# Itanta Analytics — Full Case Studies > Concatenated, plain-text export of every published Itanta Analytics case study. Source of truth: https://itanta.ai/success-stories # Accelerating Smart Manufacturing: Britannia's Digital Leap with Itanta URL: https://itanta.ai/success-stories/britannia-smart-manufacturing-itanta Company: Britannia Industries Limited Industry: Food Manufacturing ## At a glance - **6** — Production Lines Connected - **5** — Iconic Brands Covered - **Since 1892** — Legacy of Excellence ## About Britannia Industries Limited Britannia Industries Limited is one of India's oldest and most trusted food companies, founded in 1892 in Kolkata. A flagship company of the Wadia Group, Britannia is a market leader in biscuits, bread, cakes, and dairy products, with a portfolio spanning iconic brands like Good Day, Tiger, NutriChoice, Milk Bikis, and Marie Gold. The company operates multiple manufacturing facilities across India and exports to over 80 countries. Headquarters: Bangalore, India · Industry: Food Manufacturing / FMCG · Size: Enterprise (13,000+ employees) ## Introduction This case study shares how Britannia, one of India's largest food manufacturers, partnered with Itanta Analytics to improve its day-to-day operations through digital transformation. The company was facing common manufacturing challenges such as manual data logging, limited real-time visibility, and delays in identifying production issues. With Itanta's no-code platform, Britannia was able to gain better visibility into operations, automate alerts, and bring key performance data into one place. This helped teams on the ground react faster and gave managers reliable information to track performance. The project showed how a simple, step-by-step approach to digital adoption can make a big difference in how a factory runs. ## Operational Challenges - **Manual Data Logging:** Operators were recording critical production parameters manually which was inefficient and prone to errors. Also leads to data inconsistences. - **Workload Imbalance:** Engineers were spending hours manually compiling reports for compliance and weekly reviews, leading to inefficient reporting cycles and over-reliance on technical experts. - **No Real-Time Visibility:** Data was collected at the end of the shift or day and analyzed manually due to which anomalies were detected late and couldn't pinpoint issues. - **Siloed Systems:** Without integration between systems, data remained siloed across processes. This made it difficult to correlate key metrics and each new line or facility required fresh configurations from scratch due to the lack of a unified data architecture. - **No Centralized Alerts:** Alerts for production issues were either entirely manual or didn't exist. This delayed root cause identification and created communication gaps between departments. ## Highlights - 6 production lines connected into a unified monitoring ecosystem - Real-time production monitoring with live OEE calculations and tonnage tracking - Mobile app alerts for critical deviations in MIHS, packing, molding, and baking - Automated data flow from SCADA replacing manual data entry entirely - Auto-generated compliance and performance reports freeing up engineering time - Formula Builder with automated deviation calculations (Set vs Actual values) ## Background Britannia Industries Limited stands as one of the most established and reputable food enterprises in India, with a history stretching back to 1892. The company aimed to enhance its manufacturing processes. In line with a steadfast dedication to operational excellence, Britannia has welcomed digital innovation to boost productivity, guarantee compliance with food safety regulations, and optimize production effectiveness. The objective was to reduce manual data input and improve machine oversight. - Good Day - Tiger - NutriChoice - Milk Bikis - Marie Gold The launch of a Smart Factory approach was designed to deliver immediate visibility and centralized notifications, decreasing machinery downtime and quality inconsistencies throughout production facilities. This optimization endeavor encompassed production lines associated with some of India's most iconic food brands, recognized for their extensive consumer appeal and leadership across categories. ## Laying the Digital Foundation ### System Overview To address these pressing challenges, rather than relying on fragmented tools and manual processes, the solution called for a more integrated, scalable, and intelligent system. This led to the implementation of a robust architecture designed to streamline data flow, enable real-time monitoring, and support informed decision-making across operations. - Smart Factory Integration: Itanta Analytics platform connects Britannia's 6 production lines (Mixing, Molder, Baking, Oven, CMS and Packing) with MIHS (Minor Ingredient Handling System) into a unified monitoring ecosystem. - Real-time Production Monitoring: Live tracking of line efficiency, OEE calculations, production tonnage, downtime analysis, and ingredient deviation monitoring across all manufacturing processes. ### Key Components The architecture integrates data collection, processing, visualization, and mobile alerting into a seamless pipeline. - Data Collection: Data was collected from Kepware OPC DA server integrated with ABB DCS. - Itanta's Platform: DS Manager processes data using industry-standard OPC protocols, while Dashboard Builder creates real-time dashboards showing molder/cutter speeds, baking times, roller speeds (RPM), and flour-cream ratios. - Mobile Alert System: The Itanta Mobile App was developed for critical deviations in MIHS, packing machine performance, molding issues, and baking parameters. - Formula Builder and UNS: Automated deviation calculations (Set vs Actual values), package machine tracking with start/end times, and comprehensive downtime statistics. ## Itanta's Solutions - **SCADA integration + auto logging:** Automated Data Flow from SCADA to Itanta via DS Manager. Manual data entry was fully replaced with real-time automated logging improving data accuracy. - **Unified data layer via DS Manager:** All equipment and process data from SCADA to packaging lines, was consolidated into a single platform, to ensure end-to-end traceability across the plant. - **Dashboards with live data feeds:** Line supervisors and operations teams gained live visibility into production KPIs enabling quicker diagnosis of anomalies and data-driven decisions during shifts. - **Mobile app alerts:** Automated alerts allowed teams to act on issues instantly, such as equipment faults. Reduces unplanned downtime and improves first-response times. - **Auto-generated reports & visual dashboards:** Engineers no longer had to compile reports manually. Routine compliance and performance reports were automated, freeing up time for higher-value work. ## Britannia's Dashboards - **1. Mixing Dashboard Overview:** - **2. Packing Overview Dashboard:** ## Conclusion By tapping into Itanta Analytics' powerful out-of-the-box platform, Britannia Industries kickstarted its journey toward becoming a truly connected Smart Factory—without writing a single line of code. - Established real-time data and operational findings - Used built-in SCADA integration, dashboards, and deviation tracking - Enabled faster response with Itanta Mobile App alerts and live metrics - Empowered teams to monitor performance and reduce downtime Most importantly, this transformation wasn't built from scratch—it was achieved by simply unlocking the full potential of Itanta's existing platform. --- # AWL Agri Business Ltd. Transforms Tank Farm Operations with Itanta's No-Code Analytics Platform URL: https://itanta.ai/success-stories/awl-tank-farm-operations-itanta Company: AWL Agri Business Ltd. Industry: Agricultural Processing / Edible Oil > How Itanta delivered real-time SCADA monitoring and production dashboards for enhanced oil refinery management at AWL Agri Business Ltd. ## Challenge With over 2,141 data tags from 11 SCADA systems, operators struggled to access consolidated views of tank levels, temperature, density, and volume. Production data across neutralization, bleaching, deodorization, and winterization remained siloed, while manual reporting delayed critical decisions. ## Outcome Itanta unified 2,141 data points from 11 SCADA systems into real-time dashboards, automated daily stock and production reports via cron scheduling, and provided end-to-end product flow tracking—all without writing a single line of code. ## At a glance - **2,141** — Data Tags Unified - **11** — SCADA Systems Integrated - **7 AM** — Daily Auto-Reports ## About AWL Agri Business Ltd. AWL Agri Business Ltd. (Adani Wilmar) is one of India's leading producers of edible oil, operating large-scale oil refinery and tank farm facilities with complex production processes including neutralization, bleaching, deodorization, and winterization across multiple facilities. Headquarters: India · Industry: Agricultural Processing / Edible Oil Refining · Size: Enterprise ## Introduction Manufacturing companies can use Itanta Analytics' Core Platform to generate interactive reports and dashboards from industrial automation systems. Connections to databases and SCADA systems enable operations teams to turn industrial information into business findings. This case study looks at how AWL Agri Business Ltd., one of the top producers of edible oil in India, used Itanta's platform Analytics to deploy a complete tank gauging and production monitoring system. By offering real-time visibility into tank farm inventory, production procedures, and operational performance across multiple facilities, the project shows how cutting-edge analytics tech can digitize traditional oil refinery operations. ## Challenges Faced - **Limited Real-Time Visibility into Tank Farm Operations:** With over 2,141 data tags from 11 SCADA systems, operators struggled to access consolidated views of tank levels, temperature, density, and volume across different crude oil categories. - **Fragmented Data Across Multiple Production Systems:** Vast amounts of data across various production processes including neutralization, bleaching, deodorization, and winterization remained siloed within individual SCADA systems, making it difficult for management to track daily production metrics and efficiency. - **Manual Reporting and Delayed Decision-Making:** Production teams relied on manual data compilation for daily stock reports and production summaries. Critical operational data was only available at scheduled intervals rather than providing continuous visibility into production performance. - **Inability to Track Product Movement and Loading Operations:** Needed better visibility into product movement between tank farms, refinery processes, and loading operations. Without integrated monitoring, operators couldn't efficiently optimize logistics across the facility's complex supply chain. - **Complex System Integration Requirements:** The facility's diverse industrial automation infrastructure required seamless integration with Microsoft SQL databases while maintaining compatibility with existing SCADA systems. The challenge was creating a unified monitoring solution without disrupting ongoing operations or requiring extensive technical expertise. ## Highlights - 2,141 data tags from 11 SCADA systems unified into real-time dashboards - Automated daily stock reports generated at 7 AM via cron scheduler - Multi-process production monitoring across neutralization, bleaching, deodorization, and winterization - End-to-end product flow tracking from unloading through refinery to loading and packing - Seamless Cimplicity SCADA with SQL Server integration without code changes - HTML5 platform requiring no additional software or technical training This project proves that advanced manufacturing analytics is no longer reserved for companies with large IT budgets or technical teams. ## AWL Agri Business Ltd. _India's Leading Edible Oil Producer_ AWL Agri Business Ltd. (Adani Wilmar) is one of India's top edible oil producers, operating large-scale oil refinery and tank farm facilities with complex multi-process production operations. - One of India's leading producers of edible oil with multiple production facilities - Operates tank farm facilities across MTF1 and MTF2 with diverse crude oil categories - Production processes span neutralization, bleaching, deodorization, and winterization - Infrastructure includes 11 SCADA systems with 2,141 data tags and Microsoft SQL databases - Handles Cotton Seed Oil (17 tanks), KGMO (3 tanks), FGNO (3 tanks), and more AWL's partnership with Itanta demonstrates how traditional oil refinery operations can be digitized without disrupting existing infrastructure. ## Itanta System Architecture ### Data Acquisition PLC (Programmable Logic Controllers) capture real-time operational data from tank farm equipment, flow meters, and sensors. - Field devices collect parameters like tank levels, temperature, density, volume, and mass across MTF1 and MTF2 facilities. ### Data Aggregation SCADA Systems with Microsoft SQL Server collect data from PLCs via industrial ethernet network. - Microsoft SQL Server stores 2,141 data tags with 2-minute logging intervals from 11 SCADA systems. - Itanta DS Manager connects to SQL Server database and processes raw industrial data. - Centralized database consolidates all operational data streams. ### Data Visualization Itanta Platform for Tank Gauging Reports transforms processed data into interactive dashboards. - Creates real-time monitoring interfaces for tank farm and production operations. - Builds automated report templates for daily stock and production summaries. ### Data Distribution Delivers dashboards through standard web browsers (Google Chrome). - Provides automated report generation with cron schedulers (7 AM daily reports). - Enables access across all organizational levels without technical training requirements. ## How Itanta Solved These Challenges - **Real-Time Dashboard Creation:** Itanta's no-code dashboard builder consolidated 2,141 data tags from 11 SCADA systems into unified web-based interfaces. Teams gained real-time visibility across MTF1 and MTF2 facilities through standard web browsers. - **Automated Report Generation:** Using Itanta's cron scheduler feature, AWL automated daily stock reports (7 AM) and 24-hour production reports, providing consistent operational findings. - **Multi-Process Production Monitoring:** Itanta's multi-source integration created unified dashboards for operations like Cotton Seed Oil (17 tanks), KGMO (3 tanks), and FGNO (3 tanks), plus refinery processes including neutralization, bleaching, and deodorization. - **Product Flow Tracking System:** The platform's flow visualization provided complete visibility into product movement from unloading → refinery → loading → packing, enabling operators to track quantities and optimize supply chain logistics. - **Seamless SCADA Integration:** Itanta's Cinplicity SCADA with SQL Server connector enabled direct connection to existing SCADA infrastructure without code changes or operational disruptions. The HTML5 platform required no additional software or technical training. ## Snapshot of Report Tank Farm Reports - **Tank Farm Report:** Comprehensive tank farm inventory showing tank capacity, commodity type, product code, product dip, temperature, density, volume, and quantity for all tanks across the facility. - **Production Shift Report:** Neutralization process monitoring with shift-wise data including crude oil feed, caustic, hot water, vacuum system, steam, air, power consumption, and cooling parameters at 2-minute intervals. ## Conclusion By unifying 2,141 data points from 11 SCADA systems, AWL Agri Business Ltd. eliminated manual reporting, achieved real-time operational visibility, and empowered their teams to make data-driven decisions without technical expertise using Itanta's no-code platform. - Unified 2,141 data tags from 11 SCADA systems into consolidated real-time dashboards - Automated daily stock reports and 24-hour production summaries via cron scheduling - End-to-end product flow tracking from unloading through refinery to loading and packing - Seamless integration with Cimplicity SCADA and Microsoft SQL without code changes - Zero-code deployment accessible through standard web browsers with no additional software This project proves that advanced manufacturing analytics is no longer reserved for companies with large IT budgets or technical teams. Any manufacturer can now digitize their operations, optimize processes, and unlock significant operational efficiencies using existing infrastructure, demonstrating that the future of industrial intelligence is accessible, immediate, and transformative. --- # Batch Reports, Machine Status, and Energy Analysis for Alltech's Bioplex Plant URL: https://itanta.ai/success-stories/alltech-bioplex-batch-reporting-energy-monitoring-itanta Company: Alltech Biotechnology Pvt. Ltd. Industry: Biotechnology / Animal Nutrition Manufacturing > Itanta's web application sits on top of Alltech Biotechnology's Rockwell FTV & PLC setup — turning slurry, drying, and packing data into batch reports, machine running status, and energy dashboards. ## Challenge Alltech's Bioplex process — slurry, drying, and packing — ran on Rockwell FTV SCADA and a Rockwell PLC, but needed batch reports, machine running status, and energy analysis dashboards, plus a way to record parameters like Moisture, Solid, Density, and pH that aren't captured automatically. ## Outcome Itanta's web application now logs 192 tags across 10 data source collections over Ethernet/IP and Modbus TCP, delivering slurry and drying batch reports with manual entry, a machine running status dashboard for all three Bioplex machines, and an energy analysis dashboard with daily consumption calculated in Formula Builder. ## At a glance - **192** — Tags Used - **10** — Data Source Collections - **3** — Bioplex Machines Monitored ## About Alltech Biotechnology Pvt. Ltd. Alltech Biotechnology Pvt. Ltd. runs a Bioplex production process spanning slurry, drying, and packing, controlled by a Rockwell PLC with FactoryTalk View SCADA. Industry: Biotechnology / Animal Nutrition Manufacturing ## Introduction Alltech Biotechnology Pvt. Ltd. needed analytical dashboards and batch reports for its Bioplex process, built on top of its existing Rockwell FactoryTalk View (FTV) SCADA and Rockwell PLC infrastructure. Itanta's web application collects data from the Rockwell PLC and an energy meter, stores it in Itanta's own database, and presents it as batch reports for the drying and slurry processes, a machine running status dashboard, an energy analysis dashboard, and a manual entry form for parameters that cannot be captured automatically — all accessible through a standard web browser for managers, engineers, supervisors, and operators. ## Highlights - 192 tags across 10 data source collections on a 256-tag license - Batch data logging over Ethernet/IP from the Rockwell PLC - Energy meter connected over Modbus TCP, logged every 1 minute - Drying batch parameters logged every 5 minutes from batch start to end - Manual entry form for slurry parameters not captured automatically - Role-based users: full dashboard access and operator-only manual entry ## Project Scope & Data Sources _What Itanta was configured to collect at Alltech_ The project covers three logging patterns — batch data logging over Ethernet/IP, cyclic data logging over Ethernet/IP with namespaces, and cyclic data logging over Modbus TCP — feeding five user interfaces: the Drying Batch Report, Slurry Batch Report, Manual Entry form for slurry manual data, Energy Analysis Dashboard, and Machine Running Status Dashboard. - 192 tags used out of a 256-tag license, organized into 10 data source collections - Ethernet/IP Connector: batch and archive collections for the Bioplex Drying and Bioplex Slurry processes - Ethernet/IP Connector with Namespace: raw drying duration, packing duration, and machine status data processed through namespace outputs - Modbus TCP: a dedicated archive collection for the Energy Dashboard - Every report carries Alltech's logo in the header with the report name, and page numbers in the footer ## Project Architecture ### Data Sources The FBD (Fluid Bed Dryer) machine is controlled by a Rockwell PLC, and an energy meter (MFM386 - Select) measures the plant's electrical parameters. - Itanta DS Manager reads from both devices — the Rockwell PLC over Ethernet/IP and the energy meter over Modbus TCP. ### Connectors The Itanta Ethernet IP Connector and Itanta Modbus Connector move data from the devices into the Itanta database. - Ethernet/IP handles batch data logging for the Bioplex drying and slurry processes, plus cyclic data logging with namespaces for drying duration, packing duration, and machine status calculations. - Modbus TCP handles cyclic logging of the energy meter parameters. ### Processing & Analytics Itanta Analytics and the Itanta Formula Builder work on the stored data. - Namespaces derive each machine's running status from PLC start-command signals, and On-Change formulas calculate running durations. - Formula Builder calculates daily energy consumption from the meter's absolute energy reading. ### Dashboards & Reports Itanta dashboards and reports present the results: the Drying Batch Report, Slurry Batch Report, Manual Entry form, Machine Running Status Dashboard, and Energy Analysis Dashboard. - The Itanta Analytics Platform runs alongside FTV SCADA on the same industrial PC. ## What Itanta Delivered - **Slurry Batch Report with Manual Entry:** Selecting a batch number shows the slurry process data for that batch — start time, end time, serial number, and process parameters. Moisture, Solid, Density, and pH are not captured automatically, so a manual entry form lets operators record them after batch completion; saved values appear in the same report, with serial numbers kept unique per batch per day. - **Drying Batch Report:** A batch-wise report showing Batch Number, Start & End Date/Time, Operator Name, and Total Batch Time, along with drying parameters such as FD Heating, FD Cooling, Pug Mixer, Seed Frequency, Beltweigher Weight, Liquid Flow Rate, Feed Pump Frequency, FBD Inlet/Outlet Temperature, Moisture PGM, Moisture FBD, Seed Silo Weight, Batch Density, and Liquid Level — logged every 5 minutes from batch start to end. - **Machine Running Status Dashboard:** Running status for the Bioplex Slurry, Drying, and Packing machines is derived from PLC start-command logic via namespaces, with On-Change formulas calculating running duration. The dashboard shows current Running/Stopped status, running minutes versus total duration for the selected day, a status trend graph, and a donut chart per machine. - **Energy Analysis Dashboard:** Energy meter data arrives over Modbus TCP and is logged every minute: average voltage LN/LL, average current, power factor, net and absolute energy readings, and phase-wise voltage and current. Daily energy consumption is calculated in Formula Builder from the absolute energy reading, with energy, voltage, and current trends on the dashboard. - **User Management:** Two users were configured: a plant user with permission for all Alltech dashboards, and an operator user restricted to the Manual Entry dashboard only. ## Snapshots of Dashboards & Reports - **Slurry Batch Report:** Batch-wise slurry process data including start/end times, serial number, moisture, solid, pH, density, water used, and operator name. - **Drying Batch Report:** Complete drying process record for a selected batch, logged every 5 minutes with heating, cooling, temperatures, weights, and moisture parameters. - **Machine Running Status Dashboard:** Running/Stopped status, running duration, status trend, and donut visualization for the Bioplex Slurry, Drying, and Packing machines. - **Energy Analysis Dashboard:** Live energy parameters, phase-wise voltage and current, and energy, voltage, and current trends from the Modbus-connected energy meter. ## Conclusion With Itanta running alongside Rockwell FTV SCADA on the same industrial PC, Alltech gets structured batch records for its slurry and drying processes, a clear machine-wise view of running performance, and continuous energy monitoring — with manual-entry provisions where automatic capture isn't possible, and role-based access so operators see exactly what they need. --- # BPCL's Digital Transformation Journey with Itanta Analytics URL: https://itanta.ai/success-stories/bpcl-digital-transformation-itanta Company: BPCL Industry: Oil & Gas / City Gas Distribution > How Itanta Platform Revolutionized City Gas Distribution Operations ## Challenge BPCL operated over 100 city gas distribution stations across multiple geographical areas using fragmented manual processes that caused operational inefficiencies, delayed reporting, and limited real-time visibility. ## Outcome BPCL partnered with Itanta Analytics to deploy Project Anubhav, implementing the SCADAvantage platform, delivering significant reductions in manual work, improved operational visibility, and substantial cost savings. ## At a glance - **5-Min** — Data Polling Interval - **4** — Sales Categories Tracked - **Real-Time** — Station Monitoring ## About BPCL Bharat Petroleum Corporation Limited (BPCL) is a Fortune Global 500 Indian oil and gas company, one of India's largest state-owned enterprises operating in petroleum refining, distribution, and city gas distribution. Headquarters: Mumbai, India · Industry: Oil & Gas / City Gas Distribution · Size: Enterprise (10,000+ employees) ## Introduction In the rapidly evolving energy sector, the ability to monitor, analyze, and act on operational data in real time is critical to achieving efficiency, safety, and scalability. BPCL's city gas distribution network, spanning over 100 stations across multiple geographical areas, required a transformative approach to overcome fragmented manual processes. This case study explores how BPCL, through Project Anubhav, leveraged the SCADAvantage platform and Itanta Analytics to digitize its entire CGD operations, replacing manual workflows with automated, real-time intelligence. ## The Challenge Before Itanta, BPCL's city gas distribution operations faced several critical obstacles in managing over 100 stations effectively. - **Fragmented Monitoring:** Over 100 stations lacked a unified monitoring platform, with each station relying on local SCADA systems without centralized visibility into operations across the network. - **Manual Data Collection:** Operators manually recorded flow rates, pressures, and gas compositions, leading to data inconsistencies, human errors, and delayed reporting across stations. - **Delayed KPI Analysis:** Critical metrics like compressor utilization, station availability, and gas quality were calculated hours after data collection, preventing timely operational decisions. - **Communication Failures:** Unreliable communication links between field RTUs and the central SCADA system caused gaps in real-time data, resulting in blind spots across the network. - **Inconsistent Alarm Management:** Alarm thresholds and responses varied across stations with no standardized escalation procedures, leading to inconsistent safety and operational responses. - **Role-Based Access Gaps:** No granular access control existed, making it difficult to provide role-appropriate dashboards to different organizational levels from operators to management. ## Highlights - Unified platform monitoring 100+ CNG and city gas stations in real time - Automated data collection with 5-minute polling intervals from SCADAvantage - Instant KPI calculations replacing 6-8 hours of manual reporting - Dual-path communication backup ensuring continuous data flow - Role-based dashboards for operators, supervisors, and management Project Anubhav represents a blueprint for how energy companies can transform fragmented operations into a unified, data-driven ecosystem. ## Bharat Petroleum Corporation Limited _Powering India's Energy Future_ Bharat Petroleum Corporation Limited (BPCL) is a Fortune Global 500 Indian oil and gas company and one of India's largest state-owned enterprises. With a vast network spanning refineries, retail outlets, and gas distribution stations, BPCL plays a pivotal role in India's energy infrastructure. - Operates one of India's largest city gas distribution (CGD) networks across multiple geographical areas - Manages over 100 CNG and city gas stations serving industrial, commercial, and domestic customers - Processes four key sales categories: CNG, Industrial, Commercial, and Domestic gas distribution - Utilizes SCADAvantage as the core SCADA platform for real-time field data acquisition and processing - Committed to digital transformation through Project Anubhav, modernizing operations with data-driven decision making - Serves as a critical energy infrastructure provider supporting India's transition to cleaner fuel sources Through strategic partnerships and technology adoption, BPCL continues to drive operational excellence and innovation across its expanding city gas distribution network. ## System Architecture ### Data Acquisition The acquisition layer captures field data from distributed stations using Remote Terminal Units (RTUs) that feed into the SCADAvantage system. - RTUs at each station collect real-time field data including flow rates, pressures, temperatures, and gas compositions. - SCADAvantage System processes incoming SCADA data, handling protocol conversion and signal conditioning from multiple RTU sources. ### Data Aggregation The aggregation layer extracts and structures data from the SCADAvantage database for analytics consumption. - SCADAvantage Database stores all processed SCADA data in a structured format for reliable data persistence. - ODBC Connector extracts data at 5-minute intervals, transforming raw SCADA records into analytics-ready datasets for the visualization layer. ### Data Visualization The visualization layer delivers real-time dashboards and reports through the Itanta Cloud platform. - Web Application Data Source hosted in the cloud provides the data backbone for all dashboard and reporting components. - Dashboards & Reports deliver interactive visualizations including compressor utilization charts, station availability tracking, and sales category monitoring across Daily, MTD, and YTD periods. ## Itanta's Approach _Project Anubhav: SCADAvantage-Powered Intelligence_ The Itanta platform was deployed as a comprehensive analytics layer over BPCL's existing SCADAvantage SCADA infrastructure. It brought together automated data collection, real-time processing, and role-based visualization—transforming fragmented manual operations into a unified digital ecosystem. - **Automated Data Collection:** ODBC connectors extract real-time data from SCADAvantage database every 5 minutes, eliminating manual entry and ensuring 99% data accuracy across all stations - **Communication Backup Solutions:** Dual-path communication with automatic failover ensures continuous data flow even when primary links fail, eliminating blind spots in monitoring - **Instant KPI Calculations:** Real-time computation of compressor utilization, station availability, and gas quality metrics—reducing reporting from 6-8 hours to minutes - **Unified Real-Time Monitoring:** Single dashboard providing live visibility across all 100+ stations with geographic mapping and drill-down capabilities for instant operational awareness - **Role-Based Dashboard System:** Customized views for operators, supervisors, and management with granular access controls and permission-based data visibility - **Proactive Alarm Management:** Standardized alarm thresholds across all stations with automated escalation procedures and historical alarm analytics for continuous improvement The result was a complete digital transformation of BPCL's CGD operations—from fragmented manual processes to a unified, automated, and intelligent monitoring ecosystem. ## Sneak Peek of the Dashboards BPCL's operational dashboards provide comprehensive views of compressor performance and station availability across the entire CGD network. - **Compressor Utilization:** Bar charts displaying compressor utilization percentages across all locations for the previous day, enabling quick identification of underperforming or overloaded compressors. - **Station Availability:** Stacked bar charts showing station availability and unavailability hours by geographic area, helping operations teams prioritize maintenance and improve uptime. ## Results Project Anubhav delivered a comprehensive digital transformation across BPCL's city gas distribution network, replacing manual workflows with automated, real-time intelligence. - **100+ — Stations Digitized.