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Asset Readings & Route Stops

See the Complete Picture

This article focuses on technical details of asset readings and route stops. For the complete Asset Condition Monitoring workflow (how readings enable proactive maintenance), see Asset Condition Monitoring.

Overview​

Asset readings are the structured measurements captured during operator rounds. Unlike free-form observations, readings are tied to specific asset attributes (like "discharge pressure" or "bearing temperature") and stored in a way that supports both current-state monitoring (last known value) and historical trend analysis.

Route Stop Attributes ✅

Route Stops now define which specific attributes to capture at each stop, providing a structured checklist.

When configuring a route, administrators select which attributes to capture at each stop. Operators see only the configured attributes during round execution, reducing cognitive load and ensuring consistent data collection.

What is an Asset Reading?​

An asset reading is a single measurement captured at a specific point in time for a specific asset attribute. It includes:

  • Value: The actual measurement (numeric, text, boolean, or option depending on attribute type)
  • Timestamp: When the reading was captured
  • Operator: Who recorded the reading
  • Context: Which round and route stop the reading came from (if applicable)
  • Unit: The unit of measurement (inherited from the asset attribute definition)

Reading Types​

Readings can be captured for different types of asset attributes:

Numeric Readings​

  • Counters: Running hours, production counts, cycle counts
  • Decimals: Temperature (°C or °F), pressure (bar, psi), flow rate (L/min), vibration (mm/s), voltage, current, etc.

Other Reading Types​

  • Boolean: Pass/fail checks, on/off state
  • Text: Serial numbers, comments, free-form notes
  • Options: Dropdown selections (e.g., condition: Good/Fair/Poor)

Route Stops​

A route stop is a stop on an operator round where specific readings are captured. Each route stop defines:

  • Target: Which asset or functional location to inspect
  • Attributes to Measure: Which asset attributes require readings at this route stop
  • Order: The sequence of this route stop within the round

For example, a round might have route stops like:

  1. Route Stop 1: Pump P-101 → measure discharge pressure, suction pressure, bearing temp
  2. Route Stop 2: Pump P-102 → measure discharge pressure, suction pressure, bearing temp
  3. Route Stop 3: Heat Exchanger HX-201 → measure inlet temp, outlet temp, differential pressure

Last Known Value​

Every asset attribute maintains a last known value — the most recent reading recorded for that attribute. This provides:

  • Quick Status: See the current state of any asset at a glance
  • Dashboard Views: Display last known values across multiple assets for rapid assessment
  • Baseline for Comparison: New readings can be compared against the last known value to detect changes

The last known value is automatically updated every time a new reading is captured.

Historical Readings​

Every reading is also stored in a historical record with full context:

  • Timestamp: Exact date and time the reading was captured
  • Value: The measurement recorded
  • Operator: Who captured the reading
  • Round & Route Stop: Which round and route stop this reading came from
  • Device: Which mobile device was used (for audit purposes)

This historical data enables:

  • Trend Analysis: Plot readings over time to identify degradation patterns
  • Audit Trail: Full traceability of who recorded what value and when
  • Comparison: Compare readings across different operators, shifts, or time periods
  • Threshold Detection: Identify when readings started to drift outside acceptable ranges (used in Phase 2)

Data Flow​

  1. Setup: Define asset types with required attributes (e.g., "Centrifugal Pump" requires "discharge pressure", "suction pressure", "bearing temp")
  2. Create Route: Create a route with route stops, each specifying which asset and which attributes to measure
  3. Execute Round: Operator opens the round on mobile and walks through route stops
  4. Capture Reading: At each route stop, operator enters values for the required attributes
  5. Store Locally: Reading is stored on the mobile device (offline-first)
  6. Update Last Known Value: The asset attribute's last known value is updated (locally)
  7. Add to History: Reading is added to the historical record (locally)
  8. Sync: When connectivity is available, readings sync to the server
  9. Server Processing: Server updates last known values and historical records for all synced readings

Validation​

Readings are validated against the asset attribute's data type and constraints:

  • Numeric ranges: Min/max values defined on the attribute type (e.g., temperature must be -50 to 150 °C)
  • Required vs. optional: Some attributes may be required at certain route stops
  • Data type: Integer readings can't have decimals, boolean readings must be true/false, etc.

Validation happens on the mobile device before sync, ensuring data quality even when offline.

Visual Range Indicators​

When operators enter readings, the interface provides immediate visual feedback on whether values are within acceptable ranges:

StatusColorWhen Applied
NormalGreen 🟢Value is within min/max range
WarningAmber 🟡Value is near the limit (within 10% of boundary)
AlertRed 🔴Value exceeds min/max range

This color coding is consistent across all platforms (Web, iOS, Android) and helps operators quickly identify abnormal conditions.

Range Definition​

Ranges are defined on the AttributeType:

  • MinInt / MaxInt: Integer attribute ranges
  • MinDecimal / MaxDecimal: Decimal attribute ranges

If no range is defined, all values display as normal (green).

