement all read from the same database. The 1.8 hour mean time to repair next to the top failure modes is not a report someone assembled. It is the same records the technicians closed, counted, and it is the active repair time rather than the whole wait: the six hours between a machine stopping and somebody reaching it are in the downtime figure beside it, where they belong.

Separate System Component	Typical Annual Cost (Mid-Size Plant)
CMMS (10 users at $50/user/month)	$6,000 per year
OEE software (per-line licensing)	$5,000–$20,000 per year
Andon hardware system (one-time)	$10,000–$50,000
Custom integration development between systems	$50,000–$200,000
Total first-year cost	$76,000–$276,000

ProAlert's integration cost: $0. Maintenance, quality, procurement, production and video share one database from day one. When a downtime event creates a work order, the work order already carries the asset state, the OEE at the time of failure, and the product that was running. No middleware. No data mapping. No integration project.

Work Order Management

ProAlert's work order system handles the full lifecycle from creation through completion, with automatic operational context captured the moment each work order is created.

Auto-Creation from DT Calls

When a Downtime (DT) call closes, a Work Order is created automatically with the equipment, failure cause, asset OEE state, and product already populated. No duplicate entry.

WorkOrderContext Snapshot

Full operational context captured at Work Order creation: asset state, OEE value, active shift, product being run. Post-mortem analysis has everything it needs without reconstructing history.

Task-Level Breakdown

Break work orders into individual tasks with step classification flags (safety, inspection, repair). Starting a task automatically opens a continuous labor timer segment.

WorkOrderEvent Log

Typed event log captures every lifecycle transition (created, assigned, started, completed) with timestamps and the identity of the executing technician.

Mean Time to Repair (MTTR)

MTTR calculated from the active repair time on each failure record, not from the whole interval between the machine stopping and the job being closed. The wait before a technician arrives is tracked separately, so a slow response shows up as a response problem rather than inflating your repair figure. Trend by asset, category and technician to find chronic reliability problems.

Video Evidence on Tasks

Event-triggered video clips linked to the originating DT call are accessible directly from the Work Order. Technicians reviewing the failure days later see exactly what happened.

The Revision That Governed This Job

A work order names the controlled document its procedure came from and carries a "Rev N" badge. Not which procedure exists today, but which revision governed this job on this day... which is the question an auditor actually asks.

Skip With a Reason, or Add a Step

A technician can skip a step with a stated reason, or add one that was not on the template. Both stay on the record, so the difference between the procedure as written and the work as done is visible rather than inferred.

Continuous Time Tracking

Timer segments accumulate across the web and the tablet as tasks start and pause, and completing the work order writes the labour row automatically. Issuing a part to the job writes the matching parts record, so maintenance cost reconciles against inventory.

ProAlert CMMS work order list showing sixteen work orders across open, approved, scheduled, in progress and completed states, each with its type, priority, asset, due date and assigned technician — **The queue a planner works from.** Corrective, preventive, predictive, inspection and safety work sit in one list, each row already carrying the asset it belongs to and the technician who owns it. Priority runs from Planned through Emergency, so what has to move today is legible without opening anything.

ProAlert work order WO-202608-0182, a high priority corrective job on INJ-001 for hydraulic pressure loss on a clamp circuit, in progress at three of seven tasks, each completed step signed off by name and time, with the work order linked back to the downtime call that raised it — **One work order, opened.** A clamp circuit pressure loss on an injection press, raised by a downtime call and carrying the machine, the priority and the assigned technician with it. The procedure is broken into seven steps with three signed off, each stamped with who completed it and when. The link back to the call that raised it stays on the record, so the job and the stoppage it answered are never two separate stories.

The same work order, in the technician's hand

Work order WO-202608-0182 above and the two phone screens below are the same record at the same moment. The planner sees it on a desk. The technician who is actually holding the wrench sees it on a phone at the machine. Neither is a separate app, and nobody re-keys anything between them.

