Overview
The system generates three distinct report formats, each tailored for specific audiences and use cases:| Report Type | Format | Target Audience | Key Features | File Size |
|---|---|---|---|---|
| Executive PDF | 1-page PDF | Plant Managers | Health Grade (A-F), KPIs, Last 2 Logs | ~50 KB |
| Analyst Excel | Multi-sheet XLSX | Data Analysts | Summary + Operator Logs + Raw Sensor Data | ~200 KB |
| Industrial Certificate | 5-page PDF | Engineers | ML Explainability, ROI, Audit Trail | ~150 KB |
The Snapshot Rule: All reports use persisted HealthReport data from the moment of generation. Values are NOT re-computed. This ensures audit compliance and reproducibility.
Executive PDF Report
Purpose
High-impact 1-page summary for Plant Managers and Operations Directors who need quick health status without technical details.Contents
Page Layout
Page Layout
Header
- Asset ID and Report Generation Date
- Model Version and Report ID
- Letter Grade: A (Excellent) → F (Critical)
- Grade Color: Green → Red
- Health Score: 68/100
- Description: “Good Condition”
- Max Vibration (g)
- Days to Maintenance
- Critical Alerts Count
- Risk Level (Color-coded)
- Degradation Index: 32.0%
- Damage Rate: 0.00162 /s
- Remaining Useful Life: 47.3 hours
- Last 2 Operator Logs (Event Time, Type, Severity, Note)
- Generation Timestamp (UTC)
- Model Version
- Report ID (first 8 chars)
Health Grade Mapping
| Health Score | Grade | Color | Description |
|---|---|---|---|
| 90-100 | A | Green | Excellent - Continue standard monitoring |
| 75-89 | B | Light Green | Good - No immediate action |
| 50-74 | C | Amber | Fair - Add to next maintenance cycle |
| 25-49 | D | Orange | Poor - Schedule maintenance soon |
| 0-24 | F | Red | Critical - Immediate attention required |
API Endpoint
Example Output
Analyst Excel Report
Purpose
Multi-sheet workbook for Data Analysts and Reliability Engineers who need granular data for trend analysis and correlation studies.Sheet 1: Summary
Key Metrics (Vertical Layout):| Metric | Value |
|---|---|
| Report ID | a3f8b2c1-7d4e-4b9a-8f2c-1e5d6a7b9c0d |
| Asset ID | Motor-01 |
| Report Generated (UTC) | 2026-03-02 14:23:15 UTC |
| Health Score | 68/100 |
| Health Grade | C |
| Risk Level | MODERATE |
| Maintenance Window (Days) | 18.5 |
| Model Version | detector:2.0|baseline:2024-01-15 |
| --- | --- |
| Degradation Index (DI) | 32.0% |
| Damage Rate (DI/s) | 0.00162 |
| Remaining Useful Life (Hours) | 47.3 |
| --- | --- |
| Total Data Points | 4,587 |
| Session Duration (Hours) | 1.27 |
| Max Vibration (g) | 0.2453 |
| Max Current (A) | 18.72 |
| Total Anomalies Detected | 23 |
Sheet 2: Operator_Logs
Ground-Truth Maintenance Events (sorted by Event Time descending):| Event Time | Type | Severity | Technician Note |
|---|---|---|---|
| 2026-03-02 12:15:00 | Corrective Maintenance | HIGH | Bearing replaced due to excessive vibration |
| 2026-03-01 08:30:00 | Scheduled Inspection | MEDIUM | Routine inspection completed — no anomalies observed |
| 2026-02-28 16:45:00 | Calibration | LOW | Sensor calibration verified within tolerance |
| … | … | … | … |
Sanitized Notes: Empty or placeholder notes (e.g., “aaa”, “test”) are replaced with professional defaults like “Routine inspection completed — no anomalies observed.”
