The Manufacturing Operations Platform
That Scales With You
From a single press cell to a 10-plant enterprise, ProAlert™ runs maintenance, procurement, quality, asset compliance, daily management, workforce costing and production planning on one database and one login... configured to your plant structure rather than the other way around.
Fourteen Operational Disciplines. One Database. One Login.
Every one of these ships today, on the same asset model and the same audit trail. Maintenance leads the list because it is what most plants buy first. Response coordination sits last because it is one discipline of fourteen, not a description of the platform. Maintenance management (CMMS) is bundled with ProAlert Core, and Quality ships with it. Materials, Aviation, OEE, Video, EdgeSense and ISO 55001 are licensed separately, and ISO 55001 depends on maintenance. Entitlement is enforced in the navigation itself, so a plant sees exactly what it has licensed.
1. Maintenance Management (CMMS)
Work orders with SLA tracking, task checklists, labor time and parts consumption. Versioned work procedures under an author, checker and approver chain, with every work order pinning the revision it ran. Preventive maintenance triggered by time or meter reading, inspections that record Pass, Fail or N-A and turn a failure into work, temporary-fix control with escalation timers, 5-Why root cause analysis, and ISO 14224 (Equipment Reliability Data Standard) failure taxonomies with a filterable failure register.
2. Procurement and Supply Chain
Purchasing dashboard and planning board, request-for-quote workflow, purchase orders with configurable multi-level approval chains, a personal pending-approvals queue, low-stock reporting, parts demand forecasting, forward preventive-maintenance parts requirements, and supplier catalogues. Receiving resolves a destination and can split one delivery across storerooms and bins. Materials staging and lot traceability run on the same records: a material lot register with a running balance and ledger, lot capture at pick, delivery to the line, the lot the operator declares loaded at the machine, production lot genealogy, and where-used and composition reports.
3. Quality and Nonconformance
A nonconformance register that raises itself from an audit finding, a failed inspection, a scrap-threshold violation or a quality-dispositioned call, with a fillable corrective-action card and cost capture. Reject codes and groups, scrap capture with per-source thresholds and an approval queue, defect heat mapping by cavity and by physical location on the part, a customer-found defect register feeding external PPM (Parts Per Million), internal PPM and first-time-through on the daily board, FMEA (Failure Mode and Effects Analysis) worksheets, and governed document control with an approval queue, revision handover and electronic signature capture.
4. Asset Lifecycle and Compliance
A complete ISO 55001 (Asset Management System) module: policy with acknowledgement tracking, Strategic Asset Management Plan, objectives, internal audits with a finding lifecycle on one enforced vocabulary, management reviews and a Plan-Do-Check-Act workflow. Asset financial records with depreciation, a transfer workflow between legal entities with per-asset history, profitability analysis, and FAA Airworthiness Directive tracking with a dashboard whose tiles open the list they count.
5. A-FMDS Daily Management
A digitised lean daily-management system: the SQDCP daily board and a TV layout, automatic gap detection against plan, problem records with lifecycle and ownership, action registers, escalation rules, coaching records, Leader Standard Work checklists, tiered meetings with agendas that build themselves, and compliance scoring. Five drill-down levels run from the board to a metric trend, a slice, a driver Pareto, an OEE decomposition and a "did the fix hold" view, and an administrator can publish a board so a shop-floor screen shows it with no sign-in.
6. Workforce and Labor Costing
Workforce administration, teams, positions, organizational assignment, crew templates and a crew check-in kiosk, a skills matrix showing coverage per role and how many roles sit below it, time-clock punch import by webhook with employee mapping and reconciliation, and three labor dashboards... plant view, finance view and asset profitability... each with CSV and Excel export.
7. Production Planning and Scheduling
Shifts and crews defined as data, so a plant schedules any number of named shifts rather than three. Floor Schedule HUD (Heads-Up Display) with a live shift timeline, kanban cards with customer records, planned downtime scheduling with per-shift allowances, product and part masters, stocking units and manufacturing routes. Finalizing a shift locks the die runs, releases the materials staging list and raises the changeover work orders the die changes imply, and a run does not start until the readiness gate passes for the product actually scheduled next.