ProAlert mobile app work order list for a maintenance technician, showing five assigned orders across in progress, scheduled and approved states, each with its work order number, asset, due date and task completion count — **My Orders, five of them.** Colour carries priority, so the emergency guard interlock fault sorts itself out visually before anything is read.

ProAlert mobile work order detail for WO-202608-0182 on injection press INJ-001, showing High priority, In Progress status, three of seven tasks passed, and photo, video, start and skip controls on the next open step — **Three of seven, signed off at the machine.** Each remaining step carries its own camera and video buttons, so the evidence is attached where the work happens.

Preventive Maintenance (PM) Scheduling

ProAlert's Preventive Maintenance (PM) system generates Work Orders automatically from a schedule, with the procedure and required parts already attached. PM compliance is tracked against the plan and reported as a bounded Key Performance Indicator (KPI).

PM Trigger Type	Example Use Case
Time-Based	Lubricate spindle bearings every 30 days. The system generates the Work Order on schedule regardless of machine state.
Meter-Based	Replace hydraulic fluid every 10,000 press strokes. EdgeSense IoT (Internet of Things) cycle counts drive the meter reading automatically.

Those are the two trigger types a schedule can be saved on. Condition and event triggers appear in the interface but cannot be selected, because a schedule that cannot generate a due date is a schedule that quietly does nothing. An abnormal condition still becomes work through a different route: a failed inspection step or an EdgeSense rule raises a work order and a gap on the daily board directly, rather than pretending to be a maintenance schedule.

PM Completion Rate calculation: Calculated using a burn-down denominator bounded to [0, 100]. A PM completion rate that can exceed 100% is not a useful KPI. ProAlert's calculation stays numerically honest even during high-compliance periods. A generated PM work order also gets a due-date floor, so it is never born already overdue, and completing one from the web closes its schedule and advances the next due date without anyone opening the tablet.

PM Schedules Run From Templates

A PM schedule is wired to a work template version, so a generated PM work order arrives with its step list already on it. Inline PM task lists can be converted into reusable templates in bulk, and a dry-run report shows what would be converted, relinked, skipped or failed before anything is committed.

Inspections That Turn Into Work

An inspection step records Pass, Fail or N-A on large buttons. A failed step opens a "Follow-up: Failed inspection" work order by itself, and a failed critical step also raises a gap on the daily management board, so the miss is visible outside maintenance. Triggers are configurable and every firing is logged.

ProAlert preventive maintenance schedule board showing 47 active schedules, four of them overdue and highlighted in red, one due tomorrow, each row carrying its cadence, next due date and its own compliance percentage with done and late counts — **Forty-seven schedules, and the four that slipped.** Daily, weekly and monthly cadences sit in the same list, each with its own next due date and its own compliance history. The four genuinely overdue schedules sort to the top and are called out in red rather than buried, and the compliance percentage beside each one, with its done and late counts, shows whether a slip is a one-off or a pattern.

Failure Analysis and Root Cause Analysis (RCA)

ProAlert captures structured failure data at every downtime closure and feeds it directly into Pareto analysis and 5P (5 Principles Problem Solving) Root Cause Analysis workflows.

ISO 14224 Failure Mode Library

Define failure modes using the ISO 14224 (Equipment Reliability Data Standard) structure. Failure causes, consequences, and remedies tracked at the category level for cross-asset analysis.
5P Problem Solving with PDF Export

Structured 5P RCA workflow: Problem Statement, 4M (Machine, Material, Man, Method) Analysis, Root Cause identification, Countermeasures, and Follow-up verification. Exports as a formatted PDF for quality record archives.
Failure Analysis Dashboard, Clickable End to End

Visual Pareto analysis of failure trends by mode, cause, and asset, fed automatically from every downtime closure. The KPI tiles, the root-cause distribution, the availability chart and the Recent Failures list all drill into the filtered failure records behind them, and the failure register itself filters, reads and exports to CSV. A failure record is written on every close path and describes itself in a sentence rather than arriving blank.
Temporary Fix (Yellow Banner) Escalation

Temporary fixes trigger a yellow banner visible on the Andon HUD (Heads-Up Display), mobile app, and EdgeSense local display. Escalation timers with configurable thresholds ensure follow-up Work Orders are generated before the temporary fix becomes a permanent one.

