This section outlines typical alert configurations used in industrial settings. Each case includes:
Objective: Why the alert exists
Trigger: When the alert should fire
Action: What to do when it triggers
Configuration: Table of field values to use in Alert Manager
Use Case 1: Motor Over-Temperature
Objective: Prevent unplanned downtime and motor damage caused by overheating.
Trigger: Motor surface temperature remains at or above 80 °C for the last 15 minutes.
Action: The Maintenance team inspects cooling, bearings, and wiring.
Field | Setting | Rationale |
Name | Line 1 – Motor 27 Over-Temp | Easily searchable |
Target | 80 °C | OEM insulation class F rating |
Evaluation Frequency | 15 min | Matches sustained overheating |
Delay (Advanced Settings) | 0 | Data arrives in real time |
Enable alerts | Yes | Activate monitoring |
Exception rules | avg/min is at least 3 units above or equal to the selected target. | One exception = 3°C overshoot |
Alerts | ≥10 exceptions in last 15 min | Confirms sustained over-temp |
Severity | High | Critical equipment risk |
Notifications | Email, SMS, MS Teams | Email to Department Engineers. SMS to technicians working on the line. |
Use Case 2: Compressed-Air Pressure Drop
Objective: Avoid cylinder stalls and tool-change misfires.
Trigger: Header pressure is below 1% of the set-point (≤ 5.94 bar if target = 6.0 bar) for the last 5 minutes.
Action: Utilities crew checks compressors, dryers, and leaks.
Field | Setting | Rationale |
Name | Header Pressure Drop | Clear for operators |
Target | 6.0 bar | Normal operating set-point |
Evaluation Frequency | 5 min | Matches trigger window |
Delay (Advanced Settings) | 0 | Real-time |
Enable alerts | Yes | Activate monitoring |
Exception rules | avg/min is at least 1% below the selected target | 1% tolerance band |
Alerts | ≥3 exceptions in last 5 min | Filters transient dips |
Severity | High | Production-critical utility |
Notifications | Email, SMS | Notifies compressor crew. |
Use Case 3: Water Overuse
Objective: Detect excessive consumption caused by manual overrides or leaks.
Trigger: Water usage is above 10% of the set-point for the last 1 hour.
Action: Operations reviews valve settings and investigates leaks.
Field | Setting | Rationale |
Name | Water Overuse | Descriptive |
Target | Plant max (set-point) | Site-defined |
Evaluation Frequency | 1 hour | Trend-level check |
Delay (Advanced Settings) | 5 min | Data delay |
Enable alerts | Yes | Activate monitoring |
Exception rules | avg/15min is at least 10% above the selected target | 10% margin |
Alerts | ≥3 exceptions in last 1 hour | Sustained misuse only |
Severity | Medium | Cost impact, low safety risk |
Notifications | Email, SMS | Informs production & utilities team. |
Use Case 4: Water Use During Production Downtime
Objective: Identify unintended water consumption when production is idle.
Trigger: Any water flow above a near-zero baseline during scheduled downtime for the last 15 minutes.
Action: Operators inspect valves, automation settings, and equipment status; take corrective action.
Field | Setting | Rationale |
Name | Water Use – Downtime | Easily found |
Target | 0 (near-zero) usage | Expected when stopped |
Evaluation Frequency | 15 min | Detects sustained flow |
Delay (Advanced Settings) | 0 | Real-time |
Enable alerts | Yes | Activate monitoring |
Exception rules | avg/min is at least 10% above the selected target | Ignores sensor noise |
Alerts | ≥3 exceptions in last 15 min | Ensures persistence |
Severity | High | Indicates cost, waste, or operational oversight |
Notifications | Email, SMS | Informs production & utilities team. |
Use Case 5: Excessive Vibration
Objective: Catch mechanical faults (bearing wear, misalignment) before major failure.
Trigger: Vibration velocity is above 5% of the threshold (e.g., 5 mm/s) for the last 5 minutes.
Action: Maintenance checks alignment, bearings, and mounting bolts.
Field | Setting | Rationale |
Name | Motor Vibration Alert | Clear & actionable |
Target | 5 mm/s (rms) | Based on ISO 10816 or OEM spec |
Evaluation Frequency | 5 min | Matches trigger window |
Delay (Advanced Settings) | 0 | Real-time |
Enable alerts | Yes | Activate monitoring |
Exception rules | avg/min is at least 5% above or equal to the selected target | 5% buffer |
Alerts | ≥4 exceptions in last 5 min | Persistent vibration |
Severity | High | Imminent mechanical risk |
Notifications | Email, SMS | Fast escalations |