Production Alert Triage & Escalation
Thousands of SCADA and MES alerts per shift — classified, correlated, and escalated in under 30 seconds. No alert fatigue. No buried criticals. Every operator focused on what actually matters.
Your operators are drowning in alerts they can't prioritize
A typical production floor generates thousands of SCADA and MES alerts every shift. Temperature deviations, pressure fluctuations, conveyor faults, PLC warnings — the list never stops. Most of them are noise. But buried in that noise are the alerts that will shut down a line, damage equipment, or create a safety hazard.
Operators develop "alert blindness." They start acknowledging everything just to clear the screen. Critical warnings get the same treatment as nuisance alarms. By the time someone realizes an alert was serious, the line is already down and the damage is done.
The data to separate signal from noise already exists — production schedules, maintenance history, equipment baselines, historical failure patterns. The problem is that no human can cross-reference all of it in real time. That's exactly what AI was built to do.
From raw alert to smart escalation — automatically
Alert Ingestion
Alerts stream in from SCADA, MES, PLCs, historians, and monitoring platforms. SectorFlow normalizes every alert into a common format — regardless of source, protocol, or vendor — and deduplicates repeated signals from the same root event.
Context Enrichment
Each alert is enriched with production context: current batch and recipe, equipment maintenance history, scheduled downtime windows, recent operator actions, and upstream/downstream line status. An alert with context is an alert you can actually act on.
Impact Assessment
The AI evaluates production impact, safety risk, and equipment damage potential. It correlates the alert against historical failure patterns to determine whether this is a nuisance alarm, a developing trend, or an imminent critical event — and assigns a severity classification accordingly.
Smart Escalation
Critical alerts are routed to the right person immediately — shift lead, maintenance tech, or plant manager — based on alert type, severity, and on-shift personnel. The escalation includes full context: what happened, why it matters, what to check, and recommended actions.
Continuous Monitoring
After escalation, the AI continues watching the alert stream for related signals. If the situation develops — additional sensors trigger, conditions worsen, or the issue spreads to adjacent equipment — the AI automatically updates the escalation with new context and adjusts the severity level.
This isn't a dashboard — it's an alert operations engine
Every capability your plant floor needs to cut through the noise, built in from day one.
Multi-Source Alert Parsing
Ingests alerts from SCADA, MES, PLCs, historians, and monitoring tools. Normalizes across vendors and protocols into a unified format for consistent triage.
Production Schedule Correlation
Cross-references alerts against the active production schedule — a temperature spike during a changeover means something very different than one mid-batch.
Severity Auto-Classification
Automatically classifies every alert by severity using your plant's criteria — production impact, safety risk, equipment damage potential, and regulatory exposure.
Historical Pattern Matching
Compares current alert patterns to historical failure sequences. If this combination of signals preceded a breakdown before, the AI flags it before it happens again.
Maintenance Schedule Awareness
Knows when equipment is under scheduled maintenance, recently serviced, or overdue for PM. Alerts during maintenance windows are deprioritized; alerts on overdue equipment are escalated.
Smart Escalation Routing
Routes escalations to the right person based on alert type, severity, and shift roster. Includes auto-escalation timers — if no acknowledgment within your threshold, it goes up the chain.
Connects to the systems you already run
Splunk
PagerDuty
ServiceNow
Microsoft Teams
Datadog
Slack
SCADA Systems
MES
Don't see your monitoring platform? We integrate with any system via API. Talk to us.
What plant teams are seeing
Alert noise reduction
Avg. triage time
Missed critical alerts in pilot
Based on pilot deployments. Your results will depend on alert volume, equipment mix, and system configuration.
"Our operators were seeing 4,000+ alerts per shift and acknowledging most of them without reading. We had a critical bearing failure alert buried under 200 nuisance alarms last year — cost us $1.2M in unplanned downtime. Since deploying this flow, alert fatigue is gone. Critical events get immediate attention with full context, and my operators actually trust the alert system again."
— VP of Plant Operations, Fortune 500 Manufacturer
Frequently Asked Questions
See What 30-Second Alert Triage Looks Like for Your Plant
Book a 30-minute discovery call. We'll walk through the Production Alert Triage flow with your alert data and your escalation rules.
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