What it produces
PM work orders released on time with kits and procedures attached, and closed with real readings that set the next due point.
Workflows
Preventive Maintenance
the scheduled inspection and servicing of equipment on time or usage intervals to prevent breakdowns before they happen
The job in one minute
Who owns it
The maintenance and reliability planner, with production supervisors, operations, EHS, the warehouse and purchasing.
How often
Daily releases, weekly planning.
Why it hurts
Calendar PMs are easy. Usage PMs are not. The press that ran three shifts needs its PM before the one that ran one, but the counter lives on an HMI, an IoT dashboard or a dial someone photographs. The planner copies readings into a spreadsheet, decides what is due and releases orders by hand. Kits come up short. Production will not give up the press on Tuesday.
Closing leaks too. Technicians write on paper. Labor, parts and readings reach the ERP days later, if ever, so the meter baseline never resets and the next PM comes due at the wrong count. And a PM released without its lockout procedure is missing its most important attachment.
Systems it touches
The agent reads machine dashboards and exports but never writes to machine controls. It attaches the current lockout procedure from your document library and carries CMMS labor and parts into the ERP when maintenance runs separately. Product →
- ERP or EAM maintenance module
- Standalone CMMS
- Sensor
- IoT dashboards
- Technician mobile apps
- Outlook
- Excel
- SharePoint or OneDrive
12 steps · 5 actions · 6 decisions · 1 human reviews
The workflow, step by step
Action Decision Human review Select a step in the flowchart to jump to it.
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Action · Agent
Read meters from HMI or IoT exports, or from photos of mechanical counters.
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Decision · Agent
A reading lower than the last one, or higher than the machine could possibly have run, goes to review.
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Decision · Agent
Due when the calendar date falls inside the horizon or usage reaches the interval, whichever comes first. Skip if an open PM already exists.
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Action · Agent
Generate the work order with tasks, estimated hours and kit.
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Decision · Agent
Assets with hazardous energy must carry their lockout procedure ID. Missing means stop.
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Decision · Agent
Reserve kit parts on hand. Any shortfall creates a requisition and flags the order.
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Decision · Agent
The date must fit a downtime window on the production calendar. Conflicts go to the planner.
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Human review · Planner
The planner and production supervisor agree the date.
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Action · Agent
Release the order and notify the assigned technician.
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Action · Agent
Read the completed checklist, from a mobile form or scanned paper, and check every reading against its limits.
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Decision · Agent
Any reading out of limits opens a corrective work order linked to the PM.
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Action · Agent
Enter labor and parts, record readings, close the order, reset the meter and confirm the next due point moved.
✓ Done
See it done in the Gallery
Rules vs judgment
A second deferral in a row goes to the operations manager before it saves.
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Exact rule
- Plausibility, due date, duplicates, procedure check, kit reservation, window fit, limit checks
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Model reads
- Photos of dials and scanned paper checklists, with a confidence check
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Person decides
- Deferring a due PM; any PM touching lockout, confined space or a safety system; repairs beyond the automatic corrective order; interval changes (reliability)
When it stops
Needs data
- 01
The operator or technician is asked by name, with the source photo attached.
- 02
Released with the annual inspection scheduled as its own PM; EHS is told.
Needs a decision
- 03
Requisition created, order flagged a day ahead.
- 04
Planner and supervisor decide.
Needs parts
- 05
Reassigned before release.
- 06
Corrected before closure and the kit flagged for review.
What you end up with
- A weekly due list already checked for duplicates, kits, windows and procedures.
- Work orders that close with real readings, so the next PM comes due at the right count.
- Deferrals counted per asset with reasons, so nothing slides month to month.
- Evidence for reliability: findings per PM and breakdowns between PMs, so intervals change on data.
Questions
What happens when production will not release the machine?
The planner defers with a reason and new date. Two deferrals in a row escalate automatically.
Can the agent read counters directly from machines?
It reads what a person can see: an HMI, a dashboard, an export or a dial photo. Where a clean data feed exists, it uses that.
Does this help with lockout audits?
It keeps the procedure ID on every relevant order and schedules the annual procedure inspection. An authorized person still does the inspection.
We already use a mobile CMMS app. Does that matter?
Even better. The agent reads the submitted form instead of a scan, and everything after is the same.
No prompts. No babysitting. No Integrations.