From Machine Stop to Closed Work Order, With Nothing Re-Keyed

The path from a stopped machine to a closed work order

A bearing fails on a stamping press. In a plant running ProAlert, every step below is a normal function of the platform, and none of them involves a file leaving one system and arriving in another.

1. The stop is recorded against the asset, from a downtime call raised at the machine or from an EdgeSense device where one is fitted.
2. The Availability component of that asset’s OEE reflects the stoppage without anyone entering it again.
3. The call routes to the maintenance role configured for that press. The first responder to claim it is the only one dispatched, and every step of the response is timed.
4. Where video is licensed, a clip covering the seconds before and after the stop is captured and attached to the record.
5. A work order is created from the matching standard work template, already carrying the asset, the run, the product and the shift.
6. The technician’s labor accrues against the work order from the moment the first task starts.
7. The replacement part is consumed from a storeroom, inventory drops, and the reorder point raises a purchase requisition into the approval chain.
8. Closure captures equipment, detail, cause and resolution against the ISO 14224 taxonomy, behind the responder’s PIN.

A plant running separate products typically performs steps 1, 3 and 5 in three of them, then reconciles the records afterward. See OEE, Maintenance and Shop-Floor Response in One System.

What the work order already knows when it opens

Every work order captures a snapshot at the moment it is created: the asset state, the OEE value, the active shift and the product being run. A failure review months later has the conditions in front of it rather than having to reconstruct them.

• A typed history. Started, paused, a measurement taken, a step skipped, an escalation, finished... what actually happened, not just a final status.
• A controlled procedure. Standard work templates are versioned under an author, checker and approver chain, and each work order pins the revision it ran.
• Safety steps that cannot be skipped. LOTO (Lockout/Tagout) steps are classified as safety tasks and need confirmed completion before the work order can close.

Checking whether the fix held

Closing the work order is not the end of the question a plant manager actually asks. ProAlert answers it three ways, all from the same records.

• Root cause with an effectiveness check. 5-Why RCA (Root Cause Analysis) records carry an effectiveness verification, so a countermeasure is confirmed rather than assumed.
• The daily board follows it. The stoppage appears as a gap on the A-FMDS (Automated Floor Management Development System) daily board and is promoted to a problem with an owner and a due date, which escalates on its own if nothing moves. The fifth drill-down level, “did the fix hold”, shows the same metric over three ranges after the countermeasure.
• Recurrence you can count. Because closure is classified against one failure taxonomy, repeat failures by asset and failure mode are counted rather than searched for in free text.

Improvement ideas follow the same discipline. A Kaizen (Continuous Improvement) record captures before and after measurements and the actual savings, and is verified against its estimate before it closes.

Questions buyers ask next

Can a downtime event automatically create a maintenance work order?

Yes. In ProAlert, when a downtime call closes, a maintenance work order is created automatically with the equipment, failure cause, OEE state and product already populated. Downtime and maintenance share one database, so there is no integration copying records between them.

How can a plant check whether a maintenance fix actually worked?

ProAlert gives three checks from the same records: 5-Why root cause analysis with an effectiveness verification, a "did the fix hold" view on the A-FMDS daily board that shows the metric over three ranges after the countermeasure, and repeat-failure counts by asset and failure mode from the ISO 14224 classification captured at closure.

What failure classification does ProAlert use when a call is closed?

Closure captures equipment, detail, cause and resolution against the ISO 14224 (Equipment Reliability Data Standard) failure taxonomy, behind the responder PIN, so failure history is structured and comparable across assets.

Does the technician have to re-enter the machine, shift or product on the work order?

No. A work order raised from a downtime call carries a snapshot of the asset state, OEE value, active shift and product at the moment it was created.