Schematic view of an automated process for detecting and dispatching machine faults, fully AI-generated
All solutions20 / Maintenance & service

Maintenance & service

Detect and dispatch machine faults automatically

Every reported machine fault is automatically turned into a service order and assigned to a technician. Dispatch only decides on exceptional cases, instead of reading each alert and assigning work orders by hand.

Process architecture

From a machine alert to a service order.

The chain takes over the machine's alert, classifies the fault and priority and creates the order in the system of record. Standard cases go straight to the technician, exceptional cases to dispatch, and return to the same flow after approval.

Process diagram

  • 09Nodes
  • 10Connections
  • 03Phases
Environment

01Input

Fault & context

The fault is picked up and enriched with machine master data and history.

2 Steps

02Process

Classification & approval

Fault and priority are determined, the rules are checked and exceptional cases are prepared for dispatch.

4 Steps

03Output

Order & record

The service order is created, handed to the technician and the case is documented.

3 Steps

Source01

Pick up the fault

The machine reports a condition value or fault code that detects the breakdown and starts the case with the machine and the time.Details

Process node 01Source

Pick up the fault

The machine reports a condition value or fault code that detects the breakdown and starts the case with the machine and the time.

Interfaces
  • Microsoft Graph API
  • SharePoint API
Next steps
Data02

Load machine and master data

Machine type, bill of materials, service history and location are attached to the case through the prepared view.Details

Process node 02Data

Load machine and master data

Machine type, bill of materials, service history and location are attached to the case through the prepared view.

Interfaces
  • Azure AI Document Intelligence
  • Mistral OCR
  • Dataverse API
Next steps
Action03

Determine the fault and priority

Fault code and machine type produce the fault pattern with a priority, complemented by recognisable consequences for production.Details

Process node 03Action

Determine the fault and priority

Fault code and machine type produce the fault pattern with a priority, complemented by recognisable consequences for production.

Interfaces
  • Power Automate
  • Azure Functions
  • Microsoft Graph API
Next steps
Decision04

Check the rules

Fault code, spare parts and the criticality of the machine are checked against the agreed rules instead of a decision by eye.Details

Process node 04Decision

Check the rules

Fault code, spare parts and the criticality of the machine are checked against the agreed rules instead of a decision by eye.

Interfaces
  • Azure OpenAI GPT
  • Anthropic Claude
  • AI Builder
Next steps
Approval05

Approve the exceptional case

If the fault code is unknown or the machine is essential, dispatch decides on the basis of the case.Details

Process node 05Approval

Approve the exceptional case

If the fault code is unknown or the machine is essential, dispatch decides on the basis of the case.

Interfaces
  • Teams Adaptive Cards
  • Power Apps
Next steps
System06

Create the service order

The approved case is created in the system of record as a service order with machine, priority and spare parts.Details

Process node 06System

Create the service order

The approved case is created in the system of record as a service order with machine, priority and spare parts.

Interfaces
  • Dynamics 365 API
  • Azure Service Bus
Next steps
Result07

Hand the order to the technician

The service order is available to the responsible technician with fault pattern and priority on the tablet.Details

Process node 07Result

Hand the order to the technician

The service order is available to the responsible technician with fault pattern and priority on the tablet.

Interfaces
  • Power BI API
  • Teams Webhook
Next steps
Result08

Inform dispatch

Dispatch receives the status with machine, priority and planned assignment.Details

Process node 08Result

Inform dispatch

Dispatch receives the status with machine, priority and planned assignment.

Interfaces
  • Power BI API
  • Teams Webhook
Result09

Record the case

Alert, classification, decision and completion are archived and stay linked to the machine.Details

Process node 09Result

Record the case

Alert, classification, decision and completion are archived and stay linked to the machine.

Interfaces
  • Power BI API
  • Teams Webhook
  • Standard path
  • Direct path
  • Review required
  • Exception
  • Return

Steps in execution order

System landscape

Interfaces and apps working together.

  • Microsoft

    Microsoft Graph API

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    SharePoint API

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Azure AI Document Intelligence

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Mistral OCR

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Dataverse API

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Power Automate

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Azure Functions

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Azure OpenAI GPT

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Anthropic Claude

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    AI Builder

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Teams Adaptive Cards

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Power Apps

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Dynamics 365 API

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Azure Service Bus

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Power BI API

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Microsoft

    Teams Webhook

    Möglicher Baustein für die Microsoft-Systemvariante.

  • Interfaces in use

    MQTT

    Reports condition values and faults of the machines over the plant network to the processing chain.

  • Interfaces in use

    Odoo External API

    Creates the service order in the system of record and keeps it up to date.

  • Interfaces in use

    PostgreSQL

    Read-only access to the prepared view of the machine master data.

  • Interfaces in use

    n8n

    Drives the flow from the alert to the work order, visible and adaptable by the company.

  • Interfaces in use

    RabbitMQ

    Queue between intake and processing, absorbing load spikes and maintenance windows.

  • Possible apps & platforms

    Odoo

    System of record for faults, service orders and machine history.

  • Possible apps & platforms

    Grafana

    Overview of machine conditions, kept in view by dispatch.

  • Possible apps & platforms

    Odoo Mobile

    Feedback and completion of the order directly at the machine.

  • Possible apps & platforms

    Mail

    Notification about new service orders.

Implementation in context

Robust in everyday use.

The process replaces no system, it uses the existing ones: the machines keep reporting over the plant network, the maintenance system remains the system of record and master data stays where it is maintained. New is only the path in between.

Decisions are rule-based where the rules are unambiguous and human where they are not. The company sets the limits itself; both paths are documented on the case.

Machine data does not leave the plant network. If a model classifies the fault pattern, it runs in the company's own data centre; only read access to the prepared view reaches the master data.

If the processing fails or the maintenance system is down for an update, a queue holds the alerts. Every case carries an identifier so the same fault never produces two orders.

Starting point

A machine reports faults itself, but today the alert ends on a screen that no one watches continuously. Whoever finally notices the error gathers machine history, spare parts and ownership by hand and enters the order manually. Time passes before a technician reaches the machine, and some alerts simply get lost in daily business.

Target picture

Every reported fault exists as a service order with priority and ownership as soon as the machine reports it. Dispatch only decides where the rules are not clear-cut, and each decision is documented together with its basis.

Expected benefits

  • Every reported fault leads to a service order without a manual trigger.
  • Dispatch works on exceptional cases instead of individual alerts.
  • Duplicate orders for the same fault are ruled out.
  • Every decision carries its basis and its approver.
  • Faults, reaction times and completions can be evaluated at any time.

Prerequisites to start

  • 01A documented access to the maintenance system with an interface and a technical user
  • 02A machine connection that delivers condition values and fault codes over the plant network
  • 03Maintained machine master data with unique identifiers, bills of materials and owners
  • 04One named person in dispatch to approve exceptional cases
  • 05A decision on criticality and priority rules per machine type

Your next step

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