Out-of-tolerance checks best practice – conditional number fields

Autonomous Maintenance Inspections

Autonomous Maintenance, a focus for many of our customers, requires machine operators to take on simple maintenance tasks (like cleaning, inspecting and lubricating components). This frees up time for the maintenance team, allowing them to focus on predictive and/or preventive measures.

With conditional numbers, it is possible to provide additional required inputs if an inspection is out of tolerance.

Elements that might be out of tolerance and case damage to machines or product quality issues include:

  • Heat - A machine or component is running too hot for a prolonged period of time
  • Pressure - A machine or component is running at a too high or too low pressure
  • Moisture - A machine or component has a moisture reading that is too high
  • Gaps - In-feed gap sizes for machines like conveyors could be too large or too small


Set up your forms with conditional number fields

If a number is out-of-tolerance, usually the operator will either want to report that it was a temporary issue and was corrected immediately or that maintenance is required. If it was corrected immediately, your maintenance teams will still want to capture the data. If maintenance is required, you will want to alert the maintenance team and initiate a project.

Some tips for setting up the form include:

  • Add a Number field requesting the heat, pressure, moisture information
  • Add a Callout Box field alerting “The X is out of range.” conditional upon the Number field being greater than X tolerance.
  • Add a Conditional Email field that provides the next step option for the operator, either immediate corrective action or maintenance required. If the operator selects “maintenance required”, set up the system to email your maintenance team. Note: you can ask your email administrator to set up an “alias” for your maintenance team that will email multiple people. Make this field conditional upon the Number field being greater than X tolerance.
  • Add Paragraph and Photo Upload fields to capture data on the abnormality. Make these fields conditional upon the Number field being greater than X tolerance.
  • You can use the form to capture data about what maintenance activities occurred. We like to add an Infobox that makes it clear to the operator that they have completed their part of the process followed by a Multiple Choice field that asks the maintenance team to begin their process. This field is helpful for reporting as well because you can generate reports on how many CIL abnormalities requested maintenance vs how many required maintenance.
  • Add whatever field you would like to collect for maintenance activities. This example includes Date/Time fields for when the activities were started and were completed, a Paragraph field and a Photo field to document the activities.
  • You could also add an Equipment field to document what resources the maintenance team used to document the process.

Form Builder


Form with Conditional Logic

conditional number example

Weever is Operational Excellence Software that empowers the pursuit of perfection by enhancing operational visibility, collaboration and productivity in quality, maintenance, safety and production.

To learn more about how Weever can help you attain results in OpEx, please feel free to get in touch.