Alert Manager – Real-World Use-Case Reference

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