** Complete digital transformation across all CGD stations in the network - **99% — Data Accuracy.** Automated collection via ODBC connectors eliminated manual entry errors - **Real-Time — KPI Generation.** Instant computation of critical metrics replaced hours of manual calculation - **Minutes — vs 6-8 Hours.** Dramatic reduction in reporting cycle time from hours to minutes - **Scalable — Foundation Built.** Platform ready to support additional stations, regions, and future analytics needs ## Conclusion Project Anubhav demonstrates how the right technology partnership can transform operations at scale. Through the SCADAvantage platform and Itanta Analytics, BPCL achieved a comprehensive digital transformation of its city gas distribution network. - Eliminated manual data collection—automated ODBC extraction ensures consistent, accurate data across 100+ stations - Real-time visibility—unified dashboards replaced fragmented local SCADA views with centralized monitoring - Proactive monitoring—standardized alarms and automated escalation replaced inconsistent manual responses - Scalable foundation—platform architecture supports expansion to additional stations and regions - Faster decisions—KPI reporting reduced from 6-8 hours to minutes, enabling timely operational action - Role-based access—customized views ensure each organizational level sees relevant, actionable data - Communication resilience—dual-path backup ensures continuous data flow even during primary link failures In a world where energy infrastructure demands both reliability and intelligence, Project Anubhav proves that digital transformation at scale is not only possible—it's the foundation for operational excellence. Itanta Analytics enabled BPCL to turn raw SCADA data into real-time operational intelligence. --- # Centralized Dam Monitoring & Reporting for UJVNL's Dam Sites URL: https://itanta.ai/success-stories/ujvnl-dam-monitoring-itanta-core-platform Company: Uttarakhand Jal Vidyut Nigam Limited (UJVNL) Industry: Power & Utilities – Hydropower / Dam & Water Management > How Itanta's Core Platform gave UJVNL live visibility into water level, velocity, discharge, and weather data across its dam sites — from a single web-based platform ## Challenge UJVNL needed a centralized web-based system to monitor dam operational data — water level, velocity, discharge, battery voltage, and weather station parameters — and generate daily reports for dam safety, water management, and regulatory compliance. ## Outcome A web-based monitoring and reporting solution deployed in 2–4 weeks: 4 systems with 35 tags each, data logged every 5 minutes, live dashboards and structured reports accessible from one platform. ## At a glance - **4** — Systems Monitored - **35** — Tags per System - **5 min** — Data Logging Frequency - **2–4 wks** — Deployment Timeline ## About Uttarakhand Jal Vidyut Nigam Limited (UJVNL) Uttarakhand Jal Vidyut Nigam Limited (UJVNL) is a large power and utilities company operating in renewable energy, primarily specializing in hydroelectric power, with 10+ plants. Industry: Power & Utilities – Hydropower / Dam & Water Management · Size: Large (10+ plants) ## Introduction Water dam reports are vital for ensuring dam safety, structural integrity, and environmental sustainability. They provide data related to structural health, environmental impact, water management, and regulatory compliance — helping minimize risks and maximize benefits. Uttarakhand Jal Vidyut Nigam Limited (UJVNL), a large hydropower company with 10+ plants, needed a centralized web-based system to monitor dam operational data and generate daily reports. The team required visibility of important dam parameters such as dam level, velocity, voltage, discharge, and AWS weather parameters. Itanta deployed a web-based monitoring and reporting solution on its Core Platform, fetching real-time data from the MS SQL database through the Itanta SQL Connector and DS Manager — delivered within a 2–4 week deployment timeline. ## The Core Challenge Before Itanta Dam safety and water management demanded centralized, always-current visibility - **No Centralized Monitoring:** The team required a centralized web-based system to monitor dam operational data instead of checking individual systems separately. - **Critical Parameters Across Sites:** Visibility was needed for important dam parameters — dam level, velocity, voltage, discharge, and AWS/weather parameters — for safety, water management, and operational review. - **Daily Reporting Requirements:** Water dam reports are vital for dam safety, structural integrity, environmental sustainability, and regulatory compliance, requiring structured daily report views. ## Highlights - Centralized monitoring for 4 systems with 35 tags per system - Live values updated every 5 minutes, with 24-hour historical trend graphs - Overview Dashboard, Site Data Report, and AWS Report delivered, plus a detailed Discharge Report view - Real-time data fetched from MS SQL via the Itanta SQL Connector and DS Manager - Single web-based platform for dam level, velocity, discharge, voltage, and weather parameters From scattered, manual monitoring to a centralized, dashboard-based review process — deployed in just 2–4 weeks. ## Solution Architecture ### Dam Sensors & SCADA Field sensors at the dam sites feed operational data — water level, velocity, discharge, battery voltage, and AWS weather parameters — into the SCADA system. ### SQL Database & Itanta SQL Connector SCADA data lands in the MS SQL database. The Itanta SQL Connector fetches real-time data with cyclic, 5-minute logging — 35 tags for each of the 4 systems. ### DS Manager & Itanta Platform DS Manager streams the connected data to the Itanta Platform, which serves live dashboards, historical trend graphs, and report tables in any standard web browser. - Data flow: Dam Sensors → SCADA → SQL Database → Itanta SQL Connector → DS Manager → Itanta Platform - Data logged every 5 minutes; VM data updated every 15 minutes ## What Was Deployed _A web-based monitoring and reporting solution on the Itanta Core Platform_ The solution fetched real-time data from the MS SQL database through the Itanta SQL Connector and DS Manager and displayed it on the Itanta Platform — live dashboards and reports for all key dam parameters. - **Live Dam Parameter Monitoring:** Water level, velocity, discharge, and battery voltage displayed in bar charts using the Latest aggregator, updated every 5 minutes for each dam. - **24-Hour Historical Trends:** Historical values shown in graphs with the X-axis set to a 1-day duration, plotting separate series for each dam's velocity, discharge, voltage, and water level tags. - **Automatic Weather Station (AWS) Data:** Wind speed, wind direction, temperature, relative humidity, solar radiation, rainfall, and air pressure displayed dam-wise in live bar charts and structured reports. - **Structured Daily Reports:** Site Data Report and AWS Report present all parameters at a 5-minute interval in dynamic tables using the Absolute aggregator, with report headers showing start/end timestamps. ## Dashboards & Reports Itanta delivered an Overview Dashboard plus structured report views, giving engineers and supervisors live values, historical graphs, and paginated report tables from a single web interface. - **Overview Dashboard:** All live dam details in one view — water level, velocity, discharge, and battery voltage in bar charts, historical 24-hour graphs, and dam-wise AWS live values. - **Site Data Report:** All dam parameters at a 5-minute interval in a dynamic table — voltage, velocity, discharge, and water level plotted per dam using the Absolute aggregator. - **Discharge Report:** Detailed discharge report for the early warning system, presenting discharge, level, and velocity values over the selected date range. - **AWS Report:** All AWS parameters at a 5-minute interval in a dynamic table — wind speed, wind direction, temperature, relative humidity, solar radiation, rainfall, and air pressure per weather station. ## Measurable Outcomes Centralized monitoring, automatic logging, and structured reporting from a single web-based platform - **4 — Systems Monitored.** Centralized monitoring for 4 systems with 35 tags per system - **5 min — Automatic Data Logging.** Data logged automatically every 5 minutes; VM data updated every 15 minutes - **4 — Dashboards & Reports.** Overview Dashboard, Site Data Report, Discharge Report, and AWS Report - **24 hrs — Historical Trends.** Live monitoring plus 24-hour historical trends from a single web-based platform ## What Changed Day-to-Day for the Team The team moved from scattered or manual monitoring toward a centralized, dashboard-based review process. - Engineers and supervisors view live dam parameters and review 24-hour historical trends from one platform instead of checking individual systems separately. - Structured reports for site data and AWS data are accessible with updated date/time values, latest values, graphs, and report tables for operational review. - When the UJVNL/Temflo team saw live dam parameters and AWS values updating automatically every 5 minutes, they could immediately understand the operational status of the dams from a single web interface. --- # Cipla Brings Process & Energy Monitoring Together with Itanta URL: https://itanta.ai/success-stories/cipla-process-energy-monitoring-itanta Company: Cipla Industry: Pharma & Life Sciences > How Itanta's Core Platform replaced manual readings and Excel reporting with real-time plant data, energy calculations, dashboards, and automated reports ## Challenge Before Itanta, readings and operational data were manually collected, recorded, and maintained in Excel. The process was time-consuming and prone to human error. ## Outcome Itanta's Core Platform automatically collects plant process and EMS data from WinCC/SQL, calculates energy consumption, and displays real-time information through dashboards and automatically generated reports. ## At a glance - **1–2 mo** — Deployment Timeline - **Real-time** — Process & Energy Data - **Automatic** — Data Logging - **Core** — Platform Deployed ## About Cipla Cipla operates in Pharma & Life Sciences, producing advanced pharmaceutical formulations and oral solid dosage forms across a large organization with 10+ plants. Industry: Pharma & Life Sciences · Size: Large (10+ plants) ## Introduction Cipla operates in Pharma & Life Sciences, producing advanced pharmaceutical formulations and oral solid dosage forms. The supplied report views cover process, energy, chiller, pump, water-chiller, and other-utility data from Cipla's Goa and Indore operations. Before Itanta, readings and operational data were manually collected, recorded, and maintained in Excel. This made the process time-consuming and prone to human error, while teams had to wait for manual readings and report preparation before reviewing plant performance. Itanta's Core Platform was deployed in 1–2 months to automatically collect plant process and EMS data from WinCC/SQL, calculate energy consumption, and present the results through real-time dashboards and automatically generated reports. ## The Challenge Before Itanta Manual readings made process and energy reporting slow and error-prone - **Manual Data Collection:** Readings and operational data had to be collected manually from plant systems and equipment. - **Excel-Based Records:** The collected information was recorded and maintained in Excel, creating a separate manual reporting process. - **Delayed, Error-Prone Reporting:** Manual handling made the work time-consuming and increased the risk of human error while preparing process and energy reports. ## Highlights - Automatic collection of plant process and EMS data from WinCC/SQL - Energy consumption calculated within the Itanta Core Platform - Real-time process and energy data available through dashboards - Automatically generated reports for energy, EMS, chillers, pumps, and utilities - Manual readings and report preparation reduced, giving the team faster access to plant information From manual readings and Excel records to real-time process and energy visibility with automatically generated reports. ## Solution Architecture ### Plant Equipment & Utilities Water chillers with KPIs, pumps, energy meters, and other utilities provide the plant process and energy data. ### PLC, SCADA & VM Workstation The plant data flows through the Siemens 1200 Series PLC and SCADA to the VM workstation, where WinCC and SQL hold the operational data. ### Itanta Core Platform Itanta collects the WinCC/SQL data, calculates energy consumption, and presents process and energy information through dashboards and reports. - Data flow: Plant Equipment & Utilities → Siemens 1200 Series PLC → SCADA → VM Workstation / WinCC / SQL → Itanta ## What Was Deployed Itanta connected Cipla's existing plant data environment to a single platform for faster process and energy review. - **Automatic Data Collection:** Process and EMS data from WinCC/SQL is collected automatically instead of relying on manual readings. - **Energy Consumption Calculation:** The Core Platform calculates energy consumption from the connected plant data and makes the results available for review. - **Real-Time Plant Visibility:** Teams can directly access current process and energy data through dashboards rather than waiting for manually prepared records. - **Automated Reporting:** Energy, EMS, chiller, pump, water-chiller, and other-utility reports can be generated automatically in less time. ## Dashboards & Reports The supplied views show how Cipla's process, energy, chiller, pump, and utility information is organized for real-time review and reporting. - **Goa Energy Consumption Report:** Monthly energy consumption report for Cipla Goa Unit 2, listing chiller energy sources and total energy consumption per day. - **Goa Chiller KPI Report:** Chiller KPI view with chiller running load, coefficient of performance, specific energy consumption, condenser effectiveness, evaporator effectiveness, and related measurements. - **Goa Other Utilities Report:** Time-based report for cooling-tower, chilled-water, and other utility parameters, with a selected start and end time. - **Indore EMS Daily Report:** Daily Energy Management System report for structured review of plant energy information. - **Indore Water Chiller Report:** Water chiller report for reviewing chiller operating conditions and associated process parameters. ## Measurable Outcomes Faster access to reliable process and energy information - **Automatic — Data Logging.** Plant process and EMS data is logged automatically instead of being collected manually. - **Automatic — Report Generation.** Reports are generated automatically, reducing the effort required to prepare them. - **Real-time — Data Availability.** The team can directly access current process and energy data in Itanta. - **Reduced — Manual Readings.