Sheet 3: Raw_Sensor_Data
Complete Sensor Timeline (up to 10,000 recent samples):| Timestamp | Vibration (g) | Current (A) | Voltage (V) | Power Factor | Anomaly_Score | Status |
|---|---|---|---|---|---|---|
| 2026-03-02 14:23:15 | 0.245 | 17.3 | 228.5 | 0.89 | 0.72 | ANOMALY |
| 2026-03-02 14:23:14 | 0.238 | 17.1 | 229.2 | 0.90 | 0.68 | ANOMALY |
| 2026-03-02 14:23:13 | 0.120 | 15.8 | 230.1 | 0.92 | 0.12 | NORMAL |
| … | … | … | … | … | … | … |
API Endpoint
Column Widths (Auto-sized)
Industrial Certificate (5-Page PDF)
Purpose
Comprehensive technical report for Reliability Engineers and Maintenance Teams who need ML explainability, ROI analysis, and audit compliance.Page 1: Executive Summary
- Title: “Industrial Asset Diagnostic Report”
- Asset Info Box: ID, Type, Timestamps, Model Version
- Health Gauge: 0-100 semicircular dial with color-coded zones
- Key Metrics Row: RUL (days), Risk Level, Anomaly Score
- Summary Paragraph: Risk-level-specific narrative
Page 2: Sensor Analysis
Current Readings Table:| Sensor | Value | Unit | Baseline | % Deviation | Status |
|---|---|---|---|---|---|
| Voltage | 228.50 | V | 230.00 | -0.7% | NORMAL |
| Current | 17.30 | A | 15.00 | +15.3% | ELEVATED |
| Power Factor | 0.89 | - | 0.95 | -6.3% | ELEVATED |
| Vibration | 0.245 | g | 0.00 | N/A | CRITICAL |
| Power | 3.52 | kW | 3.28 | +7.3% | ELEVATED |
| Sensor | Min | Max | Mean | Std Dev |
|---|---|---|---|---|
| Voltage | 225.0 | 232.0 | 229.3 | 1.8 |
| Current | 14.2 | 18.7 | 16.1 | 1.2 |
| … | … | … | … | … |
- Sensor readings with nearby maintenance events
- Highlights high anomaly scores + maintenance logs
- Used for supervised ML training
Page 3: ML Explainability
Feature Contribution Chart (Horizontal Bar Chart):- 🔴 Vibration Variance contributed 45.2% to the risk assessment. Current value (0.17g) is 5.2σ from baseline. [CRITICAL]
- 🟡 Current Peak-to-Peak contributed 28.7% to the risk assessment. Current value (8.5A) is 3.1σ from baseline. [ELEVATED]
- …
“The primary contributor to the current risk state is Vibration. This factor showed the highest deviation from expected baseline values and requires immediate attention as part of the maintenance response.”
Page 4: Business ROI & Maintenance
ROI Analysis Table:| Metric | Value | Notes |
|---|---|---|
| Est. Preventive Maintenance Cost | $2,000 | Planned service intervention |
| Cost of Unplanned Failure | $50,000 | Includes downtime + repairs |
| Potential Savings | $48,000 | Per prevented failure event |
| ROI Multiplier | 25x | Return on maintenance investment |
- For CRITICAL: “Isolate asset from critical production lines if possible”
- For HIGH: “Schedule maintenance window within next 48-72 hours”
- …
Page 5: Audit Trail & Compliance
Process Log (Millisecond Precision):| Step | Process | Timestamp (UTC) | Status |
|---|---|---|---|
| 1 | Data Ingestion | 2026-03-02 14:20:15.000 UTC | ✓ Complete |
| 2 | Feature Extraction | 2026-03-02 14:20:15.127 UTC | ✓ Complete |
| 3 | Batch ML Inference | 2026-03-02 14:20:15.245 UTC | ✓ Complete |
| 4 | Health Assessment | 2026-03-02 14:20:15.318 UTC | ✓ Complete |
| 5 | Report Persistence | 2026-03-02 14:20:15.402 UTC | ✓ Complete |
| 6 | PDF Report Generation | 2026-03-02 14:23:15.789 UTC | ✓ Complete |
Timestamps use millisecond precision (e.g.,
.127, .245) to show processing latency for audit purposes.- Same table as Executive PDF but extended (up to 50 events)
- Severity color-coding: CRITICAL (red), HIGH (orange), MEDIUM (amber), LOW (green)
- ✅ ISO 55000 - Asset Management: Report adheres to data integrity and traceability requirements
- ✅ ISO 13374 - Condition Monitoring: ML-based anomaly detection follows diagnostic framework
- ✅ IEC 60812 - FMEA: Health scoring includes failure mode analysis
API Endpoint
Report Generation Workflow
Smart Filename Convention
All reports follow the pattern:Report_Motor-01_20260302_1423.pdf(Executive)Report_Motor-01_20260302_1423.xlsx(Analyst)Report_Motor-01_20260302_1423.pdf(Industrial - same as executive filename)
The Snapshot Rule
Implementation
Report Customization
Color Schemes
ROI Constants
When to Use Each Report
Executive PDF
Use When:
- Presenting to non-technical stakeholders
- Weekly/monthly status reports
- Immediate health snapshot needed
- 1-page = quick review
- Health grade (A-F) is intuitive
- Fits on a single screen
Analyst Excel
Use When:
- Trend analysis over time
- Correlating sensor data with maintenance
- Training supervised ML models
- Raw data for custom analysis
- Operator logs for ground truth
- Filterable/sortable in Excel
Industrial Certificate
Use When:
- Root cause analysis
- Regulatory compliance audits
- Engineering design reviews
- ML explainability for trust
- ROI justification for budget approval
- Audit trail with millisecond timestamps
Source Code Reference
Key implementation files:- Executive PDF:
backend/reports/generator.py:140-454- 1-page summary generator - Analyst Excel:
backend/reports/generator.py:457-646- Multi-sheet workbook - Industrial Certificate:
backend/reports/industrial_report.py- 5-page technical report (1374+ lines) - Report API:
backend/api/integration_routes.py-/integration/download-reportendpoint - Constants:
backend/reports/constants.py- Colors, costs, thresholds - Mock Data:
backend/reports/mock_data.py- Simulated 24h stats and trends
Next Steps
Sensor Ingestion
Learn how data flows into the system for report generation
Health Assessment
Understand the metrics that power these reports