About Asset Intelligence

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Feature availability by platform, plan type, and user type

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Asset Intelligence is available on the Enterprise plan. For more information, contact your MaintainX® representative.

Asset Intelligence in MaintainX is a set of modules, features, and practices that bring equipment and sensor data into MaintainX automatically, detect when an asset needs attention, and help your team act on it. Instead of a historical view built from data your teams enter manually, you get an accurate, real-time view of asset condition.

With Asset Intelligence, your team can move past reactive maintenance. You can catch problems before they cause downtime, trigger work from real usage and condition data instead of guesswork, and build the kind of accurate, continuous equipment history that reliability programs and root cause analysis depend on.

Overview

Asset Intelligence follows three steps: connect your data, detect problems, and act on them.

1. Connect: Bring your equipment and sensor data, known as connected data, into MaintainX as meter readings, using an OT data connector, a purpose-built sensor, or the REST API. For more information, see Data Sources.

   note

   Monitors can't use data that you send through the REST API. They use data that arrives through an OT data connector.

2. Detect: Use monitors to watch your assets and their meters. When a monitor finds a problem, MaintainX responds based on the kind of monitor. It updates an asset's status when the asset stops running, creates a work order when equipment reports a fault code, or raises an alert when a temperature or current reading is unusual for that asset.

3. Act: Review the alert, and then confirm it or dismiss it. From a confirmed alert, your team can create a work order and track the fix. For more information, see Review an Alert.

Where to Find Asset Intelligence Features

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Asset Intelligence is only available on the MaintainX web application.

When Asset Intelligence is enabled for your organization, the web application sidebar includes an Asset Monitoring group with the following pages:

• Alerts: Review the alerts that your monitors raise. For more information, see About Alerts.
• Monitors: Create and manage the monitors that watch your assets. For more information, see About Monitors.
• Meters: Manage the meters that store readings from your data sources. For more information, see About Meters.

Monitors and Alerts

A monitor watches an asset, or the meters on an asset, for a specific kind of problem. When a monitor detects one, MaintainX responds automatically. Anomaly monitors raise an alert so your team can review it and decide what to do. Asset status and fault code monitors don't raise alerts. Asset status monitors update the asset's status, and fault code monitors create a work order.

Monitors are available for the following kinds of scenarios:

• Asset status: Detect when an asset's machine signal changes, such as when it stops running, and update the asset's status. These monitors don't raise alerts.
• Fault code: Detect when equipment reports a fault code, and create a work order. These monitors don't raise alerts.
• Temperature and current anomalies: Detect temperature or current readings that are unusual for an asset.
• Asset type anomalies: Detect unusual behavior by comparing an asset's readings against what's normal for its type. Asset type monitors are in beta and are available for pumps, fans, and compressors.

Anomaly monitors are the only monitors that raise alerts. Anomaly and asset type monitors learn what normal looks like for your assets before they start raising alerts.

The goal of an alert is to turn a meaningful finding into a work order that your team acts on. When a monitor raises an alert, your team reviews it and decides whether it matters. If it does, you confirm the alert and create a work order for it, or link an existing one, so that someone fixes the problem. If it doesn't, you can dismiss the alert, or keep watching it. When MaintainX can interpret an alert, it also provides a plain-language explanation of what it found to help you decide. Every review also helps MaintainX get better at identifying issues in the future, so the more your team uses Asset Intelligence, the more useful its alerts become. For more information, see How Alert Detection Improves With More Data.

Each alert has a review status that tracks where it is in this process: Awaiting Review, Needs Work Order, Work Order Open, Watching, Verifying Fix, Resolved, or Dismissed.

When a meter is part of a monitor, MaintainX protects it so the monitor keeps working. You can't archive the meter, move it to another asset, change its sensor or measurement type, or transfer its asset. You can still rename it, and readings continue to arrive. To change a protected meter, first remove its asset from the monitor.

Data Sources

Where asset data comes from depends on how your equipment is instrumented. MaintainX supports multiple paths in, allowing you to start with the sources you already have and add more as you connect additional equipment.

You can bring data in from:

• Operational technology (OT) systems: Programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) platforms, and MQTT brokers, connected through an OT data connector. For more information, see About OT Data Connectors.
• Purpose-built sensors: PHANTOM® wireless vibration sensors, connected through a fully managed integration with ERBESSD INSTRUMENTS®. For more information, see About Vibration Data and About the ERBESSD INSTRUMENTS Integration.
• Your own systems: Systems that use the REST API to create automated meters and send readings to them. Monitors can't use data that arrives this way.

Asset Intelligence and Connected Data

Connected data is information collected from physical equipment, sensors, and software systems, and linked across platforms so your team can see it in one place and act on it. In maintenance, it's your equipment's own record of what it's doing, such as its status, runtime, temperature, current, vibration, and fault codes, available next to the assets and work orders that your team already manages in MaintainX.

Connected data is the foundation of Asset Intelligence. It's the data that the Connect step brings in, and every later step depends on it: monitors can only watch the signals that reach MaintainX, and your team can only act on what those monitors find. For more information, see Overview.

Working with connected data covers both what you do and the capabilities that support it:

• Choose what to connect: Decide which equipment and signals matter most for the outcome you want, such as asset state, usage, or an actionable condition. For more information, see Choosing Which Data to Connect.
• Bring the data in: Stream data from your OT systems, purpose-built sensors, or your own systems. For more information, see Data Sources.
• Map it to your assets: Match each incoming tag to a meter on the right asset, with help from AI. For more information, see About Smart Tag Mapping.