** Manual readings and report preparation were reduced, and reports can be generated in less time. ## Itanta's Impact The team no longer needed to manually collect readings and prepare reports. They could directly access real-time process and energy data in Itanta and generate reports quickly. - Manual collection of plant readings was replaced with automatic data logging from WinCC/SQL. - Process and energy information became directly accessible through dashboards instead of waiting for manual readings. - Automatically generated reports made daily review faster and reduced the effort involved in report preparation. --- # Cyclic Process Monitoring & Charge ID Traceability at DFE Pharma URL: https://itanta.ai/success-stories/dfe-pharma-batch-reporting-charge-id-traceability-itanta Company: DFE Pharma India Private Limited Industry: Pharma & Life Sciences – Pharmaceutical Excipients > How Itanta's Core Platform turned WinCC SCADA data into automatic cyclic process reports and traceable batch reports — with every Charge ID in a batch identified and its process parameters a few clicks away ## Challenge Manual reporting caused delayed visibility and limited centralized process monitoring — batch details, Charge IDs, and process parameters had to be searched and verified manually from different sources. ## Outcome Deployed in 1–2 months: cyclic process data monitoring and batch reporting with Charge ID traceability. Multiple Charge IDs within a batch can be identified and traced, with pressure and temperature checked in just a few clicks. ## At a glance - **1–2 mo** — Deployment Timeline - **1 min** — Cyclic Data Interval - **5** — Equipment Types Reported - **4** — Report Types Delivered ## About DFE Pharma India Private Limited DFE Pharma India Private Limited produces pharmaceutical excipients and formulation ingredients, operating as a mid-size manufacturer with 3–10 plants. Industry: Pharma & Life Sciences · Size: Mid-size (3–10 plants) ## Introduction DFE Pharma India Private Limited manufactures pharmaceutical excipients and formulation ingredients, where batch-level traceability and process parameter records are central to daily operations. Before Itanta, manual reporting caused delayed visibility and limited centralized process monitoring. Tracing the multiple Charge IDs that make up a batch — and verifying the pressure and temperature values associated with each — meant manual searching across different sources. Itanta's Core Platform was deployed for cyclic process data monitoring and batch reporting with Charge ID traceability. It captures process data from the WinCC SCADA system's SQL Server database, links it with the respective Charge ID, and generates traceable batch reports — delivered within a 1–2 month deployment timeline. ## The Core Challenge Before Itanta Manual reporting delayed visibility into process and batch data - **Manual Reporting:** Reports were prepared manually, causing delayed visibility into cyclic process data and batch information. - **Limited Centralized Monitoring:** There was no centralized way to monitor process data — parameters had to be checked from different sources. - **Time-Consuming Verification:** Tracing Charge IDs within a batch and verifying process parameters such as pressure and temperature required manual searching and cross-checking. ## Highlights - Cyclic process reports generated automatically at a 1-minute interval for equipment such as WDT, GLR, STT, RFT, and RVDF - Batch reports clearly show multiple Charge IDs within the same batch - Pressure and temperature for each Charge ID checked in just a few clicks - Process data captured from WinCC SCADA's SQL Server via Itanta Data Source Manager - Charge Report ties each Charge ID to its equipment, start/stop times, and identification parameters From manual searching across different sources to automatic cyclic reports and one-place Charge ID traceability — deployed in 1–2 months. ## Solution Architecture ### Process Data & WinCC SCADA Process data from the plant flows into the WinCC SCADA system, where it is stored in the SQL Server database. ### Itanta Data Source Manager Itanta's Data Source Manager connects to the WinCC SCADA SQL Server database and streams the process data to the Itanta Platform. ### Itanta Platform The Itanta Platform links captured process data with the respective Charge ID and serves cyclic process reports, charge reports, and traceable batch reports. - Data flow: Process Data → WinCC SCADA (SQL Server) → Itanta Data Source Manager → Itanta Platform ## What Was Deployed Itanta's Core Platform captures process data from the WinCC SCADA SQL Server database and links it with the respective Charge ID — delivering four capabilities: - **Cyclic Process Reports:** Automatic reports at a 1-minute interval for process equipment — WDT, GLR, STT, RFT, and RVDF — covering values such as temperature, pressure-based vent parameters, and header steam pressure with PV, SP, and MV columns. - **Charge ID Traceability:** Each charge is identified with its recipe, lot number, Charge ID, dispersion tank, GLR, STT, RFT/RVDF, and settler details along with start and stop times. - **Traceable Batch Reports:** Batch reports list every charge within a batch with parameters such as HCL quantity, reaction time, reaction temperature, reaction pressure, settling time, and water quantities — against max/min tolerances. - **Batch-Level Visibility:** Along with each Charge ID, process parameters such as pressure and temperature can be checked in just a few clicks, reducing manual verification effort. ## Reports Delivered Itanta delivered cyclic process reports for the plant's process equipment plus charge and batch reports, giving the team one place to review process data and trace every Charge ID within a batch. - **WDT Report:** Cyclic report for the wood pulp dispersion tank (WDT-2310) at a 1-minute interval — header steam pressure and temperature with PV, SP, and MV values. - **GLR Report:** Cyclic report for the glass-lined reactors (GLR-1110 to GLR-1140) at a 1-minute interval — temperature and pressure-based vent parameters per reactor. - **Charge Report:** Charge identification parameters for each Charge ID — recipe number and name, lot number, dispersion tank, GLR, STT, RFT/RVDF, and settler numbers with start and stop times. - **Batch Report:** All charges within a batch in one table — wood pulp quantity, HCL quantity, reaction time, temperature and pressure, settling time, and water flows against max/min tolerances. ## Measurable Outcomes Batch-level visibility with less manual verification effort - **Multiple — Charge IDs Traced per Batch.** Multiple Charge IDs within a batch can be easily identified and traced - **Few clicks — Parameter Checks.** Pressure and temperature for each Charge ID checked in just a few clicks - **Reduced — Manual Verification.** Manual data searching and verification effort was reduced - **1–2 mo — Deployment Timeline.** Deployed on the Itanta Core Platform in 1–2 months ## Itanta's Impact Day-to-day work became easier — cyclic process data, batch details, Charge IDs, pressure, and temperature values can be checked quickly from the system. - Cyclic process reports are generated automatically instead of being prepared manually. - Batch reports clearly show multiple Charge IDs within the same batch, with related process parameters such as pressure and temperature in one place. - The team first saw real value when cyclic data review, batch verification, and Charge ID traceability became faster — with manual searching from different sources reduced. --- # Digitizing Dairy Excellence: Sangam Dairy's Transformation with Itanta Analytics URL: https://itanta.ai/success-stories/sangam-dairy-digital-transformation-itanta Company: Sangam Dairy Industry: Dairy / Food & Beverage > Transforming Disconnected Systems into Unified Intelligence for Sangam Dairy ## Challenge Sangam Dairy's advanced milk processing facility ran on disconnected Rockwell PLCs, flowmeters, weighbridges, and manual paper records—creating data silos, time-consuming manual workflows, and no real-time visibility across parallel processing lines. ## Outcome Working with system integrator CRK, Itanta Analytics delivered a comprehensive Industrial IoT web application that unified PLC and manual data, automated batch logging, enabled digital quality gates, and provided real-time visibility from weighbridge to dispatch. ## At a glance - **30-Sec** — Automated Batch Logging - **3** — Parallel Lines Monitored - **Real-Time** — Quality Gates ## About Sangam Dairy Sangam Dairy (Sangam Milk Producer Company Limited) is one of South India's leading dairy cooperatives, operating an advanced milk processing facility serving farmers and consumers across Andhra Pradesh and Telangana. Its digital transformation was led by CRK, a leading system integrator, in partnership with Itanta Analytics. Headquarters: Andhra Pradesh, India · Industry: Dairy / Food & Beverage · Size: Large Cooperative ## Introduction When CRK, a leading system integrator, sought to digitally transform their client Sangam Dairy's advanced milk processing facility, they partnered with Itanta Analytics to bridge the gap between industrial automation and actionable intelligence. This case study reveals how Itanta delivered a comprehensive Industrial IoT web application that unified data points from Rockwell PLCs, automated manual workflows, and provided real-time visibility across weighbridge operations, pasteurization processes, quality labs, and predictive maintenance. Discover how the Itanta-CRK partnership turned operational complexity into competitive advantage—delivering enhanced efficiency, complete traceability, and data-driven decision-making for Sangam Dairy, one of South India's leading dairy cooperatives. ## Pain Points in Dairy Operations Before Itanta, Sangam Dairy's processing operations were held back by fragmented systems and manual workflows that could not scale with the plant's complexity. - **Disconnected Data Across Systems:** Data from Rockwell ControlLogix PLCs, flowmeters, weighbridges, and sensors existed in isolated silos with no unified platform for aggregation or analysis. - **Time-Consuming Manual Processes:** Operators spent hours manually recording weighbridge entries, lab quality parameters (FAT, SNF, COB, acidity), filling machine data, and lab utility checks—introducing inefficiency and errors. - **Complex Multi-Compartment Calculations:** Managing production across different sections (Raw Milk Storage Tank, Pasteurized Milk Storage Tank, Cream lines) with multiple lines (B1L1, B1L2, E1L1, E1L2) and tracking batch statuses (Aborted/Completed/Ended) created operational complexity manual systems couldn't handle. - **No Real-Time Visibility:** Running three parallel processing lines simultaneously without live monitoring, management couldn't track batch status, temperatures, or equipment performance across operations in real time. - **Poor End-to-End Traceability:** Tracking each tanker from weighbridge through lab testing, processing across different lines, and final dispatch was fragmented across paper records, compromising quality control. - **Reactive Maintenance:** No systematic tracking of valve stroke counts, motor running hours, or preset maintenance thresholds resulted in unexpected equipment failures and unplanned downtime across the facility. ## Highlights - Unified Rockwell ControlLogix PLC data into a single Industrial IoT platform - Automated batch-type logging at 30-second intervals across processing sections - Digital quality gates (FAT, SNF, COB) ensuring only Pass results proceed - Real-time visibility across three parallel pasteurization circuits - Bi-directional PLC writeback for complete tanker-to-dispatch traceability The Itanta platform amplified Sangam Dairy's existing Rockwell ControlLogix infrastructure through intelligent Analytics Layer integration—without disrupting it. ## Sangam Dairy _A Leading South Indian Dairy Cooperative_ Sangam Dairy operates an advanced milk processing facility serving farmers and consumers across Andhra Pradesh and Telangana. Its operations span weighbridge intake, raw and pasteurized milk storage, cream lines, quality labs, and dispatch—powered by Rockwell ControlLogix automation. - Processes milk across Raw Milk Storage Tank, Pasteurized Milk Storage Tank, and Cream line sections - Runs multiple production lines including B1L1, B1L2, E1L1, and E1L2 - Operates three parallel processing circuits: CIP, milk pasteurization, and cream pasteurization - Relies on Rockwell ControlLogix PLCs, flowmeters, weighbridges, and quality lab instrumentation - Manages end-to-end traceability from tanker intake at the weighbridge through dispatch - Partnered with system integrator CRK to drive its digital transformation with Itanta Analytics By unifying automation and manual workflows, Sangam Dairy laid the foundation for a fully digital, traceable, and data-driven dairy operation. ## System Architecture ### Data Collection Layer Multiple data sources across the facility feed real-time information into the platform. - PLC Systems — several tags from Rockwell ControlLogix covering Labs, Tanks, and different types of storage. - Manual Forms — weighbridge operator entries for tanker details, driver information, and compartment data. ### Integration Hub — Data Source Manager Itanta's DS Manager orchestrates all data flows using the Ethernet IP Connector for PLC communication. - Aggregates automated sensor data and manual entries into organized collections for unified processing. - Connects directly to Rockwell ControlLogix PLCs via the Ethernet IP Connector. ### Bi-Directional Communication A critical writeback loop enables data entered at the weighbridge to flow back to the PLCs. - Ensures downstream lab operations and processing logic have access to tanker information. - Powers quality gates and production tracking with consistent, shared data. ### Dashboard Visualization The Itanta Platform delivers real-time web dashboards accessible via standard browsers. - Displays process parameters, batch statuses, quality metrics, maintenance alerts, and production tracking. - Provides simultaneous visibility across all processing lines from any browser. ## How Itanta Transformed CRK Operations _From Disconnected Systems to Unified Intelligence_ Itanta deployed a comprehensive Industrial IoT web application over Sangam Dairy's existing Rockwell ControlLogix infrastructure—unifying data, automating workflows, and digitizing quality and traceability across the plant. - **Unified Data Integration:** Deployed the Ethernet IP Connector to integrate all tags from Rockwell ControlLogix PLCs into organized collections, creating a single source of truth. - **Intelligent Automated Logging:** Implemented batch-type data logging with 30-second intervals—when running boolean bits turn true, data logs automatically until batch completion. - **Namespace Configuration:** Deployed namespace monitoring for milk transfer lines, analog inputs, maintenance valves, and motors—pivoting time-sorted data into line-wise, equipment-wise actionable reports. - **Multi-Section Production & Quality Management:** Created trigger-based logging across Raw Milk and Pasteurized Milk sections, custom forms with 'Get Value' buttons for real-time weights, and digital quality gates (FAT, SNF, COB) ensuring only 'Pass' results proceed. - **Centralized Real-Time Dashboard System:** Delivered unified dashboards providing simultaneous visibility into three parallel processing lines—CIP, milk pasteurization, and cream pasteurization—accessible from any browser. - **Complete Traceability with PLC Writeback:** Built integrated workflows using the Analytics Layer for bi-directional communication—weighbridge data automatically writes back to the PLC for downstream lab operations. The result was a connected, automated, and traceable dairy operation—built on top of Sangam Dairy's trusted Rockwell ControlLogix infrastructure. ## Data Visualization Sangam Dairy's dashboards provide real-time visibility into cold storage conditions and lab quality testing across the facility. - **Cold Storage Inventory:** Real-time temperature monitoring across Milk Cold Storage, Curd Cold Storage, Cold Blast Room, and Incubation Room sections—tracking each zone in Deg.C with time-stamped readings for full cold-chain assurance. - **Lab Testing Report:** Compartment-wise quality results for each tanker—capturing FAT, CLR, SNF, acidity, COB, organoleptic, heat stability, and alcohol tests—with instant digital quality gates ensuring only passing milk proceeds to processing. ## Before vs After Itanta didn't just implement new software—it fundamentally changed how Sangam Dairy operates, turning disconnected systems and manual processes into a story of digital transformation. - **Unified — One Platform.