Precision Data Capture.
Zero Guesswork.
ProAlert™ connects to your existing equipment signals and transforms raw machine data into structured, real-time intelligence... without replacing a single piece of hardware. At its core, ProAlert is built on a proprietary Business Resource graph: an organizational model that routes every event, work order, and escalation through your actual plant structure.
Three Layers. One Seamless Picture.
ProAlert's technology stack is purpose-built for the demands of manufacturing environments... reliability, low latency, and the ability to operate fully on your plant's local network, independent of internet connectivity.
Edge Capture Layer
Lightweight edge devices connect directly to PLC outputs, discrete I/O, and sensor signals. No changes to existing machine logic required.
Processing & Rules Engine
Events are classified, validated, and enriched in real time. Business rules... shift schedules, escalation paths, OEE targets... are applied instantly.
Local Server & Dashboards
Processed data is delivered to role-based dashboards and available via REST API for downstream systems... all with sub-second latency, all on your network.
50+ Data Points Automatically Captured
ProAlert turns raw machine activity into structured production intelligence without relying on handwritten notes or end-of-shift memory. Every event becomes usable data for supervisors, CI leaders, and plant managers.
Shift Timing
Track shift start and stop timing, transitions, and event timing with the context needed to understand what really happened on the floor.
Cycle Durations
Capture cycle time, deviations from standard, and duration trends automatically at the work-center level.
Scrap Type & Location
Record what was scrapped, where it occurred, and which product, station, or process step was affected.
Downtime Causes
See the difference between maintenance, material, changeover, quality, and other downtime causes without manual reclassification later.
Team Response Times
Measure how quickly support teams respond, how long calls stay open, and where escalation paths are helping or hurting throughput.
Call Log Notes
Attach operator notes, cause details, and resolution notes to each call so the data tells the full story, not just the timestamp.
Works With What You Already Have
ProAlert's edge devices read the signal types that are already present on a North American plant floor. Connect with existing hardware... no rip-and-replace required, and no changes to machine logic. Where a controller exposes a Modbus-capable port, which covers most Rockwell, Omron, Siemens, Fanuc and Mitsubishi installations we meet, EdgeSense talks to it directly. Where it does not, a discrete output is all that is needed.
- Discrete I/O (24VDC / dry contact) and GPIO inputs
- Modbus TCP and Modbus RTU to the PLC, addressed by host, port and slave ID
- Analog, environmental and accelerometer sensors, plus serial-attached channels
- Andon pull-cord and stack-light inputs
- A productive-state input that flips the asset between running and idle, driving andon colour and OEE
Structured Data That Fits the Rest of Your Stack
ERP & Job System Connectivity
ProAlert publishes its data through a documented REST API, so any ERP or job system that can consume REST can consume ProAlert... SAP, Plex and Epicor included. There is no pre-built vendor connector, and none is needed.
Flexible Export Formats
Move production data into the reporting workflow that works for you with export options including Excel, CSV, and JSON.
Open API
REST API with full documentation. Connect ProAlert data to your ERP, BI tools, or any custom downstream system.
Built to Match the Demands of a Running Plant
Local Buffering
Edge devices buffer events locally during network interruptions and sync automatically when connectivity is restored... no data is ever lost.
Secure by Design
TLS-encrypted data transmission, role-based access controls, and audit logging at every layer of the stack. Accounts arrive by invitation only, the first administrator is established from an emailed activation link rather than a shipped default password, and tablets and kiosks have to be approved as trusted devices before they can be used on an asset.
Runs Air-Gapped
Every front-end library is served from the ProAlert server itself. There is no content delivery network to reach, so boards, kiosks and dashboards render correctly on a plant network with no route to the internet at all. Per-install secrets live outside the deployment folder, so an update cannot overwrite an installation's own configuration.
High Availability
Local server architecture gives you direct control over uptime and failover. No internet dependency means no third-party outage can take down your plant floor visibility.
Remote Updates and Recovery
Platform updates and edge device rules are applied remotely by the ProAlert team over a secure connection. A device rule authored in the browser is pushed to the device unchanged, a stalled camera recorder detects itself and recovers, and a sensor unplugged at boot comes back on its own when it is reconnected.
Horizontal Scalability
Add machines, lines, or entire plants without architectural changes. The platform scales to thousands of concurrent data points.
Open API
REST API with full documentation. Connect ProAlert data to your ERP, BI tools, or any custom downstream system when real-time event data needs to move beyond the shop floor.
Introducing EdgeSense... ProAlert's Purpose-Built Edge Device
EdgeSense is the hardware layer that makes ProAlert possible on any plant floor. Designed specifically for manufacturing environments, EdgeSense connects directly to your existing machine signals and delivers data to the ProAlert server on your plant's local network in real time... without modifying a single line of PLC code.
- Industrial-grade hardware rated for plant-floor environments
- Discrete I/O, GPIO and Modbus TCP/RTU to the PLC out of the box
- A local queue that keeps counting through an outage and replays on reconnect
- A visual rule builder, so edge behaviour is configured rather than coded
- Remote provisioning, approval and configuration from the web application
- DIN-rail mountable, compact form factor
Want to see how ProAlert connects to your equipment?
We'll walk you through a technical demo with your specific machine types.
