Precision Monitoring.
Zero Guesswork.
ProAlert's architecture connects to your existing equipment signals and transforms raw machine data into structured, real-time intelligence... without replacing a single piece of hardware.
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 even when cloud connectivity is interrupted.
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.
Cloud Dashboard & API
Processed data is delivered to role-based dashboards and available via REST API for downstream systems... all with sub-second latency.
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 support the most common industrial signal types found in North American manufacturing facilities. Connect with existing hardware... no rip-and-replace required. That includes Rockwell, Omron, Siemens, and other widely deployed PLC platforms already running on your floor.
- Discrete I/O (24VDC / dry contact)
- PLC communication (Rockwell/Allen-Bradley, Omron, Siemens, Fanuc, Mitsubishi)
- OPC-UA and OPC-DA protocol support
- Ethernet/IP and Modbus TCP/RTU
- Andon pull-cord and stack-light inputs
Structured Data That Fits the Rest of Your Stack
ERP & Job System Connectivity
Keep the generic integration flexibility you expect while connecting ProAlert data to systems your team already knows, including SAP, Plex, and Epicor.
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.
High Availability
Redundant cloud infrastructure with automated failover. Monitored around the clock with proactive incident response.
OTA Updates
Edge device firmware and platform software updated over-the-air... no plant floor downtime for maintenance.
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 cloud platform in real time... without modifying a single line of PLC code.
- Industrial-grade hardware rated for plant-floor environments
- Supports discrete I/O, PLC comms, and OPC-UA out of the box
- Local event buffering... no data lost during network interruptions
- OTA firmware updates... zero maintenance downtime
- 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.