** Isolated data points became one unified platform accessible organization-wide - **30-Sec — Automated Logging.** Hours of manual paperwork replaced by automated batch logging every 30 seconds - **Predictive — Maintenance Alerts.** Reacting to equipment failures gave way to predictive alerts for valves and motors - **3 Lines — Synchronized Visibility.** Fragmented triple-circuit operations became synchronized visibility across parallel lines - **Digital — Quality Workflows.** Paper-based quality checks became digital workflows with PLC writeback integration ## Conclusion When Sangam Dairy, through CRK, used Itanta, they weren't just implementing new software—they were fundamentally changing how their dairy plant operates. What started as a challenge of disconnected systems and manual processes became a story of digital transformation that empowered their entire team. - Operators trace every tanker from gate to dispatch using unique IDs - Lab technicians trigger compartment-wise testing with instant quality gates - Plant managers monitor three parallel pasteurization circuits simultaneously - Maintenance teams receive alerts when valve strokes or motor hours approach preset thresholds - A single unified platform replaced isolated data points across the facility - Digital workflows with PLC writeback replaced paper-based quality checks --- # Every EV Battery, Traceable End to End on Jendamark's Line with the Itanta Core Platform. URL: https://itanta.ai/success-stories/itanta-jendamark-royal-enfield-battery-assembly-line Company: Jendamark India Pvt. Ltd Industry: Automotive / EV Battery Manufacturing > One scan, the whole story — the Itanta Core Platform turns Jendamark's Royal Enfield EV battery line into a single, searchable traceability record. ## Challenge Six zones of rich station data, but every station used a different QR-code mix — so a single line-wide trace meant stitching tables together by hand. ## Outcome The Itanta Core Platform reads from Mitsubishi SCADA via the Itanta SQL Connector. Now one Marking QR-Code returns the full line history, with zone- and station-wise reports across every zone. ## At a glance - **6** — Production zones unified - **1 Scan** — Marking QR → full line history - **2–3 mo** — From deployment to live reports ## About Jendamark India Pvt. Ltd Jendamark India builds turnkey assembly lines, test stations and traceability systems for the automotive industry. For Royal Enfield, it engineered the EV battery line — cell sorting through laser marking — instrumented with Mitsubishi PLCs and Mitsubishi SCADA. Headquarters: India · Industry: Automotive Assembly Lines & Industrial Automation · Size: Large (10+ plants) ## Introduction Jendamark builds the lines that assemble precision automotive products. For Royal Enfield, it engineered an EV battery line that takes raw cells to a marked, tested pack — through cell sorting, module building and testing, sub-assembly, two pack lines and laser marking, all on Mitsubishi PLCs feeding Mitsubishi SCADA. A line this instrumented is only as useful as the questions you can ask of it. The data was all there — but each station used a different QR mix, so one line-wide trace meant correlating tables by hand. Enter the Itanta Core Platform: deployed on top of the line, it turns that multi-zone SCADA data into single-scan traceability for production, quality and engineering. ## The Challenge The line captured everything. Turning it into one traceable record was the hard part. - **Data scattered across zones:** A full report had to pull from six zones and dozens of stations — with no common search flow to tie them together. - **QR codes differed station to station:** Module, TCH, BCH, RH-Cover, LH-Cover and Marking QRs all mattered, but no single station carried them all. - **Tracing was a manual hunt:** Following one pack end-to-end meant opening table after table and matching QRs by hand — slow and error-prone. - **Data locked inside SCADA:** Everything lived in Mitsubishi SCADA on SQL Server, with no searchable reporting layer around it. - **Hard to verify a station fast:** Process time, torque, angle and OK/NG status sat in separate records, so a quick health check meant cross-referencing. - **No shared data language:** Each zone spoke its own dialect, so line-wide questions couldn't be asked in one place. ## Highlights - Built on the Itanta Core Platform — deployed on top of the existing line - Full line traceability from a single Marking QR-Code - All six production zones consolidated - End-to-end QR linking — Module, TCH, BCH, RH-Cover, LH-Cover, Marking - Station-wise reports for P10, P20, P40, P50, P70, P120, P170 and more - Reads from Mitsubishi SCADA via the Itanta SQL Connector A searchable traceability layer on top of an existing Jendamark line — no change to the PLCs or SCADA, built around data the line already produces. ## How the Itanta Core Platform Sits On Top of the Line ### Assembly line → Mitsubishi PLCs Every station across all six zones and laser marking runs on Mitsubishi PLCs, capturing parameters and QR-coded results for each part. ### Mitsubishi SCADA → SQL Server PLC data aggregates into Mitsubishi SCADA, which logs every event to SQL Server — the line's system of record. ### Itanta SQL Connector → Core Platform The Itanta SQL Connector reads from SCADA (software version 6.00.00.07) into the Core Platform — leaving controllers and SCADA untouched. ### QR mapping in the Core Platform The platform links Module, TCH, BCH, cover and Marking QRs once, so a single reference resolves to every station a pack passed through. ### Entire-line & zone-wise reports On top of the mapped data: an Entire Line Report searchable by Marking QR, plus zone reports with station filtering, OK/NG status and export. ## The Solution _How the Itanta Core Platform turns multi-zone SCADA data into single-scan traceability._ - **Single-scan traceability:** One Marking QR-Code returns a pack's full history across every zone and station — no more matching QRs by hand. - **Every zone, one report set:** Cell Sorting, Module Building, Module Testing, Sub-Assembly and both Pack Lines, unified into one consistent set of reports. - **QR-linked station joins:** Module, TCH, BCH, RH-Cover, LH-Cover and Marking QRs are mapped once in the platform, not rebuilt for every query. - **Station-wise reporting & export:** Per-station views of process time, torque, angle and OK/NG status — filterable and exportable on demand. ## Royal Enfield Line — Reports & Dashboards Full line traceability by Marking QR, plus zone- and station-wise reports with parameters, results and OK/NG status. - **Cell Sorting — BSA60 Station:** Station-wise report for the BSA60 cell-sorting station: date/time, time difference, shift, part QR-code, box QR, cell QR, grade and per-cell station result — every sorted cell, queryable after the fact. - **Cell Sorting — BSA10 Zone Report:** Zone-wise report for BSA10 with per-shift part counts and an OK/NG status split, backed by a detailed table of date/time, box barcode and station name — the health of the zone at a glance. - **Cell Sorting — BSA50 Zone Report:** BSA50 cell-sorting report showing shift-wise throughput, OK/NG distribution and the underlying records (box QR, station name, row number, cell QR) for the sorted cells. - **Sub-Assembly — PSA20 Report:** Sub-assembly report for station PSA20 with shift-wise part counts, OK/NG status and a detailed log of time difference, shift, station name and part QR-code for each assembled part. - **Pack Line-1 — PSA50 Report:** Pack Line-1 report at station PSA50: shift-wise output, OK/NG split and a record of date/time, shift, station name and RH-cover QR — traceability for the pack-build stage. - **Pack Line-2 — P70 Report:** Pack Line-2 report for station P70 with shift-wise counts, OK/NG status and the detailed table of date/time, shift, station name and RH-cover QR for every pack on the second line. ## Results What changed once the Itanta Core Platform sat on top of the line. - **One scan, whole line — Full history from a single Marking QR.** One scan returns a pack's complete, consolidated history — no more matching QRs table by table. - **Six zones, one view — Every zone consolidated.** Cell sorting, module building and testing, sub-assembly and both pack lines, unified into one report set. - **Faster root-cause — Linked records replace manual correlation.** QRs are mapped once, so tracing a deviation becomes a search instead of a manual reconstruction. - **Less manual effort — Station health, on demand.** Per-station views and export make it easy to check any station or shift for quality and production review. ## Bottom Line The Itanta Core Platform gives Jendamark's Royal Enfield battery line the one thing it lacked — a single, searchable record that ties every station together by QR code. - QR relationships mapped once across zones, not per query - Reads existing Mitsubishi SCADA — no change to PLCs or SCADA - One Marking QR resolves the full line history - Zone- and station-wise reports with OK/NG and export --- # FIAPL's Manufacturing Transformation: From Vendor Reliance to Operational Excellence with Itanta URL: https://itanta.ai/success-stories/fiat-line-losses-operational-excellence-itanta Company: FIAT India Industry: Automotive Manufacturing > Discover how Itanta's no-code manufacturing analytics platform reduced downtime and delivered measurable ROI in automotive production ## Challenge FIAPL struggled with frequent data errors, limited analytics capabilities, and an OPE stuck at 60%. Production teams relied on reactive maintenance with no early warning systems, causing cascading delays across 18+ production lines. ## Outcome Itanta deployed an intelligent Line Losses solution with real-time analytics and mobile alerts across Assembly, Paint Shop, and PBS operations—boosting OPE from 60% to 70%, enabling 1,000+ dashboards, and eliminating vendor dependency. ## At a glance - **60→70%** — OPE Improvement - **1,000+** — Custom Dashboards - **18+** — Production Lines Monitored ## About FIAT India FIAT India Automobiles Private Limited (FIAPL) is a joint venture between Tata Motors and Stellantis, operating complex multi-line automotive manufacturing operations across Assembly Shop, Paint Shop, and Painted Body Storage. Headquarters: Ranjangaon, Pune, Maharashtra, India · Industry: Automotive Manufacturing · Size: Enterprise ## Introduction Every minute of unplanned downtime in automotive manufacturing can cost thousands of dollars in lost production. For companies managing complex multi-line operations, the challenge isn't just identifying when problems occur—it's pinpointing exactly where losses happen and responding fast enough to prevent cascading delays across the entire production ecosystem. This case study reveals how Itanta Analytics transformed Fiat India Automobiles Private Limited's approach to production monitoring, deploying an intelligent Line Losses solution that turned reactive firefighting into proactive optimization. By implementing real-time analytics and instant mobile alerts across Assembly, Paint Shop, and PBS operations, FIAPL gained the visibility and speed needed to slash downtime and consistently hit production targets. ## The Challenge FIAPL's manufacturing operations faced critical production monitoring obstacles across 18+ lines that impacted overall plant effectiveness and created costly vendor dependencies. - **Data Quality & Integration Issues:** Frequent data errors and duplication in existing systems, with data mismatches between actual machine data and generated reports. The fragmented data architecture made it difficult to maintain data integrity across 18+ production lines. - **Limited Analytics & Formula Capabilities:** The existing tool lacked custom formula calculation capabilities, preventing teams from performing complex analytics on production data or calculating key performance metrics like duration analysis and loss categorization. - **Low Overall Plant Effectiveness (OPE):** FIAPL's OPE was stuck around 60%, indicating inefficiencies in production operations with no clear visibility into improvement opportunities or real-time performance tracking. - **Poor User Experience & Visualization:** The legacy system had significant language barrier issues in the UI and provided only basic table-based visualizations with no advanced filtering capabilities. - **Delayed Problem Detection:** Production teams only acted when machines broke down, with no early warning systems. This caused long machine stoppages and chain reactions where one problem led to delays across multiple production lines. - **Dependency on External Support:** FIAPL lacked internal capabilities to manage and customize their production monitoring systems, creating dependency on external vendors for system modifications and analysis. ## Highlights - OPE improved from 60% to 70% through real-time findings and proactive monitoring - 1,000+ customizable dashboards with deep filtering and slideshow views - 40+ data tags logged per second from Rockwell PLCs across 18+ production lines - Mobile alerts for instant notification when downtime exceeds thresholds - 1,992 error codes managed with unified visibility across all production lines - Internal teams trained and empowered to manage analytics without vendor dependency FIAPL's transformation with Itanta proves that the right digital strategy can turn production pain points into competitive advantages. ## FIAT India Automobiles _Automotive Manufacturing Excellence_ FIAT India Automobiles Private Limited (FIAPL) operates complex multi-line automotive manufacturing operations requiring real-time production monitoring and line loss analytics. - Operates 18+ production lines across Assembly Shop, Paint Shop, and PBS operations - Uses Rockwell PLCs generating per-second data streams from each production line - Manages 1,992 error codes across all production lines for loss categorization - Partnered with Itanta Analytics for production monitoring and line loss optimization - Committed to achieving self-sufficiency in manufacturing analytics and operational excellence FIAPL's partnership with Itanta Analytics demonstrates how automotive manufacturers can evolve from reactive operations to proactive, data-driven manufacturing excellence. ## System Architecture ### Data Acquisition Real-time production data is collected from all 18+ production lines across FIAPL's operations. - PLCs from Different Lines: Rockwell PLCs capture critical operational parameters including error codes, station codes, and production status. - Per-second data streams are generated from each individual line across Assembly Shop, Paint Shop, and PBS operations. ### Data Aggregation The aggregation layer consolidates and processes real-time data streams for analytics. - Kepware Server consolidates real-time data streams from all connected PLCs, serving as the OPC UA communication hub. - Itanta DS Manager handles complex analytics computations, manages error code configuration, performs duration calculations using Formula Builder, and executes on-change data logging for real-time monitoring. ### Data Visualization Web-based dashboards deliver real-time findings on production performance. - Itanta Platform delivers 1,000+ dashboards providing real-time findings on line losses, hourly performance data, and station-wise duration analytics. - Multiple dashboard views including shop-wise, UTE-wise, line-wise, and category-wise performance metrics with dynamic filtering capabilities. ### Data Distribution Proactive notification systems ensure rapid response to production issues. - Mobile Alerts instantly deliver critical notifications to production and maintenance teams when downtime exceeds predefined thresholds for specific stations. - Enables rapid response capabilities and immediate corrective actions to minimize production losses across the facility. ## Itanta's Approach _How Itanta Solved These Challenges_ Itanta deployed a comprehensive no-code analytics platform that unified data from 18+ production lines, enabled advanced analytics, and empowered FIAPL's teams to achieve operational