The bottom line: An asset register that only stores name, description, and maintenance history is a database, not an operational system. ProAlert's asset management connects every machine to real-time status, OEE (Overall Equipment Effectiveness) targets, call routing, cost analysis, and production history... all in one record that updates the moment anything changes on the floor.

What Happens When You Can't See Machine State

Status lives in three places and none of them agree.

The Andon board says the press is down. The MES (Manufacturing Execution System) says it's running. The maintenance team's whiteboard says it's on a planned stoppage. When status is distributed across systems, supervisors can't make decisions based on any of them... they have to walk the floor to find out what's actually happening.
Status ambiguity means the most critical problems don't get priority.

When a machine has a ProductionWarning (cycles detected while marked Down) and an active DT (Downtime) call simultaneously, which one gets attention first? Without a defined priority hierarchy, the answer depends on who's watching. With ProAlert, the answer is always deterministic: ProductionWarning beats Down beats Planned.
Discrepancies hide until they become incidents.

A machine marked Running in the system but stopped on the floor. A machine with OEE tracking off but cycles still coming through. A tablet that lost its SignalR connection 20 minutes ago but still shows green. Without discrepancy detection, these silent mismatches accumulate into shift-end surprises.
Asset cost data lives in a spreadsheet that's always out of date.

Hourly operating cost, depreciation rates, and revenue-per-unit data need to live inside the asset record to produce cost-per-downtime-event calculations. When that data is in a separate spreadsheet, cost analysis requires a manual merge that either doesn't happen or happens once a quarter.

Asset Status Priority System

Every asset in ProAlert carries a unified status model. When multiple conditions apply simultaneously, priority logic resolves to a single unambiguous state. Operators and supervisors always see the most critical condition, not whichever status happened to update last.

Priority	Status	Meaning
1 (Highest)	ProductionWarning	Cycles detected while the asset is in a Down or Planned state. A machine producing parts it shouldn't be producing is the highest-priority discrepancy on the floor.
2	Down	Unplanned downtime event active. A DT call has been placed and not yet closed. Production is stopped due to an unplanned failure.
3	Planned	Asset is stopped for a scheduled reason: break, lunch, changeover, or planned maintenance. Counts as planned downtime in OEE Availability calculation.
4	SlowProduction	Cycle rate has dropped below the configured slow-production threshold but not stopped entirely. Performance component of OEE is being affected.
5	LullInProduction	No cycles detected for longer than the configured lull threshold. Asset may have stopped without a formal DT call being placed.
6	Scheduled / Idle	Asset is within a scheduled shift window but no active run has been started, or is outside its scheduled run window.
7 (Lowest)	Running	Active production run, cycles within target range, no active DT calls or anomalies. Normal operating state.

Discrepancy Flags: In addition to status, ProAlert tracks three discrepancy conditions that surface silent mismatches: ScheduledNotRunning (shift is active but no production run has been started), MachineRunningOeeOff (cycles are being counted but OEE tracking is not active), and GuiNotConnected (the operator terminal or EdgeSense device has lost its SignalR connection). These flags are visible in the admin dashboard and broadcast to supervisors in real time.

Asset Configuration

BOBR Organizational Hierarchy

Every asset is placed in the Bill of Business Resources (BOBR) hierarchy. This placement drives which users receive alert notifications, which supervisors are responsible for response, and how OEE data rolls up to plant-level reporting. Multi-parent support allows an asset to appear in more than one organizational branch.

Product Assignment

Assign the products manufactured on each asset. Product assignment drives OEE performance targets (cycles per hour), quality scrap thresholds, and the scheduled product display on the mobile operator interface at shift start.

Asset-Call Configuration

Define which call types are available for each asset. A welding cell may offer Maintenance, Quality, and Supervisor calls. A conveyor may only offer Maintenance. Restricting available call types prevents irrelevant alerts from cluttering the floor and the call log.

Equipment and Detail Mapping

Define the equipment components and detail categories used in call closure forms for this asset. Structured equipment and detail mapping enables consistent failure classification across technicians and shifts... the foundation for reliable Pareto analysis of failure modes.

Cost Analysis Fields

Configure hourly operating cost, depreciation rate, and revenue-per-unit data at the asset level. These values drive cost-per-downtime-event calculations in the Executive Dashboard and asset profitability reports. No spreadsheet merge required.

Generic Wear Meter Schema

Track cumulative wear metrics (cycles, operating hours, stroke counts) per asset and configure maintenance triggers when thresholds are reached. Wear data feeds the CMMS preventive maintenance scheduler for condition-based maintenance without requiring a separate monitoring system.

Production Timeline System

Every production session on every asset creates a timestamped timeline record. The AssetProductTimeline captures every run, downtime event, break, and status transition into an auditable chronological history that feeds OEE calculations, shift reporting, and post-incident analysis.

Complete Shift History

Every run segment, planned downtime period, unplanned downtime event, break, and product change is recorded with start time, end time, operator, and product context. The full day's production story is available on a single timeline view for post-shift review or incident reconstruction.
OEE Baseline Snapshots

ProductAssetStatsHistory snapshots are created at product selection, capturing the OEE baseline at the start of each run segment for post-shift trend analysis. Compare actual shift performance against the baseline established at run start without manual data entry.
Source Tracking and Diagram Editor

Link production sources (dies, tooling, fixtures) to CMMS asset records with a visual floor layout editor that supports GPS coordinate markers. Maintenance teams can locate tooling on the floor without calling the tool crib. Source assignments drive die-driven OEE target adjustment at run start.

Generic Asset Register vs. ProAlert Asset Management

Generic CMMS Asset Register

Name, location, and maintenance history only
Status updated manually or via periodic batch import
No priority hierarchy — all statuses treated equally
No production timeline or OEE connection
Cost data in separate spreadsheet or ERP (Enterprise Resource Planning) module
Organizational hierarchy fixed at installation, not reconfigurable

ProAlert Asset Management

Live status with 8-level priority hierarchy, updated in under one second
Discrepancy detection surfaces silent mismatches before they become incidents
BOBR hierarchy drives alert routing, OEE rollup, and access control
Full production timeline with every run, break, and transition timestamped
Cost analysis fields built into the asset record for real-time profitability
Wear meter schema enables condition-based maintenance without add-ons

For IT and Operations Teams

Component	Technology	Notes
Asset Data Model	SQL Server relational schema, 60+ tables	Asset records reference BOBR hierarchy, product assignments, call configurations, and cost fields in a normalized schema. All foreign-key relationships enforced at the database level.
Status Broadcasting	SignalR WebSocket push via ProAlertHub	Status changes broadcast to all subscribed clients in under one second via the ProAlertHub. No polling required on client side. Status flags resolved server-side before broadcast to ensure all clients show identical priority-resolved state.
Production Timeline	AssetProductTimeline table, append-only	Timeline records are append-only... no update or delete paths in the application layer. Complete, auditable history of every production session for every asset since system installation.
API Access	REST API (Representational State Transfer Application Programming Interface) endpoints for asset CRUD and status	Full Create/Read/Update/Delete support for asset records and hierarchy management via REST. Status query endpoints return current priority-resolved state for BI (Business Intelligence) and MES integration.

See every machine's live status and full production history in one view.

Book a 30-minute demo... we'll walk through the asset hierarchy, live status priority logic, and the production timeline for a real shift.

Schedule a Demo