Parts Inventory and Procurement

ProAlert includes a full parts catalog, multi-storeroom stock management, and Purchase Order (PO) workflow. Parts consumed on a Work Order deduct from inventory automatically at task completion.

Parts Catalog

Master parts list with SKU (Stock Keeping Unit), categories, unit of measure, and pricing. Asset Bill of Materials (BOM) links parts to the specific equipment that uses them.

Multi-Storeroom Stock

Track on-hand quantities per storeroom with full transaction history, low-stock alerts, and configurable reorder point management.

Purchase Orders

Create POs, track receipts, manage vendor records, and send automatic email notifications when orders are placed or received at the storeroom.

Request for Quote (RFQ) Workflow

RFQ workflow linked to PO creation for vendor price comparison before purchase commitment. Approval chain configurable per organization.

ISO 14224 Asset Registry

ProAlert's asset hierarchy follows ISO 14224 (Equipment Reliability Data Standard), giving your maintenance data a structure that aligns with reliability engineering benchmarks and regulatory audits.

Asset Record Field	Purpose
Parent-Child Hierarchy	Represent complex machines as component assemblies. A press can have child records for the hydraulic system, electrical cabinet, and tooling holder... each with its own failure history.
Criticality Rating	Score assets by criticality with a configurable scoring system. PM resources and response priorities are allocated to the equipment that matters most.
Lifecycle Tracking	Install date, warranty expiration, depreciation rate, and end-of-life date tracked per asset for capital planning and insurance documentation.
Asset Documentation	Attach manuals, drawings, and Bills of Materials (BOMs) directly to asset records. Technicians access reference documents from the Work Order without leaving the system.
Craft and Team Assignment	Assign assets to maintenance teams and craft types. Work orders route based on asset-to-team mapping without manual dispatcher coordination.

How ProAlert Compares to Standalone CMMS

Standalone CMMS (Fiix, UpKeep, Limble)

Maintenance management only... no OEE, no Andon
$20–$70 per user per month
Work orders carry no production context
Integration with OEE and Andon costs $50,000–$200,000
No video evidence capability
No physical Andon button integration

ProAlert CMMS

CMMS + OEE + Andon + Video in one shared platform
Work orders automatically include OEE state, shift, and product at failure
A maintenance programme that shares one database with quality, procurement, planning and asset compliance
Video evidence accessible directly from Work Order tasks
Mobile app with offline capability included
Integration cost: $0... single shared SQL Server database

For IT and Systems Teams

Component	Technology	Notes
Data Model	62-table CMMS schema (SQL Server)	Full ISO 14224-aligned entity structure via Entity Framework Core migrations. Standard SQL Server backup and recovery applies to all CMMS data.
Mobile Access	.NET MAUI (Multi-platform App UI)	Work orders, labor entry, parts usage, and asset lookup available natively on iOS and Android with offline mode when connectivity is lost.
API Integration	REST API (Representational State Transfer)... CMMS endpoints	Full Work Order lifecycle via API for ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) integration. JWT (JSON Web Token) bearer authentication on all endpoints.
Licensing Model	Bundled with ProAlert Core	Maintenance management is bundled with ProAlert Core, so every installation includes it; seats are granted to the users who need it, and a user without a seat sees a Learn More prompt on locked CMMS screens. Module entitlement is enforced server-side rather than only hidden in the menu. Materials, Aviation, OEE, Video, EdgeSense and ISO 55001 are licensed on top of the core, and ISO 55001 depends on CMMS. Contact the team for licensing terms.
Deployment	On-premises or private cloud	Same server as the ProAlert web application. No separate CMMS server, database, or network zone required.

See maintenance management that knows your production context.

Book a 30-minute demo... we'll walk through a Work Order from DT call closure to failure analysis, including automatic context capture and parts tracking.

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