Once connected data reaches MaintainX as meter readings, you can use it throughout Asset Intelligence and in other parts of MaintainX, such as automations and maintenance plans.

Asset Intelligence and Maintenance Maturity

Maintenance maturity describes how far a team has moved from reacting to equipment failures toward preventing and even prescribing the right fix before a failure occurs. Asset Intelligence makes the later stages possible. Each stage depends on equipment and sensor data reaching MaintainX automatically instead of your team entering it manually.

Most maintenance teams move through the same progression as they mature:

• Reactive: Fixing equipment only after it fails. For example, a pump seizes and a technician creates a work order after the fact.
• Preventive: Servicing equipment on a fixed calendar or usage interval. For example, a maintenance plan schedules a conveyor inspection every 90 days, regardless of how much it's been used.
• Condition-based: Acting on real-time equipment data. For example, an automation creates a work order the moment a vibration reading crosses a threshold you define.
• Predictive: Forecasting failures with data analytics and machine learning. For example, MaintainX reviews trends in an asset's sensor history and flags a likely bearing failure before it happens.
• Prescriptive: Automatically recommending and scheduling the right repair action. For example, instead of only flagging the coming failure, MaintainX recommends the specific repair task and parts needed.

With Asset Intelligence, a signal from your equipment reaches MaintainX as a meter reading and creates a work order before the equipment fails (condition-based maintenance). As readings accumulate, patterns emerge that flag the next failure sooner (predictive maintenance) and eventually point to the right fix (prescriptive maintenance).

For a deeper look at each stage, see Maintenance Maturity: Why It Matters and How to Increase It on the MaintainX blog.

Required Modules and Features

Asset Intelligence is a combination of several MaintainX modules and features. Each one handles a different part of the path from a raw signal to completed work:

• Meters: Store the readings that reach MaintainX from your data sources, whether that's a PLC tag, a sensor, or your own system calling the REST API. For more information, see About Meters.
• Monitors and Alerts: Watch your assets and meters for problems. Anomaly monitors raise an alert when they find one. For more information, see About Monitors and About Alerts.
• OT Data Connectors: Bring PLC, SCADA, and sensor data into MaintainX automatically, so meters update without manual entry. For more information, see About OT Data Connectors.
• Automations: Turn an incoming meter reading into an immediate action, such as creating a work request or work order, or updating an asset's status. For more information, see About Automations.
• Maintenance Plans: Use a usage trigger to generate preventive maintenance work orders from actual runtime or cycle counts instead of a calendar. For more information, see About Maintenance Plans.
• Reporting and Asset Health Reports: Turn the resulting equipment history into reliability metrics you can track over time and share with stakeholders. For more information, see About Reporting and About Asset Health Reports.

When you purchase Asset Intelligence, you get access to all of these modules and features. To get started, contact your MaintainX representative.

Notable Use Cases

The following use cases show common ways maintenance teams use equipment data in MaintainX to address recurring maintenance challenges. Each demonstrates how equipment data supports data-driven workflows and a shift from reactive to proactive maintenance.

• Set Up Real-Time Monitoring: Real-time monitoring brings your equipment's live status and fault codes into MaintainX. It updates an asset's status the moment its state changes, and creates a work order when your equipment reports a fault code that matters, providing you with more reliable reporting data and allowing your team to act without waiting for someone to report a problem.
• Set Up Usage-Based Maintenance: Usage-based maintenance uses maintenance plans to trigger a work order from actual runtime hours, cycle counts, or production activity. Assets that run harder get serviced more often, and assets that run less aren't over-maintained.
• Set Up Condition-Based Maintenance: Condition-based maintenance creates a work request or work order when a condition, such as temperature, vibration, or pressure, crosses a threshold you define, or raises an alert when a monitor detects an anomaly. This lets your team respond to early warning signs instead of a failure.
• Set Up Predictive Maintenance: Predictive maintenance uses the vibration monitoring program to catch early signs of failure in rotating equipment. MaintainX sets up the sensors, and MaintainX vibration analysts review what they find and create a work order for your team only when action is needed.

Asset Intelligence makes it possible to act on equipment condition in real time or trigger maintenance from actual equipment usage using a data-driven approach.

tip

These are the most common patterns, but they represent a starting point rather than a limit. Asset Intelligence is built to let maintenance teams extend it into solutions shaped by their own unique business and operational needs.

Measure the Impact of Asset Intelligence

Once you've connected your equipment and sensor data to MaintainX, several existing reports show whether it's making a difference:

• Asset health metrics: When you set up real-time monitoring, MaintainX updates an asset's status continuously without any manual reporting required. Asset Health Reports, such as the Availability Over Time report, the MTBF-MTTR report, and the Total Downtime report, reflect real conditions in near real time. Compare these metrics before and after connecting an asset to see the effect on reliability and unplanned downtime.
• Reactive-to-preventive shift: Work orders generated by condition-based and usage-based maintenance automations that use templates can carry a Work Type of Preventive, while unplanned fixes are typically logged as Reactive. Track that ratio in Reporting over time to see whether Asset Intelligence is reducing reactive work.
• Monitor activity: Each monitor's details page shows how much your connected equipment is generating: the asset status changes, work orders, or alerts that the monitor has created, a count for the last 24 hours, and a searchable list of recent activity by asset. This is the quickest way to see what a monitor is doing for you. If you also use automations, each automation's Action History shows every run, skip, and failure.

Use these signals together to identify how your connected assets and data sources are performing.

Learn More

• About Maintenance Plans
• About OT Data Connectors
• About Smart Tag Mapping