Machine Failure Risk Classifier: OpenAI + Slack + Twilio

Turn machine telemetry into actionable downtime risk alerts—automatically

This n8n workflow receives machine sensor readings via a webhook, enriches them with maintenance history from your CMMS, uses OpenAI to classify machine failure risk, and then creates CMMS work orders plus alerts teams in Slack and SMS via Twilio—with every event logged to Google Sheets.

What this workflow does

• Receives telemetry: Listens for a POST webhook containing machine_id, plant, metric, value, threshold, timestamp.
• Normalizes data: Converts the incoming payload into a consistent schema for downstream processing.
• Pulls context from CMMS: Fetches maintenance history from your CMMS API to inform the risk assessment.
• Classifies risk with OpenAI: Sends the live reading + maintenance history to OpenAI to return a structured result (risk band, failure probability, recommended action).
• Routes by risk band: Splits outcomes into Critical, Warning, or Normal.
• Acts on Critical/Warning: For Critical and Warning, creates a CMMS work order using the recommended action; for Critical, also sends an alert to Slack and an SMS via Twilio.
• Auditable tracking: Appends the event and OpenAI risk assessment to a Google Sheets sheet named “Downtime Risk Register”.

Use cases

• Reduce unplanned downtime by automatically converting telemetry spikes into failure risk categories and next-step work orders.
• Notify operations teams faster when a machine is classified as Critical (Slack + Twilio SMS).
• Maintain audit-ready records of every risk decision, tied to the sensor reading and maintenance history.

Technical details

• n8n nodes/integrations: Webhook, set, switch, OpenAI, Slack, Twilio, sticky note.
• OpenAI: Uses gpt-4o-mini (must be available in your account).
• CMMS API: Configurable base URL + required HTTP authentication/headers for history and workorders endpoints.
• Outputs: CMMS work orders (Critical/Warning) + Slack/Twilio alerts (Critical) + Google Sheets logging (“Downtime Risk Register”).