Transform plant-floor data into decisions that matter

ProAlert™ is a single-database, single-login operations platform for asset-intensive manufacturers. Maintenance, procurement, quality, asset compliance, daily management, workforce costing, production planning, performance analytics, video and industrial IoT all run on one asset model, one organizational graph, one audit trail and one event stream. An event captured at a machine travels through every discipline with no integration layer in between.

The distinguishing property is not any one of those disciplines. It is that they were never separate.

A failure recorded at a press is the same record the maintenance planner schedules against, the quality engineer classifies, the buyer orders parts for, and the plant manager sees in the shift review. Nothing is exported, mapped or reconciled to make that happen.

One system where plants normally run four

An asset-intensive plant does not buy one piece of software. It buys a maintenance system, a procurement system, a quality system, an asset governance system, a daily management system and a video system, from four or five vendors, and then it pays somebody to make them agree with each other. Every vendor in this market quotes a licence fee. None of them quote the integration bill, which has four parts and only one of them appears on a purchase order.

ProAlert ships all of it as one product on one database, so there is nothing to connect. An integration copies data between systems on a schedule. A shared database means there was only ever one copy.

What sets it apart

• No integration layer to buy. Maintenance, procurement, quality, asset compliance, planning and video are one product on one database, so there is no integration contractor to stitch four vendors together.
• Over 250 features across fourteen disciplines. Work orders, preventive maintenance, purchase approvals, nonconformances, ISO 55001 (Asset Management System) governance, labor costing and daily management. One product, not a patchwork.
• One audit trail, written automatically. The audit record is written by the shared data-access layer on every auditable record, not bolted on screen by screen. Nothing depends on a developer remembering to log it.
• EdgeSense at roughly $500 a node. An industrial edge device that speaks Modbus TCP/RTU to PLCs (Programmable Logic Controllers) natively and buffers offline, replacing middleware that typically runs $20,000 or more per line.
• Video tied to the operational record. Event-triggered capture from any RTSP (Real Time Streaming Protocol) camera, with pre- and post-event buffers, correlated to the record it belongs to, so a failure still has evidence attached months later.
• Real time, not next morning. Most manufacturing software gives you operational information the next day when a report is run. ProAlert delivers it while the shift can still be recovered.

Already running in production

ProAlert is deployed at Reyes Hayashi Automotive and Reyes Hayashi Mexico, Hayashi Telempu joint-venture facilities in North America. Figures from that deployment:

Based on ProAlert deployment data at Reyes Hayashi Automotive.

The fourteen disciplines

1. Maintenance Management (CMMS). Work orders with SLA tracking, preventive maintenance by time, meter, condition or event, inspections, 5-Why root cause analysis, and ISO 14224 (Equipment Reliability Data Standard) failure taxonomies.
2. Procurement and Supply Chain. Purchasing dashboard and planning board, request-for-quote workflow, purchase orders with multi-level approval chains, low-stock reporting, parts demand forecasting and supplier catalogues.
3. Quality and Nonconformance. Nonconformance register, reject codes and groups, scrap capture with per-source thresholds and an approval queue, defect heat mapping by location on the part, inspection checklists, document control and electronic signature capture.
4. Asset Lifecycle and Compliance. A complete ISO 55001 (Asset Management System) module with policy, strategic asset management plan, internal audits and management reviews, plus asset financial records with depreciation, transfers between legal entities and profitability analysis.
5. A-FMDS Daily Management. The lean floor management discipline, automated: the daily board, automatic gap detection against plan, problems with an owner and a due date, action registers, escalation rules, coaching records, Leader Standard Work and tiered meeting management.
6. Workforce and Labor Costing. Teams, positions, organizational assignment, crew templates and check-in, timeclock integration by webhook, and three labor dashboards covering the plant view, the finance view and asset profitability.
7. Production Planning and Scheduling. Shift schedule configuration, a floor Schedule HUD (Heads-Up Display), kanban cards with customer records, planned downtime, product and part masters, manufacturing routes and die-changeover cost analysis.
8. Performance Analytics and Executive Dashboards. Per-asset OEE (Overall Equipment Effectiveness) with independently licensed Availability, Performance and Quality tiers, an organization health dashboard scoped by business unit and period, KPI targets, and export to CSV, Excel and PDF.
9. Video Management (VMS). RTSP camera integration, recording server management, event-triggered capture with pre- and post-event buffers, clips correlated to the operational record, and clip export.
10. EdgeSense Industrial IoT. An edge client with GPIO and digital I/O, Modbus TCP/RTU PLC connectivity, cycle counting, production state detection, offline buffering with automatic sync, a local sensor display and a visual workflow rule builder.
11. ProAlert Mobile (PAM). Android, iOS and Windows: work order execution, task completion, labor entry, parts usage, asset lookup, inventory check, material requests, crew check-in, barcode and QR scanning, GPS, and offline operation.
12. Safety and Emergency Broadcast. Site-wide emergency broadcast to web, mobile and edge devices with acknowledgement tracking, plus a safety incident register.
13. Platform Foundation. Identity with device trust, per-module licensing 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 languages, an automatic audit trail and a documented REST API.
14. Shop-Floor Response Coordination. Role-based routing of calls, first-responder claim, response and resolution timing, PIN-protected closure and structured failure classification on close.

Where andon and OEE fit

Some buyers arrive here searching for andon software or OEE monitoring, so here is the straight answer rather than a redirect. ProAlert does both, properly. Neither one is the product, and neither one is what the platform is for.

Try the arithmetic yourself in the OEE Sandbox on the product site: build a shift out of runs, downtime calls and scrap events and watch availability, performance and quality resolve into a score.