independence. - **Unified Data Integration Platform:** OPC UA Connector interfacing directly with FIAPL's Kepware Server to collect real-time data from all Rockwell PLCs across 18+ production lines, logging 40+ data tags per second including error codes - **Advanced Formula Builder & Analytics:** Custom calculations for duration analysis, loss type categorization, and advanced analytics across 1,992 error codes, empowering teams with sophisticated analytical capabilities for data-driven decision making - **Real-Time Performance Optimization:** Real-time monitoring, defect identification, and root cause analysis capabilities helped FIAPL achieve OPE improvement from 60% to 70%, resulting in significant productivity and revenue gains - **Interactive No-Code Dashboards:** 1,000+ customizable dashboards with slideshow views, providing intuitive visualization with deep filtering capabilities—enabling users to trace loss reasons across shop-wise, line-wise, and station-wise dimensions - **Proactive Mobile Alert System:** Mobile alert systems with real-time time loss tracking, enabling faster maintenance actions and proactive response to production issues, significantly reducing unplanned downtime - **Team Training & Independence:** Trained FIAPL's internal teams and provided user-friendly interfaces, enabling them to manage their own production analytics without vendor dependency The result was a complete transformation—from reactive firefighting to proactive optimization, with FIAPL achieving self-sufficiency in manufacturing analytics. ## Sneak Peek of the Dashboards FIAPL's Line Losses dashboards provide multi-dimensional views of production performance, from shop-wise summaries to detailed station-level loss analysis with advanced filtering. - **Line Losses Dashboard — Duration & Location Analysis:** Shop-wise (Pie), UTE-wise (Bar Drilldown), Line-wise (Bar Drilldown), and Station-wise (Bar Drilldown) duration analysis in minutes, with category-wise loss breakdown across all production lines. - **Line Losses Dashboard — Occurrence & Reasons:** Distribution of Occurrence (Donut) and Reasons (Group by Drilldown) with Category-wise (Graph) loss analysis, enabling teams to identify root causes and prioritize corrective actions. ## Results Itanta Analytics delivered transformative results across FIAPL's manufacturing operations, turning a reactive, vendor-dependent operation into a self-sufficient, data-driven manufacturing powerhouse. - **60→70% — OPE Improvement.** Overall Plant Effectiveness boosted through real-time findings and proactive monitoring - **1,000+ — Custom Dashboards.** Customizable dashboards with slideshow views and deep filtering capabilities - **40+ — Tags Per Second.** Data tags logged per second from Rockwell PLCs across all production lines - **1,992 — Error Codes Managed.** Error codes tracked with unified visibility across 18+ production lines - **Zero — Vendor Dependency.** Internal teams fully trained and empowered to manage analytics independently ## Customer Testimonial > With Itanta's no-code analytics interface and seamless integration with automation systems, our team quickly created tailored analytics. Within 1 year of deployment we have made significant savings! — Satej Revankar, CIO, FIAT India Automobiles Private Limited ## Conclusion From operational chaos to manufacturing mastery, FIAPL's transformation with Itanta Analytics proves that the right digital strategy can turn production pain points into competitive advantages. What started as a fragmented, reactive operation evolved into a self-sufficient, proactive manufacturing powerhouse. - Conquering complexity at scale—managing 1,992 error codes across 18+ production lines with unified visibility - Turning alerts into action—mobile notification systems that prevent minor issues from becoming major production disasters - Empowering internal champions—transforming FIAPL teams from vendor-dependent to analytics-independent operators - Building performance momentum—achieving OPE improvements through real-time findings Today, using Itanta, FIAPL doesn't just monitor production—they orchestrate it. Every line, every station, every error code tells a story that drives immediate action and continuous improvement. --- # From Data to Decisions: How SKF Optimized Energy Operations Using Itanta URL: https://itanta.ai/success-stories/skf-energy-optimization-itanta Company: SKF Industry: Manufacturing > Itanta Analytics: Powering real-time energy findings and shift-level visibility without a single line of code. ## Challenge SKF needed a scalable solution to monitor and analyze its top energy consumers—compressors, chillers, and furnaces—across 80+ meters in real time, replacing manual reporting with actionable findings. ## Outcome Using Itanta's no-code analytics platform, SKF achieved 100% automated reporting, integrated 5,000+ energy tags, and realized ROI within 6 months—without writing a single line of code. ## At a glance - **5,000+** — Energy Tags Integrated - **100%** — Automated Reports - **6 Months** — Time to ROI ## About SKF SKF India Ltd., a subsidiary of Sweden-based AB SKF, is a leading provider of bearings, seals, mechatronics, lubrication systems, and condition monitoring services. Established in 1923, SKF has grown into a cornerstone of India's industrial landscape. Headquarters: Pune, India · Industry: Manufacturing & Precision Engineering · Size: Enterprise (10,000+) ## Introduction The ability to monitor, analyze, and act on energy usage in real time supports operational efficiency and sustainability. SKF needed a scalable solution to monitor and analyze its top energy consumers—compressors, chillers, and furnaces—and make informed decisions. This case study explores how SKF, a global leader in precision engineering, leveraged the Itanta Analytics platform to modernize its Energy Management System (EMS) at its Bangalore facility. ## The Challenge Before Itanta, SKF's Bangalore facility faced several critical obstacles in managing energy operations effectively. - **Manual Data Collection:** Energy data from 80+ meters across compressors, chillers, and furnaces was gathered manually—consuming valuable engineering hours and introducing delays in decision-making. - **Fragmented Visibility:** No unified view existed across equipment types and shifts. Data was siloed in spreadsheets and disconnected systems, making cross-functional analysis nearly impossible. - **Delayed Reporting:** Reports were generated manually on a weekly or monthly basis, meaning anomalies and inefficiencies were discovered too late to take corrective action in real time. - **Scalability Constraints:** The existing approach couldn't scale as SKF added more meters and data points. Custom-coded solutions required IT involvement and long development cycles. - **No Real-Time Alerts:** Without automated monitoring, unusual consumption spikes or equipment anomalies went unnoticed until the next manual review cycle. - **Sustainability Tracking Gap:** SKF's Lean, Green, Digital (LGD) strategy demanded precise energy tracking to meet sustainability goals—but the existing tools couldn't deliver the granularity needed. ## Highlights - Unified platform for monitoring 80+ energy meters in real time - Custom dashboards for shift-wise and equipment-level visibility - Live data updates every few minutes—no coding required - Helps align plant operations with sustainability and smart factory goals - Scalable success—SKF expanded Itanta to other plant sites after proven results at the initial facility This is not just a case of digital transformation—it's a blueprint for how industrial facilities can harness no-code analytics to turn raw data into real-time intelligence. ## SKF India _Driving Innovation in Engineering and Smart Manufacturing_ SKF India Ltd., a subsidiary of Sweden-based AB SKF, is a leading provider of bearings, seals, mechatronics, lubrication systems, and condition monitoring services. Established in 1923, the company has grown into a cornerstone of India's industrial landscape. - Headquartered in Pune with 6 manufacturing units across the country - Serves critical sectors: automotive, energy, construction, aerospace, and general industry - Backed by a vast distributor and service network across India - Guided by the Lean, Green, Digital (LGD) strategy for sustainable, smart operations - Focus on smart manufacturing and IoT integration to enhance productivity - Initiatives like the "Future Factory" program aim to digitize and streamline operations end-to-end With a focus on innovation and digital transformation, SKF India continues to set benchmarks for operational excellence and sustainable growth in the industrial sector. ## System Architecture ### Data Acquisition The acquisition layer uses Itanta DS Manager to bring data into the system. Two key components enable this: - SQL Connector: Connects to external databases and brings in relevant data efficiently. - Unified Namespace Configuration: Organizes incoming data in a clear and consistent way, making it easier to manage, access, and use across the system. ### Data Aggregation In this layer, data is processed and transformed using the built-in Formula Builder. - Formula Builder: Allows users to create custom calculations and apply logic to the data—without writing any code. This helps turn raw data into meaningful metrics that match specific operational or business needs. ### Data Visualization This layer enables users to easily interpret data through customizable dashboards. - No-Code Dashboard Builder: Empowers users to build real-time dashboards using drag-and-drop components like pie charts, tables, and line graphs. These visual tools help monitor key metrics such as power consumption metrics. ### Data Distribution The distribution layer supports various channels to share findings and reports, ensuring flexibility in delivery. - Scheduler: Automates the sending of reports and alerts through multiple options such as email, data exports, and notifications. In this case, email was primarily used to keep stakeholders consistently informed and enable timely decision-making. ## Itanta's Approach _No-Code Intelligence, Real-Time Action_ The Itanta platform was deployed as a full-stack, real-time analytics layer over the client's existing SCADA and PLC infrastructure. It brought together data, automation, and visualization—without requiring custom code or IT complexity. - **Native SQL Connector:** Pull live data from SCADA/PLC systems seamlessly - **Unified Dashboards:** Monitor View and Graphical View gave stakeholders a complete view of energy flow—across all sources and consumption points - **Formula Builder:** Automated daily, shift-wise, and monthly consumption calculations—minimizing manual reporting - **Live Data Refreshes:** Ensured timely detection of anomalies or sudden spikes in usage - **Shift Configuration:** Enabled clear performance comparisons across shifts, helping identify patterns and inefficiencies - **Role-Based Access:** Delivered personalized views for operators, engineers, and managers—so each team saw only the data they needed The result was faster findings, better alignment across teams, and data-led decisions at every level. ## Sneak Peek of the Dashboards SKF's energy monitoring dashboards provide comprehensive views for operators and managers to track energy usage patterns at a glance. - **Monitor View:** Tables and pie charts are used to show the consumption across all energy sources in real time. - **Consumption Overview:** Displays real-time energy consumption data across various sources like EB, DG, and Solar, along with power factor and transformer metrics. ## Results Itanta's analytics platform delivered real-time, shift-wise findings for operational decisions. - **5,000+ — Energy Tags Integrated.** Energy tags integrated from Iconic Scada - **100% — Automated Reports.** Automated report generation - **6 Months — Time to ROI.** The implementation achieved a clear return on investment (ROI) within just 6 months - **360° — Operational Visibility.** Operational perspective across energy sources and consumption points gained by the stakeholders - **Improved — Decision-Making.** Shift-level analysis allowed teams to track and compare performance across 3 daily shifts. All meter data was unified into one platform, reducing information silos. ## Conclusion The successful deployment of Itanta Analytics at SKF showcases how modern manufacturers can unlock real-time energy intelligence through a no-code, scalable, and highly integrable platform, which provided SKF with a unified, intuitive view of its entire energy ecosystem. - Unified energy view across the entire plant—live, accurate, and accessible - No-code platform—enabled fast setup with zero coding or IT burden - Native connectors—seamless data flow from 80+ meters and sources - Live dashboards—operational findings for engineers, planners, and leadership - Faster decisions—eliminated delays caused by manual reporting - Reduced costs—no need for custom development or technical resources - Supports sustainability goals—through real-time energy tracking and optimization In a world where data is the new utility, Itanta Analytics enables manufacturers to not just collect data—but to act on it, in the moment it matters. Itanta isn't just a platform—it's a catalyst for smart, data-driven manufacturing. --- # From Manual to Digital: Itanta Analytics Powers FIAT India's Smart Workforce Management URL: https://itanta.ai/success-stories/fiat-workforce-management-itanta Company: FIAT India Industry: Automotive Manufacturing > How real-time analytics and intelligent employee substitution transformed FIAPL's workforce challenges ## Challenge FIAPL struggled with manually allocating workers to assembly lines based on skill sets, requiring 1.5 hours at every shift start. The complex four-level skill matrix across assembly lines was difficult to manage, leading to production delays and skill mismatches. ## Outcome Itanta Analytics transformed FIAPL's Associate Management system with a web-based solution for real-time attendance tracking, skill matrix management, and intelligent line balancing—reducing allocation time by 85% from 1.5 hours to just 10 minutes. ## At a glance - **85%** — Faster Workforce Allocation - **240 Min** — Saved Daily - **9x** — Faster Deployment ## About FIAT India FIAT India Automobiles Private Limited (FIAPL) is a joint venture between Tata Motors and Stellantis, operating automotive assembly shop operations with multi-shift workforce management across multiple production lines. Headquarters: Ranjangaon, Pune, Maharashtra, India · Industry: Automotive Manufacturing · Size: Enterprise ## Introduction FIAT India Automobiles Private Limited (FIAPL) partnered with Itanta Analytics, a no-code industrial analytics platform, to transform their workforce management challenges. Itanta Analytics specializes in connecting to industrial automation systems without requiring coding expertise, integrating seamlessly with PLCs, SCADA, and SQL databases. This collaboration revolutionized FIAPL's Associate Management system for Assembly Shop operations by implementing a web-based solution for real-time attendance tracking, skill matrix management, and intelligent line balancing. ## The Challenge FIAPL's assembly shop operations faced critical workforce management obstacles that impacted production efficiency across multiple shifts. - **Workforce Visibility Crisis:** Manually allocating workers to assembly lines based on skill sets required 1.5 hours at every shift start, leading to production delays. The complex four-level skill matrix (K, KP, KPR, KPRT) was difficult to manage, causing skill mismatches. - **Production Line Disruptions:** Production delays occurred when planned employees didn't show up and there was no automated substitution process. Three rotating shift groups with weekly rotations created line balancing issues affecting overall assembly shop efficiency. - **Data Fragmentation:** Attendance data was isolated from planning systems in SQL databases, with master and plan data managed separately. This created reporting gaps and limited real-time