8. Performance Analytics and Executive Dashboards
Per-asset OEE (Overall Equipment Effectiveness) with independently licensed Availability, Performance and Quality tiers, recalculated on every event that changes an input. An Organization Health dashboard scoped by business unit and shift-aligned working day with configurable thresholds, restricted to C-level roles, carrying Schedule Attainment, a safety streak and a tracked-anomaly panel. Reporting is embedded in each dashboard, with CSV, Excel and PDF export from the screen that owns the data.
9. Video Management (VMS)
RTSP (Real Time Streaming Protocol) camera integration, recording server management with stall detection, a rolling buffer set in minutes per camera, event-triggered capture covering the window before the trigger plus a configurable number of seconds after it, correlation of clips to the operational record they belong to, and clip export. A clip cannot report Ready with no footage, and deleting a camera leaves its archive intact.
10. EdgeSense Industrial IoT
A .NET 8 edge client on Raspberry Pi hardware with GPIO and digital I/O, Modbus TCP/RTU PLC (Programmable Logic Controller) connectivity, cycle counting, production state detection on a wired input, offline buffering with a local queue that replays on reconnect, a local sensor display, and a visual workflow rule builder so a customer defines edge behaviour without code. A device event can be made to raise a gap that a named reviewer has to disposition before it closes.
11. ProAlert Mobile (PAM)
A .NET MAUI (Multi-platform App UI) application for Android, iOS and Windows covering work order execution with photo and video capture on a step, task completion, labor entry, parts usage, asset lookup, inventory check, material requests and staging, controlled production documents with a count of what you owe a review on every screen, crew check-in, A-FMDS problems, actions and Leader Standard Work, barcode and QR scanning, GPS, and offline operation.
12. Safety and Emergency Broadcast
Site-wide emergency broadcast delivered to web, mobile and edge devices with acknowledgement tracking, taking over every board as a full-screen overlay. A safety incident register with coded, translated incident types and hazard categories, a green cross calendar on the daily board, and admin-authored advisory messages that scroll on the shop-floor ticker.
13. Platform Foundation
Identity with JWT and device trust management, onboarding by invitation only with the first administrator established by an emailed activation link and no shipped default password, per-module licensing with per-seat entitlement enforced in the navigation itself, a multi-parent Business Resource graph so a plant, area, line and cell can each roll up more than one way, configurable terminology, four shipped UI languages (English, Spanish, French and German), a login audit, an automatic audit trail written through the shared data-access layer, every front-end library served locally with no content delivery network so an isolated plant network still works, and a documented REST API.
14. Response Coordination
Role-based routing of shop-floor calls, first-responder claim so only one responder is dispatched, a lifecycle timing for every step that actually happened, responder distance and an arrival estimate from the transport mode, escalation of an unanswered call through a ladder that reaches the right roles in their own language, PIN-protected closure, structured failure classification on close, and public andon boards an administrator can publish to an unattended screen. This is the discipline the industry calls andon.
One System Where Plants Normally Run Four
Look at the operator tablet on the right. The machine's state, its Availability, Performance and Quality figures, the run it is part way through, and the open calls against it are all on the same screen because they are all in the same database. In most plants those four things live in four products from three vendors, and somebody pays to reconcile them nightly.
- Machine state, production run and performance figures on one record
- A work order that already knows what the line was making when it failed
- Parts consumption that moves inventory and triggers reorder without an export
- Response coordination as one lane of that record, not a separate product
From Machine Signal to Management Dashboard... in Seconds
ProAlert captures raw I/O signals from your equipment and turns them into structured operational data. Availability and performance figures, cycle-time deviations, run progress and shop-floor calls are all in the dashboard before the operator finishes the next cycle.
- Sub-second event capture and transmission
- Role-based dashboards for operators, supervisors, and executives
- Live floor map with color-coded machine status
- Historical drill-down to any event on any machine
Mobile Execution and Site-Wide Safety
ProAlert Mobile (PAM)
A .NET MAUI (Multi-platform App UI) application for Android, iOS and Windows. Technicians execute work orders, complete tasks, log labor, record parts usage, look up assets, check inventory, raise material requests, check a crew in, open A-FMDS, and scan barcodes and QR codes... offline when the network drops, syncing when it returns.
