From Alerts to Action: MaintainX + Inductive Automation Drive Predictive Maintenance

Industrial companies generate more data than ever before. But too often, it doesn’t help the people on the ground keep operations moving.

Maintenance is one of the most painful examples. A bearing starts to overheat. A motor vibrates beyond spec. The data is there, but by the time the right person sees it, the line is already down and production has taken a hit.

That’s why we’re excited to announce our collaboration with Inductive Automation, the creators of Ignition. A leading platform for SCADA and industrial connectivity, Ignition is used by thousands of organizations to get visibility and control over the entire factory floor.

Ignition customers can now trigger work orders in MaintainX automatically using cycle counts, fault codes, condition signals, and more.

For frontline teams, this means faster response times and smarter strategies to prevent failures. For industrial leaders, it accelerates digital transformation by making operational data more actionable—for both people and AI models.

The cost of disconnected equipment data

When a motor overheats or a pump shows a vibration anomaly, what usually happens?

• Someone notices (hopefully).
• They log the reading in another system.
• They create a work order manually.

By the time a technician sees the information, context is missing and the line is already down.

Delays between machine signals and maintenance action aren’t just frustrating—they come with a real cost.

Production backlogs eat into profit margins. Meanwhile, controls and maintenance teams lose hours to troubleshooting, at a time when skilled labor is already such a scarce resource.

How MaintainX & Ignition solve these challenges

Our integration solves these challenges by serving real-time data from PLCs and sensors to maintenance, safety, and operations teams in a consumer-grade mobile app.

The MaintainX module on the Ignition Module Showcase, which we unveiled at the Ignition Community Conference (ICC) this week, allows you to sync your Ignition tags with MaintainX in a matter of minutes.

You can then use the data to trigger work orders automatically, access important context in the field, and perform smarter, more cost-effective predictive maintenance.

Teams are already using the module to automate the following:

• Condition-based maintenance: When temperature, vibration, and pressure exceed thresholds, a work order is generated automatically in MaintainX. This helps teams detect equipment faults early, and address them before they escalate.
  
• Usage-based preventive maintenance (PM): Work orders are triggered based on run time or cycles, not just a calendar, enabling more precise and cost-effective PM strategies.
  
• Smarter fault tracking: If equipment fails, the downtime and failure reason is logged instantly in MaintainX—helping maintenance teams plan, prioritize, and take the right steps.

This is helping companies prevent failures, eliminate unnecessary maintenance work, and lay the foundation for AI-powered predictive maintenance.

And it closes the loop between machine signals and real-world action without controls engineers or operational technology (OT) managers needing to be the go-between.

Real-world impact

Our partners at Roeslein & Associates—a major player in design-build and energy—are already seeing the difference. Their VP, J. C. Harrison, summed it up nicely:

“MaintainX connected effortlessly with our Ignition-based SCADA systems, giving customers a real-time link between operations and maintenance.”

Picture a motor starting to overheat. With Ignition connected, the temperature tag automatically triggers a work order before the motor fails. Or a CNC machine that schedules lubrication every 500 runtime hours, eliminating wasted preventive maintenance.

Idle time and production output can also be tracked continuously, giving engineers data to uncover bottlenecks and optimize throughput.

When a technician goes out to a job, they get the best possible experience to help them complete it. They can access real-time equipment data from Ignition via the MaintainX module, and enrich those records with photos, voice clips, and AI-powered work summaries.

Unlocking more value from Industry 4.0

Industrial companies have invested heavily in digital transformation and Industry 4.0 initiatives. But these projects stall when operational data isn’t easy to access or act on.

That’s why MaintainX and Ignition are collaborating to help overcome these hurdles.

The benefits of the integration include:

• Faster time to value – No complex custom integrations or middleware required
  
• Lower total cost of ownership – Less reliance on your IT department
  
• AI-ready architecture – It provides the training data needed for next-generation predictive models

Chris Turlica, our CEO, said: “Maintenance teams are drowning in data but starving for actionable insights. Together, MaintainX and Inductive Automation bridge the critical gap between operational technology and maintenance execution.”

And Travis Cox, Chief Technology Evangelist at Inductive Automation, described it as “the next frontier in industrial efficiency.”

Get started today

The best part is that you don’t need months of custom development or IT work to make this happen.

The MaintainX module for Ignition is available today. Book a tour to see how it can help your teams reduce downtime, cut costs, and unlock the full potential of Industry 4.0.