Production
Give operators the agreed recovery information at the point of need, reducing dependence on avoidable maintenance calls.
Solutions & FAQs / Alarm management
Help operators recover, and give engineering fewer repeat problems.
An alarm should tell your team more than which light came on. Connect recovery guidance, production losses, product impact, and shift handoff so each interruption leaves your team better prepared for the next one.
The same fault should not need the same investigation every shift.
A recurring alarm can send an operator looking for help even when someone on another shift already knows the recovery steps. Meanwhile, engineering sees a long alarm list without a clear view of which faults deserve attention first. IntelliTrack™ brings the active alarm, its guidance, and its history into a workflow the whole team can use.
Give each shift access to the alarm history and recovery guidance.
Give the operator a starting point
The Active Alarms board shows standing alarms, first-out information, and configured recovery guidance. Operators can acknowledge alarms in place and follow the site's approved response.
Put recurring faults in order
Compare fault counts, duration, severity, and product impact. Use alarm journals, heat maps, and reliability reports to identify what happens most often and where engineering effort could help.
Follow the effect on the product
Alarms raised during processing appear on the Product Report. Review that context alongside the part's results when deciding whether an interruption contributed to a quality problem. Use the built-in shift handoff feature to carry the recorded alarm and downtime context into the next shift.
Engineering
Choose improvement work using recurrence and lost time rather than whichever alarm was reported most recently.
Quality
Review the alarms present during processing instead of treating every rejected part as an isolated event.
Illustrative workflow
An intermittent fixture fault keeps bringing maintenance back.
Across several shifts, operators repeatedly call for help with the same fixture alarm. The team documents an approved recovery procedure, reviews when the fault recurs, and checks the associated product records. Operators have a clearer response, while engineering can investigate the recurring condition with a defined history.1
Plan the setup around your process.
Configure meaningful machine states, fault codes, product impact, and recovery instructions. Follow site safety and escalation procedures; guidance does not authorize operators to perform maintenance outside their training. The Active Alarms board is live; historical OEE reporting uses summarized machine time. Generated shift handoff summaries require Assist and a configured Summaries provider connection.
Questions your team may ask
Will this eliminate maintenance calls?
Some interruptions may be resolved through approved operator recovery. Mechanical faults, unsafe conditions, and unresolved problems still require maintenance and the site's escalation procedure.
Can we see which alarms cost us the most?
Fault Paretos can compare counts and duration, with severity and product impact available for analysis. Meaningful results depend on the machine states and fault information your equipment supplies.
Can we connect an alarm with a rejected part?
Alarms raised while a part is being processed appear on its Product Report. That association provides investigation context; it does not by itself establish that the alarm caused the rejection.
How does this help the next shift?
The built-in shift handoff feature brings recorded alarms, downtime, and production context into a summary for the incoming team. Supervisors can review the linked reports, discuss unresolved problems, and prepare operators for recurring conditions.
Review the alarm problems affecting your line.
We can walk through operator recovery, recurring losses, and the product records needed to investigate it.
Notes
- This is an illustrative workflow, not a measured customer result. Return to example