Attachments​

Operators can attach files to individual readings to document equipment conditions:

  • Photos: Equipment state, gauge readings, visible defects
  • Documents: Inspection reports, calibration certificates
  • Notes: Detailed observations beyond the standard notes field

Attachments are stored using a pluggable storage system:

  • Local Storage: Files stored on server filesystem (development)
  • Azure Blob Storage: Cloud storage with SAS URLs (production)

Each attachment includes:

  • File name and type
  • File size
  • Optional caption
  • Download URL (generated on sync)
  • Thumbnail (for images)

See Operator Rounds - Attachments for detailed usage.

Relationship to Other Features​

Asset Attributes​

Readings are always tied to specific asset attributes. The attribute definition determines:

  • What type of value to collect (integer, decimal, boolean, text, option)
  • What unit of measurement to display
  • What validation rules to enforce
  • Whether the attribute is required or optional

See Asset Attributes for more detail.

Operator Rounds​

Operator rounds are the primary way readings are captured in Phase 1. Each route stop in a round specifies which readings to collect.

See Operator Rounds for the full round workflow.

Work Instructions​

Work Instructions provide contextual guidance when capturing readings. Instructions attached to attribute types appear directly in the reading card, helping operators with:

  • Measurement Procedures: How to take accurate, consistent measurements
  • Troubleshooting: What to do when values are abnormal

See Work Instructions for details.

Work Items​

Readings can be linked to work items for full traceability. When an abnormal reading is identified, operators can create a work item directly from the reading. This creates a many-to-many relationship:

  • One reading can spawn multiple work items (e.g., a high temperature reading might require both immediate cooling and a long-term pump replacement)
  • One work item can be linked to multiple readings (e.g., a failing bearing causes abnormal readings on temperature, vibration, and pressure)

See Work Items - Linked Readings for the complete workflow.

Phase 2: Observations & Alerts​

In Phase 2, readings that exceed thresholds or show unusual patterns can be automatically flagged as observations or alerts for triage.

See Phase 2 Features for more information.

Mobile UX Considerations​

The mobile interface for capturing readings is optimized for:

  • Speed: Large touch targets, smart defaults, minimal taps to record a reading
  • Gloves: Interface works with thick work gloves
  • Sunlight: High contrast, readable in bright outdoor conditions
  • Noise: Visual feedback for successful data entry (no reliance on audio cues)
  • Poor Connectivity: All data stored locally first; sync happens in the background

Example: Recovery Boiler Inspection at Blueprint Paper Mill​

To illustrate how asset readings work in practice, consider the Steam Boiler B-01 route stop at Blueprint Paper Mill, a mid-sized pulp and paper facility.

Route: "Morning Shift - Utilities"

Route Stop 4: Steam Boiler B-01 (Recovery Boiler)

  • Asset: Steam Boiler B-01 (Unit D – Utilities)
  • Location: Boiler house
  • Asset Type: Recovery Boiler
  • Attributes to measure:
    • Steam Pressure (bar) – normal range: 40–45 bar
    • Flue Gas Temperature (°C) – normal range: 380–420 °C
    • Feedwater Conductivity (µS/cm) – target: <5 µS/cm
    • Drum Level (%) – normal range: 45–55%
    • Flame Pattern Normal? (yes/no checkbox)
    • Running Hours (counter) – cumulative

Captured Reading Example (June 15, 2025 at 6:28 AM):

  • Steam Pressure: 42.3 bar ✅ (within 40–45 bar range)
  • Flue Gas Temperature: 405 °C ✅ (within 380–420 °C range)
  • Feedwater Conductivity: 3.2 µS/cm ✅ (below 5 µS/cm target)
  • Drum Level: 51% ✅ (within 45–55% range)
  • Flame Pattern Normal?: Yes ✅
  • Running Hours: 87,542 hours (cumulative counter)
  • Operator: John Smith (Utility Operator)
  • Timestamp: 2025-06-15 06:28:15
  • Round: Morning Shift - Utilities, Instance #1,247
  • Connectivity: Online (good signal in boiler house)

Result:

  • Last Known Value for each attribute is updated on server in real-time
  • Historical record stores this reading with full context (timestamp, operator, round)
  • Operator moves to next route stop (Air Compressor AC-12)
  • Supervisor dashboard shows Steam Boiler B-01 status as "Normal" with all readings in green

The last 7 days of Steam Pressure readings for Steam Boiler B-01:

DateTimeOperatorSteam Pressure (bar)Status
Jun 156:28 AMJohn Smith42.3✅ Normal
Jun 146:22 AMSarah Johnson41.8✅ Normal
Jun 136:30 AMJohn Smith43.1✅ Normal
Jun 126:25 AMMike Chen42.5✅ Normal
Jun 116:27 AMSarah Johnson44.2✅ Normal
Jun 106:20 AMJohn Smith43.8✅ Normal
Jun 96:31 AMMike Chen42.0✅ Normal

This historical data enables supervisors and engineers to:

  • Verify consistent operation within normal range
  • Identify any trending toward limits
  • Compare readings across different operators and shifts
  • Audit who recorded readings and when
Blueprint Paper Mill Tutorial

For a complete walkthrough of capturing readings at Blueprint Paper Mill, including offline operation and abnormal condition handling, see the Blueprint Paper Mill Tutorial.

See Also​