- Work order execution and task completion in the field
- Labor entry, parts usage, and inventory check from the machine
- Barcode and QR scanning, GPS, and offline operation
Emergency "Seek Shelter" Broadcast
When safety is the priority, ProAlert switches to site-wide emergency communication delivered to web, mobile and edge devices at once, with acknowledgement tracking so a supervisor knows who has seen it. A safety incident register holds the record afterward.
- One-tap broadcast to web, mobile, and EdgeSense devices
- Acknowledgement tracking per recipient
- Safety incident register for the follow-up record
Extend ProAlert When You're Ready
The fourteen disciplines above cover the operational workflow end to end and are shipping today. The module below sits outside that set. It is on the roadmap, it is not part of the platform now, and we will not sell it as though it were.
RIX: Real-Time Intelligence eXpert ON THE ROADMAP
A planned AI layer that would read ProAlert's SQL views and propose guided decision trees for work order creation, capture tribal knowledge, and surface patterns in live production data. It is not part of the platform today. What is shipping now is the substrate it would learn from: versioned procedures, a typed execution log on every work order, and the context each one was raised in.
- The governing principle: RIX suggests, humans approve
- Planned as AI-guided work order decision trees
- Planned tribal knowledge capture and preservation
- Read-only SQL view architecture... it would not be able to modify data
Configured for the Language Your Team Works In
Four languages ship in the interface: English, Spanish, French and German. A signed-in user picks their own, and anonymous screens such as a published shop-floor board render in the culture the installation sets rather than defaulting to English. Instructions, prompts and call workflows stay clear under pressure, and configurable terminology lets a plant rename the platform's labels to its own vocabulary.
English Work Center View
Operators and team leads see calls, statuses, and production prompts in the interface language they use every day.
Spanish Work Center View
Localized buttons, prompts, and notes reduce hesitation during downtime, quality events, and support requests. The switch is one setting on the operator's account. Both frames are the same machine at the same moment, which is why the middle button is greyed in both: a maintenance request is already open on it.
Configured to Your Plant Structure... Not the Other Way Around
ProAlert maps to your existing hierarchy: machines roll up to lines, lines to departments, departments to plants. Custom naming conventions, shift schedules, and production targets are all configurable without professional services.
- Unlimited machine, line, and department groupings
- Shift-aware aggregation and reporting
- Custom production target settings per line or machine
- User-defined loss reason codes and categories
Response Coordination
When a line stops or an operator needs help, the platform has to get one qualified person moving and record what happened. This is the discipline the industry calls andon, and ProAlert runs it as one lane of the same database that holds the work order, the parts, the nonconformance and the shift plan. Six of the platform's 146 web controllers handle it.
Role-Based Routing
A call is routed to the roles configured for that asset... maintenance, quality, materials, supervision... through the organizational graph, so the notification chain follows your actual reporting structure rather than a static distribution list.
First-Responder Claim
The first qualified responder to claim takes ownership and everyone else is released. One person is dispatched instead of three, and the plant stops paying for duplicate walks across the floor.
Response and Resolution Timing
Time to claim, time to arrive and time to resolve are recorded on every call, which is what makes response performance measurable rather than anecdotal.
PIN-Protected Closure
Closing a call requires the responder's personal PIN, tying the resolution to a real individual and producing a chain of accountability that survives an audit.
Structured Failure Classification
Closure captures equipment, detail, cause and resolution against the ISO 14224 (Equipment Reliability Data Standard) taxonomy, so the record feeds failure analysis and preventive maintenance instead of dying in a free-text note.
Responder Distance and ETA
Responder position, distance to the machine and an arrival estimate derived from the transport mode's speed are shown live while the call is open, so a supervisor can escalate before a stoppage compounds. A responder with no transport mode set still reports a distance.
Public Andon Boards
An unattended television at the end of an aisle opens a board with no shared account and no sign-in, but only for a business resource an administrator has explicitly published. Nothing else is reachable from that screen.
Arriving here from a search for andon software? Read the full andon and line-stop response page for how this maps to a traditional andon board, pull-cord and stack-light installation. Looking for OEE instead? The OEE software reference covers the arithmetic, the definition trap, and what happens to a low score.
See the platform on a live plant-floor dataset.
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