visibility into workforce deployment status for managers and shift supervisors. ## Highlights - 85% reduction in daily workforce allocation time (1.5 hours to 10 minutes) - Intelligent employee substitution based on four-level skill matching - Real-time attendance tracking eliminating workforce blind spots across three shifts - Unified dashboard integrating all workforce data into a single interface - Zero coding required for implementation using drag-and-drop interface This implementation proves Itanta's effectiveness in transforming automotive manufacturing operations through smart, no-code solutions. ## FIAT India Automobiles _Automotive Manufacturing Excellence_ FIAT India Automobiles Private Limited (FIAPL) is an automotive manufacturing company operating complex assembly shop operations with multi-shift workforce management. - Operates assembly shop operations with multiple production lines - Manages a multi-shift workforce with three rotating shift groups - Utilizes a four-level skill matrix (K, KP, KPR, KPRT) for worker competency tracking - Partnered with Itanta Analytics for digital workforce transformation - Committed to operational excellence through data-driven manufacturing FIAPL's partnership with Itanta Analytics demonstrates how automotive manufacturers can achieve dramatic efficiency gains through intelligent workforce management. ## System Architecture ### Data Acquisition The acquisition layer captures three critical data streams for workforce management. - Operators Master Data: Employee skill matrices and competency levels across the four-level system (K, KP, KPR, KPRT). - Operators Live Punch Data: Real-time attendance from biometric systems capturing clock-in/clock-out events. - Shift Info: Shift schedules, rotations, and timing configurations for three rotating shift groups. ### Data Aggregation The aggregation layer processes and correlates multiple data sources for intelligent workforce decisions. - SQL Database serves as the central repository consolidating all workforce data from master records, live attendance, and shift schedules. - Itanta DS Manager processes and correlates attendance with skill profiles, while business logic matches employees with station requirements and calculates optimal substitutions. ### Data Visualization The visualization layer delivers real-time workforce status through interactive, color-coded dashboards. - Interactive dashboards show real-time workforce status across all assembly lines with color-coded indicators: Green (present), Red (absent), Blue (assigned), Yellow (substituted). - Multi-level views from high-level daily summaries to detailed station-level information with operator names and skill sets. ### Data Distribution The distribution layer ensures the right information reaches the right stakeholders. - Managers receive workforce planning and resource allocation findings, while shift supervisors get real-time operational adjustments and deployment data. - Team leaders access line-specific status and substitution recommendations, and ICT teams monitor system health and data integrity. ## Itanta's Approach _No-Code Solutions in Action_ Itanta's no-code platform was deployed to digitize FIAPL's entire workforce management process—from attendance tracking to intelligent substitution—without writing a single line of code. - **Real-Time Intelligence:** Integrated attendance data, skill matrices, and punch data through live SQL connectors to provide instant workforce visibility. Managers complete worker allocation in 10 minutes instead of 1.5 hours - **Smart Substitution:** Intelligently matches absent employees with available workers based on skill levels (KP, KPR, KPRT) and station requirements, automatically identifying suitable replacements from present, unassigned workers - **Unified Dashboard:** Comprehensive web-based dashboard integrating all workforce data into a single interface with multiple view levels from daily summaries to detailed line operations - **No-Code Configuration:** Entire system implemented using drag-and-drop interface without complex coding. Manual data entry forms enable easy updates through individual entries and bulk Excel uploads - **Color-Coded Status Tracking:** Visual indicators across all views: Green for present, Red for absent, Blue for assigned, and Yellow for substituted employees—providing instant operational awareness - **Historical Data Analytics:** Tracks workforce patterns over time for informed decision-making, enabling trend analysis across shifts and identification of recurring attendance or skill gap patterns The result was a complete transformation of FIAPL's workforce management—from manual, error-prone processes to an intelligent, automated system delivering unprecedented visibility and control. ## Sneak Peek of the Dashboards FIAPL's workforce management dashboards provide multi-level views from daily summaries to detailed station-level information with color-coded status indicators. - **Assembly - Trim Line 1 Dashboard:** Daily summary report containing line-wise Assembly Shop employee data, providing a comprehensive overview of workforce deployment across all stations. - **Line Wise Overview Dashboard:** Color-coded operation view where Green indicates present employees, Red shows absent, Blue marks assigned workers, and Yellow highlights substituted positions. - **Line Wise Detailed View Dashboard:** Detailed station-level view showing skill sets and operator names for each operation on every station, enabling precise workforce management decisions. ## Results Itanta Analytics delivered dramatic efficiency gains across FIAPL's assembly shop operations, transforming workforce management from a manual bottleneck into a streamlined, data-driven process. - **85% — Time Reduction.** Daily allocation time reduced from 1.5 hours to just 10 minutes - **9x — Faster Deployment.** Workforce deployment process accelerated nine-fold - **240 Min — Daily Savings.** Minutes saved daily across 3 shifts from workforce allocation improvements - **Zero — Production Delays.** Eliminated production delays from workforce allocation issues - **No-Code — Implementation.** Deployed in weeks rather than months with zero coding required ## Customer Testimonial > With Itanta's no-code analytics interface and seamless integration with automation systems, our team quickly created tailored analytics. Within 1 year of deployment we made significant savings! — Satej Revankar, CIO, FIAT India Automobiles Private Limited ## Conclusion Itanta Analytics successfully transformed FIAPL's complex workforce management challenges into streamlined assembly shop operations. By replacing manual processes with intelligent automation, the no-code platform delivered unprecedented visibility and control over their multi-shift workforce. - 85% time reduction in daily workforce allocation (1.5 hours to 10 minutes) - Eliminated workforce blind spots across three shifts with real-time attendance tracking - Reduced production delays through automated employee substitution based on skill matching - Unified data systems providing managers complete workforce visibility in one dashboard - Zero coding required for implementation, significantly reducing deployment time and costs This implementation proves Itanta's effectiveness in transforming automotive manufacturing operations through smart, no-code solutions. --- # Industrial Fleet Monitoring and Clear Operational Findings: The Masibus Story URL: https://itanta.ai/success-stories/masibus-icl-compressor-monitoring-itanta Company: Masibus & ICL Industry: Industrial Automation / Compressor Manufacturing > How Itanta Built a Game-Changing Web Dashboard for India's Automation Giant ## Challenge Indian Compressors Limited (ICL) needed a robust IIoT platform to monitor 100+ compressors across multiple locations. Its automation partner Masibus had the IoT hardware, but the initial Power BI implementation couldn't handle the complex visualizations and real-time data processing ICL required. ## Outcome Itanta Analytics stepped in as the pure-play IIoT platform provider, delivering a comprehensive monitoring solution that scaled ICL from monitoring 1 compressor to 100+ compressors within just 6 months—achieving complete fleet visibility, improved uptime, and centralized performance monitoring. ## At a glance - **100+** — Compressors Monitored - **6 Months** — From 1 to 100+ - **264+** — Data Tags Integrated ## About Masibus & ICL Indian Compressors Limited (ICL) is a global compressor manufacturing company established in 1943, operating a large fleet of assets across multiple locations. Masibus, ICL's automation partner, provided the IoT hardware solution, while Itanta Analytics delivered the IIoT platform powering real-time fleet monitoring. Headquarters: India · Industry: Industrial Automation / Compressor Manufacturing · Size: Enterprise ## Introduction Industrial equipment monitoring is critical for maximizing uptime and operational efficiency. Companies with large fleets of assets need real-time visibility into equipment health, performance parameters, and predictive maintenance alerts to prevent costly downtime. Indian Compressors Limited (ICL), a global compressor manufacturing company established in 1943, needed a robust IIoT platform to monitor their fleet of 100+ compressors across multiple locations. Masibus, ICL's automation partner, provided the IoT hardware solution but faced challenges with their initial Power BI implementation—it couldn't handle complex visualizations and real-time data processing that ICL required. Itanta Analytics stepped in as the pure-play IIoT platform provider, delivering a comprehensive monitoring solution that transformed ICL's operations from monitoring 1 compressor to 100+ compressors within just 6 months. This case study showcases how the right IIoT platform partnership enabled ICL to achieve complete fleet visibility, improved compressor uptime, and centralized performance monitoring across their entire operation. ## Pain Points in Fleet Monitoring Before Itanta, ICL lacked the unified, real-time visibility needed to manage a growing fleet of compressors across multiple sites. - **No Live Monitoring:** ICL lacked centralized visibility into compressor health across multiple assets and locations, making it impossible to monitor fleet performance and predict maintenance needs. - **Data Fragmentation:** ICL's 264 data tags from compressors, sensors, and energy meters were scattered across isolated systems with no unified view of their growing compressor fleet. - **Manual Processes:** ICL's staff spent time on manual processes for daily, monthly, and yearly compressor performance reports, preventing focus on proactive maintenance and fleet optimization. - **Power BI Limitations:** ICL's initial Power BI solution couldn't handle complex customer visualization requests and struggled with real-time data processing from compressor sensors, causing delays in critical monitoring. - **Poor Equipment Uptime Management:** Without real-time alerts and service history tracking, ICL couldn't proactively manage compressor health, leading to unexpected downtime and reactive maintenance approaches. ## Highlights - Scaled from 1 compressor to 100+ compressors monitored in just 6 months - Integrated 264+ MQTT data tags into a single unified IIoT platform - Replaced Power BI with purpose-built, real-time fleet dashboards - Automated daily, monthly, and yearly compressor performance reports - Predictive maintenance with real-time alerts to service teams When hardware expertise from Masibus met Itanta's advanced IIoT platform, ICL achieved rapid, scalable digital transformation. ## Indian Compressors Limited _A Global Compressor Manufacturer Since 1943_ Indian Compressors Limited (ICL) is a global compressor manufacturing company with a large fleet of assets deployed across multiple locations. To manage a rapidly growing fleet, ICL needed real-time visibility into equipment health, performance, and maintenance needs—delivered through the Masibus-Itanta partnership. - Established in 1943 as a global compressor manufacturing company - Operates a fleet of 100+ compressors across multiple locations - Generates 264+ data tags from compressors, sensors, and energy meters - Partnered with Masibus for IoT hardware and Itanta Analytics for the IIoT platform - Required real-time monitoring, predictive maintenance, and automated reporting at fleet scale - Needed to move beyond Power BI's visualization and real-time processing limitations ICL's growing fleet demanded an enterprise-grade IIoT platform capable of scaling from a single compressor to its entire operation. ## System Architecture ### Data Acquisition from Compressor The process begins with continuous collection of operational parameters from the compressor, serving as the primary source of machine data. ### Edge Processing via IoT Device The data flows into an IoT Device, where it is preprocessed, filtered, and formatted for reliable transmission with minimal latency. ### Central Data Management — Itanta DS Manager (MQTT Connector) Using the MQTT Connector, data is securely transmitted to Itanta DS Manager, which acts as the central hub for managing, routing, and ensuring seamless real-time communication. ### Visualization The processed data is delivered to the Itanta Platform, where operators can access dashboards, analytics, and real-time performance monitoring tools. ### Writeback Functionality Writeback allows operators to adjust parameters or send instructions directly back to compressors via the IoT infrastructure, ensuring a closed-loop monitoring and control system. ## How Itanta Transformed ICL's Operations _A Purpose-Built IIoT Platform for Fleet-Scale Monitoring_ Itanta replaced ICL's limited Power BI setup with a purpose-built IIoT platform—unifying data, automating reports, and delivering real-time, color-coded fleet dashboards that scaled to the entire compressor operation. - **Centralized Fleet Command Center:** Designed unified web-based dashboards giving ICL's central team complete visibility into how each compressor performs at any given time across all locations. - **Advanced IIoT Data Integration:** Replaced Power BI with a purpose-built platform that integrated all 264+ MQTT data tags into a unified system capable of handling complex visualizations and real-time compressor monitoring. - **Automated Reporting & Fleet Scaling:** Developed automated daily, monthly, and yearly reports with the capability to rapidly scale from monitoring 1 compressor to 100+ compressors within 6 months. - **Real-Time Dashboard System:** Created comprehensive dashboards displaying live pressure, temperature, compressor status, alarms, and equipment conditions with color-coded indicators—solving Power BI's visualization limitations. - **Predictive Maintenance & Service Management:** Implemented organized digital systems for service tracking, alarm logging, and real-time alerts to service teams, dramatically improving compressor uptime and operational efficiency. The result was a scalable, real-time IIoT platform that turned ICL's compressor fleet management from reactive to proactive. ## Sneak Peek into the Dashboards ICL's dashboards deliver consolidated, real-time views of dispenser operations, daily performance, and pressure parameters across the compressor fleet. - **Dispenser Reading Dashboard:** Fixed table layout displays comprehensive details for both Disp1 Hose and Disp2 Hose operations in one consolidated view. Conditional formatting uses binary indicators (0=Close, 1=Open) for filling status, bank levels, output valves, and PT01/02 system health. Real-time metrics show last fill quality, amount, flow meter totals, dispenser totals, and current gas rates. - **Daily Report Dashboard:** Dynamic table format displays hourly operational data with automated calculations for suction, discharge, energy consumption, and runtime metrics. Comprehensive tracking monitors open/close values for suction, discharge, KWh consumption, and operating hours with automatic difference calculations and runtime formulas. - **Pressure Parameters Dashboard:** Six pressure gauges display real-time values for Gas Inlet, Direct, High, Low, Air Compressor, and Water Pressure systems. Color-coded indicators use red, green, and yellow to instantly show high, medium, and low-pressure ranges, with live data aggregation from connected sensors. ## Rapid Fleet Scaling Success From 1 to 100+ compressors in 6 months—the Masibus-Itanta partnership delivered exactly what ICL needed: a scalable IIoT platform that transformed fleet management from reactive to proactive. - **100+ — Compressors Monitored.