Asset Health
Asset Health
Asset Health is the Shop Floor module where maintenance and reliability teams see every alarm and fault, follow each line station by station, check the health of each machine, and turn recurring problems into Plex maintenance work requests.
Permissions: Asset Health needs the Asset Health licence on top of your Shop Floor licence. Without it, the module's menu entries and boards do not appear. To open the screens you need DataMagik - Viewer or DataMagik - Builder. Working an insight (changing its state, adding notes, raising a Plex work order) and acknowledging alarms need DataMagik - Maintenance or Builder, because Builder includes Maintenance. Only a Builder sees Settings.
Where to find it
- Shop Floor menu: the Shop Floor dropdown has an Asset Health group with Portal, Lines, Assets, Insights, Analytics and, for Builders, Asset Health settings.
- Shop Floor home: the five screens appear as boards next to your other Shop Floor boards. Each one opens the module for the site you chose. See Shop Floor boards.
- Inside the module (
/shop-floor/asset-health): a breadcrumb back to Shop Floor, a Site picker when you have several sites, and a tab strip with the five screens, any linked apps and Settings.
Health statuses
Every machine has one of five statuses. Each status is shown as a coloured dot and a word, never colour alone.
- Operating (green). The machine reports and nothing is wrong. Line and station views say Running.
- Warning (amber). An open warning-level incident is on the machine.
- Alarming (red). An open critical incident is on the machine. Line and station views say Faulted.
- Stopped (blue). The machine is down, idle or in setup, and has no critical incident.
- Offline (grey, with a dashed ring). No fresh signal has arrived, or the signal dropped out.
How the status is worked out
The status is worked out each time a screen asks, never stored. For an asset, the first rule that applies wins:
- Offline: silent longer than its Offline after setting (5 minutes by default), or its signal dropped out. Stale data cannot be trusted, so this outranks an alarm.
- Alarming: an open critical incident.
- Stopped: its state signal, or its linked workcenter's status, says it is down or idle.
- Warning: an open warning incident. An info incident changes nothing.
- Operating: none of the above.
A workcenter's status comes from its state or status value: setup, idle and down read as Stopped, and no value or a stale value reads as Offline. Open incidents then apply as above. Lines, areas and assets with components show the worst status below them, with Alarming ranked above Offline, so a parent points to where to look first.
Incidents come from conditions. See Conditions and escalation, and set asset thresholds in Asset Health setup.
Portal: the alarm and fault portal
The Portal is the plant-wide view.
- KPI strip: Active faults, Warnings, Lines running (for example 3 / 4) and Machine downtime today. Machine downtime is summed over every machine, so it can exceed the hours in the day; the tile says how many machines it adds up. At a desk, the strip also shows MTTR today and Top fault (30 days).
- Lines: one card per line, with its status, faults, warnings, downtime today and availability. Select a card to follow that line, or Open line detail → for the Lines screen.
- Active alarms: every open alarm at the site, with how long each has been active.
- Alarm detail: the selected alarm's Possible causes and Recommended checks, an Acknowledge button, and, when the alarm is on equipment, Add note and Create Plex work order on the insight it belongs to. Alarms on a workcenter have no insight, and the panel says so.
- Top faults: a pareto of downtime by status reason over the last 30 days, longest first, with the cumulative share. Downtime with no reason is reported separately.
- Downtime by line: today's downtime and number of stops for each line.
- Availability trend: each line's daily availability over the last 7 days (planned time minus downtime, over planned time, from Plex status events). Show as a table gives the figures as a table.
Lines
The Lines screen follows one line, picked from a list.
- Line schematic: the line's stations in material-flow order, left to right, each with its photo or icon, its status and its live Key signal. A stale value says Stale; a station with nothing reporting says No signal.
- Station detail (desk): select a station to see its open alarm and key signal.
- Today by station (desk): a timeline of today's status events for each workcenter station.
- The Lines screen also shows the KPI strip, the line's own active alarms with their detail, and the availability trend.
Assets
- Asset health summary: counts by status. Select a tile to filter the tree and lists to that status.
- Asset tree: site, areas and lines, with workcenters and assets together under each line, each parent showing its roll-up status. Use Search asset or location to find one.
- Asset detail: photos, health, Health profile, a Sensors table (signal, source, value, as of, threshold) and Open insights.
- Needs attention (wall layout): a carousel of alarming and warning assets, worst first, showing how long each has been in that state, for example "Alarming for 3d 11h".
Insights
An insight is one problem on one asset. When a condition opens an incident on an asset, it joins that asset's open insight or opens a new one named after the condition, so a bearing that alarms four times this week is one insight with four alarms.
- Filter the list by Open, Pending, In inspection, Closed or All, and select an insight.
- Move it through Pending → In inspection → Closed. You can also reopen it.
- Read the Linked alarms with their causes and checks, and add notes under Notes and history.
- Select Create Plex work order…. The first step is always a dry run: nothing is sent to Plex. The page shows the data source, the priority, every field that would be written, and anything that would stop the send.
- Select Confirm and create in Plex to raise the work request. A pending insight moves to In inspection, and the work request number is shown on the insight.
An insight gets one work request; a second confirm is refused. Priority comes from the asset's criticality and equipment from its Plex equipment, and the dry run names anything missing.
Analytics
- Signal history: pick an asset to chart each signal mapped from your historian, over 8h, 24h, 7d or 30d. The line is the average, the band is the minimum to maximum, and threshold lines come from the asset's conditions. History is always read from your own historian. See SQL historian.
- Reliability for the same window: Failures, MTBF, MTTR, Availability and Time in alarm. A failure is a critical incident that opened in the window, and downtime is the time critical incidents cover. MTBF is uptime divided by failures; MTTR is the average time to resolve a failure. Time in alarm counts incidents of every severity.
- Analytics also shows the KPI strip, Top faults, Downtime by line and the Availability trend.
Reading charts
Hover over any chart to read the value at that moment; time charts show a guide line with each series' value. With the keyboard, select the chart and use the Left and Right arrow keys to step along it (Home, End and Esc also work).
Freshness
Each panel shows Live · updated Ns ago and refreshes every 30 seconds at a desk, 15 seconds in wall mode. If a panel stops refreshing, it turns Stale and dims its figures, so old data never looks healthy.
Desk mode and wall mode
Every screen has a Desk mode and a Wall mode button. Wall mode is dark, with much larger type and fewer panels, and nothing in it depends on hovering. A Builder can change each mode's layout with Customize layout. See Asset Health setup.
On displays
Each screen can be a rotation item on a paired display, for example Asset Health · Alarm & Fault Portal or Asset Health · Lines. Choose the site for each item, and for Lines also the line. A display draws the screen in wall mode, without the module menu, and shows only its own site's data. See Shop Floor displays.