Introducing MaintainX OT Data Connectors: Turning Machine Data into Action

As manufacturers face tightening budgets and labor shortages, every minute of uptime counts. But for many maintenance teams, the data needed to improve reliability remains out of reach.

Real-time health and performance metrics are often trapped in PLCs, SCADA, and other OT systems. This disconnect leaves teams guessing when to service equipment, why downtime happens, and what action they should take next.

MaintainX’s new OT Data Connectors help to close the gap by making it easier than ever to get live machine data into the hands of maintenance teams.

With pre-built integrations for Ignition, Kepware, and MQTT, you can stream live data from the factory floor directly into MaintainX, without lengthy IT work.

This allows you to:

• Trigger work orders automatically using live usage and condition data
• Log downtime events as soon as stoppages are detected by your OT systems
• Equip technicians with vital context that helps them complete work in the field

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Four Ways OT Data Connectors Turn Your Machine Data Into Action

1. Usage-Based Preventive Maintenance

Many maintenance schedules still rely on calendar dates. While this is more effective at keeping machines online than running them to failure, it’s still imprecise and can lead to assets being over- or under-maintained.

With OT Data Connectors, you can now base your PMs on equipment usage data, like runtime hours or cycles.

MaintainX automatically generates PMs when a usage threshold is met, ensuring maintenance happens exactly when needed. This equips your team to prevent unplanned downtime without overspending on parts and labor.

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2. Condition-Based Maintenance

Sensors and PLCs already capture key health indicators like vibration, temperature, and pressure. The challenge is acting on that data before it leads to failure.

By connecting that data to MaintainX, teams can trigger condition-based work orders the moment thresholds are exceeded, making it easier to take action on early signs of failure.

For example, if a bearing’s vibration spikes or a motor’s temperature trends out of range, MaintainX automatically alerts your team and creates the appropriate corrective task with the right procedures.

This helps you prevent costly breakdowns and reduce emergency maintenance.

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3. Automated Downtime Tracking

Another challenge maintenance teams face is capturing accurate data on downtime events.

Status information in OT systems like Ignition or Kepware often can’t be accessed quickly by the maintenance team. So getting the data you need to prevent future breakdowns relies on technicians to log downtime events manually.

MaintainX’s OT Data Connectors allow you to update the real-time status of your assets the moment it changes. This improves data accuracy, gives you instant visibility into asset availability, and lets your team spend more time fixing problems instead of documenting them.

Paired with Asset Health Insights, on the MaintainX Enterprise plan, you can now see exactly which machines cause the most unplanned downtime and address root causes faster.

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4. On-the-Job Context for Technicians

Recent sensor readings or fault codes can provide vital clues for technicians as they troubleshoot and repair machines.

Connecting this data to MaintainX allows your team to monitor equipment directly within the platform, helping technicians diagnose issues faster and complete repairs.

For example, a technician might notice vibration levels began rising three shifts ago, right after a new coupling was installed. That helps pinpoint the cause as improper alignment without lengthy trial and error.

This closes the loop between diagnosis, action, and validation—empowering technicians with the information they need to perform their best work.

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A Smarter, Simpler Path to Predictive Maintenance

Today’s release isn’t just about automation. It’s about unlocking the full potential of your smart factory investments.

By connecting live equipment signals with the human context captured every day by your technicians, MaintainX closes the loop between what’s happening, why it’s happening, and what to do about it.

This creates a foundation for AI-powered predictive maintenance—helping you anticipate problems, optimize PM schedules, and take the right action at the right time.

Best of all, our self-serve connectors don’t require any integration work from your IT team.

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Ready to connect your machines?

Book a demo today, and learn how MaintainX OT Data Connectors can help your team move from reactive to predictive maintenance.