** Complete real-time visibility across ICL's entire compressor fleet - **6 Months — 1 to 100+ Scaling.** Rapid adoption demonstrating enterprise-grade platform scalability - **264+ — Data Tags Unified.** All MQTT data tags integrated into a single purpose-built platform - **Real-Time — Fleet Dashboards.** Advanced IIoT visualizations replacing Power BI's limitations ## Conclusion The Masibus-Itanta Analytics partnership delivered exactly what ICL needed—a scalable IIoT platform that solved Power BI's limitations and transformed their compressor fleet management from reactive to proactive. - 1 compressor → 100+ compressors monitored in 6 months - Power BI limitations → advanced real-time IIoT platform - Reactive maintenance → predictive alerts and uptime optimization - Disconnected operations → centralized fleet visibility - Custom visualization challenges → flexible, purpose-built dashboards When hardware expertise (Masibus) meets advanced IIoT platform capabilities (Itanta), industrial companies can achieve rapid, scalable digital transformation that delivers measurable operational improvements. --- # Itanta Transforms Cypress County Water Operations URL: https://itanta.ai/success-stories/cypress-county-water-operations-itanta Company: Cypress County Industry: Municipal Water Management > How Cypress County eliminated manual processes and achieved real-time water management with Itanta Analytics platform. ## At a glance - **90%** — Deployment Time Reduced - **41** — Parameter Formulas - **50%+** — Report Engineering Time Saved ## About Cypress County Cypress County is a municipal district located in southeastern Alberta, Canada, delivering essential water services to a large rural population through a mix of public infrastructure and regional cooperatives. Headquarters: Dunmore, Alberta, Canada · Industry: Municipal Water Management ## Introduction Cypress County in Alberta, Canada, partnered with Itanta to modernize their water management operations at Seven Persons Booster Station and Water Treatment Plant. Facing challenges with manual data logging, limited real-time visibility, and time-intensive compliance reporting, the county needed a digital solution that could integrate with their existing VTSCADA system. By cutting deployment time by almost 90%, Itanta's platform enabled a rapid shift from manual operations to intelligent automation, bringing real-time visibility and effortless regulatory compliance to this municipal water management. ## Challenges and Requirements - **Manual Data Collection & Processing:** Seven Persons facilities required manual logging of all water plant parameters, which increased logging hours and human error. - **VTSCADA Data Accessibility Limitations:** Existing VTSCADA proprietary database format restricted data access and historical analysis capabilities for operational teams. - **Time-consuming Compliance Reporting:** Monthly and annual regulatory reports required extensive manual compilation, calculation, and formatting. - **Lack of Real-Time Operational Visibility:** No continuous monitoring capabilities for critical parameters like flow rates, chlorine levels, pressure, and turbidity across facilities. - **Need for Flexible Data Management:** Required ability to modify data when necessary while maintaining complete audit trails and operator management capabilities. - **Web-Application Platform:** Required HTML5-compatible platform accessible through standard browsers with filtering capabilities and manual entry forms. ## Highlights - VTSCADA Historical Values Connector v5.0.1 - 5-minute cyclic data transfers - 41 specific parameter formulas - HTML5 web application platform - Real-time parameter monitoring - Complete audit trails ## Background Cypress County, located in southeastern Alberta, delivers essential water services to a large rural population through a mix of public infrastructure and regional cooperatives. Given its vast geographical area and dispersed population, the county has adopted a flexible and resilient approach to water distribution. Water is supplied through multiple sources, including private groundwater wells, truck-fill stations, and regional water cooperatives. Many rural residents rely on cisterns that are filled by trucked water or connected to cooperative pipelines that deliver treated potable water. In specific hamlets like Elkwater and Bullshead, untreated raw water is also available for non-potable purposes. In response to environmental variability, Cypress County also follows a multi-stage Drought Management Plan aligned with the City of Medicine Hat's water supply strategy. This plan ensures sustainable usage through conservation measures and water restrictions during periods of drought. ## Laying the Digital Foundation ### System Overview To address these challenges, rather than relying on manual processes, the solution called for a more integrated, scalable, and intelligent system. This led to the implementation of a robust architecture designed to streamline data flow, enable real-time monitoring, and support informed decision-making across operations. ### How the System Works - Lift Stations (on the left): These are physical locations where pumps are used to move water. Each lift station collects data like water levels, pump activity, and system status. - PLCs (controllers): Each lift station sends its data to a small controller (called a PLC). This controller organizes the data and sends it onward. - Network Switch: All the data from the controllers is gathered at a central point (like a data traffic hub) to be sent further up the system. - Firewall and Security: Before the data reaches the main system, it passes through a security layer that protects it from unauthorized access. - DMZ Switch: Another layer helps safely pass the information into the central monitoring area without exposing internal systems directly. - VTScada Server with Itanta Dashboard: This is the control center where all the data is displayed in one place. Here, users can check current status, receive alerts and alarms, view detailed data and monitor the system in real time. ## Solutions - **Automated Data Integration System:** Itanta VTSCADA Historical Values Connector (v5.0.1) eliminates manual data logging with 5-minute cyclic transfers from VTSCADA to accessible Itanta-DB format. - **Automated Report Generation:** Created 41 specific parameter formulas delivering automated monthly and annual SLS reports with regulatory formatting and compliance standards. This reduced the report engineering time by more than 50%. - **Real-Time Parameter Monitoring:** Continuous tracking of gas meters, chlorine scales, flow rates, turbidity, and all critical water treatment parameters with instant visibility. - **Improved Data Management:** Manual entry forms with right-click undo functionality, complete audit trails, and Excel connector integration for operator data management. - **HTML5 Web Application Platform:** Browser-compatible interface with filtering capabilities, dynamic dropdowns, and cascade filtering accessible to all stakeholder groups. ## Dashboard Images - **1. Annual Report:** - **2. Water Report Summary:** ## Conclusion Cypress County's partnership with Itanta Analytics successfully transformed their water management from manual processes to automated, real-time operations. The VTSCADA Historical Values Connector eliminated manual data logging while delivering automated compliance reporting that meets Canadian regulatory standards. - Eliminated manual data entry across Seven Persons facilities. - Enabled 24/7 real-time monitoring of critical water parameters. - Automated regulatory reporting processes. - Created scalable foundation for future expansion. This transformation demonstrates how municipal water utilities can leverage proven analytics solutions to enhance operational efficiency, ensure compliance, and build proactive water management capabilities. --- # Itanta transforms MAHLE's shop floor with live production findings URL: https://itanta.ai/success-stories/mahle-anand-filter-systems-real-time-production-itanta Company: MAHLE Industry: Automotive Components > Itanta's no-code platform brings real-time production visibility, OEE tracking and much more to MAHLE. ## Challenge Machine data and manual records sat in silos across MAHLE's Pune plant, with no shift-wise plan-vs-actual tracking and no live view of OEE — making timely decisions across management, engineering, supervision and quality difficult. ## Outcome Itanta deployed a no-code web analytics platform on top of MAHLE's existing Siemens PLCs and MySQL database — delivering live OEE (Availability, Performance, Quality) across every line, shift-wise plan vs actual, and role-based dashboards on any browser. ## About MAHLE MAHLE Anand Filter Systems Private Limited is one of four MAHLE manufacturing plants in India. The Pune facility specializes in Oil and Air Filters for the automobile sector, primarily supplying Bajaj and TATA for lightweight vehicles. Headquarters: Pune, India · Industry: Automotive Components — Oil & Air Filters ## Introduction Itanta Analytics partnered with MAHLE to deploy a real-time web analytics platform at their MAHLE ANAND Filter Systems Pvt Ltd. facility in Pune, Chennai and Delhi, delivering live OEE metrics — Availability, Performance, and Quality across all production lines. By connecting directly to MAHLE's MySQL database and enabling structured manual data entry, Itanta gave plant managers and engineers a unified, instant view of operational performance. The platform bridged the gap between automated machine data and human-recorded events, covering everything from alarm logging and rejection tracking to variant management and shift-wise production planning. ## Challenges Faced by MAHLE - **Fragmented Data Sources:** Machine data sat in one place, manual records in another, in silos, the two never spoke to each other. There was no single place to see what was actually happening across the plant. - **Disconnected Manual & Machine Data:** Critical operational data like alarms, rejections, and stoppages existed in silos, unconnected from automated machine outputs. - **No Visibility into Production Goals:** Without shift-wise plan vs. actual tracking, MAHLE had no baseline to measure OEE Performance against, making it difficult to identify where production was falling short of targets. - **Lack of Real-Time Production Visibility:** MAHLE had no unified view of live production performance, limiting timely decision-making across all teams and levels. ## ## Network Architecture ### Shop Floor Data Pipeline MAHLE's shop floor connects all line counters to Siemens Smart PLCs, transmitting data wirelessly through a central Wi-Fi gateway. A Maintenance PC consolidates manual inputs like alarms, rejections, and variant updates alongside machine data into a MySQL database, forming a single source of truth. ### Itanta Platform Layer Itanta's platform connects directly to MySQL, calculating live OEE metrics across all production lines and surfacing them through purpose-built dashboards tailored to each user group — giving management, engineers, supervisors, and the quality team relevant findings. ## How Itanta Solved These Challenges _Solutions_ - **Direct MySQL Integration:** Itanta connected the platform directly to MAHLE's MySQL database via Delta PLCs and a Wi-Fi network, establishing a reliable, real-time data pipeline from the shop floor. - **Unifying Shop Floor Data:** Structured data entry for alarms, rejection counts, and variant updates consolidated human-recorded and machine-generated data into one unified platform. - **Shift-Wise Planning & OEE Analytics:** Itanta enabled shift-level plan vs. actual tracking alongside OEE calculations; Availability, Performance, and Quality, turning raw data into actionable metrics. - **Real-Time Visibility Across the Plant:** Itanta designed purpose-built dashboards for every organizational level — management overviews, line-level reports, and manual input screens, surfacing live production data through an HTML5 web application accessible on any standard browser. ## Snapshots of Dashboards - **Planning Utility:** - **Plan vs Actual Production:** ## Results What changed at MAHLE's Pune plant once Itanta sat on top of the existing PLC and MySQL infrastructure. - **Live OEE, every line — Availability, Performance and Quality calculated in real time.** Plant managers and engineers see the same OEE numbers the lines are producing — no end-of-shift wait, no spreadsheet reconciliation. - **One source of truth — Machine data and manual inputs unified in MySQL.** Alarms, rejections, variant changes and counter values all land in the same place, so cross-checks between human-recorded and machine-generated events finally agree. - **Plan vs actual, by shift — Shift-level production tracking against targets.** Supervisors know within the shift whether a line is on track — not the next morning — and engineering has a baseline to measure Performance against. - **Right view, right team — Role-based dashboards on any browser.** Management overviews, line-level reports, quality screens and manual input forms — each team gets the dashboard built for their decisions, served as a plain HTML5 web app. ## Conclusion MAHLE's Pune facility faced a challenge common to modern manufacturers — fragmented data, manual processes, and no real-time visibility into plant performance. Itanta Analytics stepped in to change that. By deploying a purpose-built web analytics platform, Itanta addressed the core operational gaps: - Live OEE tracking — Availability, Performance, and Quality calculated in real time across every production line - Unified data infrastructure — machine data and manual inputs consolidated into a single MySQL source of truth - Role-based dashboards — purpose-built views for management, engineers, supervisors, and the quality team - Structured manual workflows — alarms, rejections, and variant updates captured and fed seamlessly into the platform --- # Krones Builds the Line. Itanta Builds the Record. URL: https://itanta.ai/success-stories/itanta-krones-coca-cola-bottling-india Company: Krones AG Industry: Food & Beverage Process and Packaging Machinery > How Itanta Turns Krones Lines Into Living Data — Five Deployments Across India's Bottling Network ## Challenge Krones-built beverage lines produced world-class output, but the data around them was effectively write-only — making post-batch quality investigation, pasteurizer audit trails and reporting a manual, time-consuming exercise. ## Outcome Itanta's Core Platform now sits on top of five Krones-equipped beverage lines across India's Coca-Cola bottling network — turning every batch into a searchable, exportable record of ingredient dosing, recipe sequence and pasteurizer events. ## At a glance - **5** — Krones-equipped lines - **501** — Signals logged - **1-Click** — Batch reports (PDF/Excel) ## About Krones AG Krones AG is the world's leading manufacturer of beverage filling and packaging lines. Headquartered in Neutraubing, Germany, Krones designs and delivers complete production lines for soft drinks, juices, water, beer and dairy — covering everything from container production and blending to filling, packaging and material flow management. Krones lines run in virtually every major beverage plant in the world, with a substantial installed base across India's Coca-Cola bottling network. Headquarters: Neutraubing, Germany · Industry: Food & Beverage Process and Packaging Machinery · Size: Global enterprise ## Introduction Krones AG builds the beverage filling and packaging lines that produce a meaningful share of the world's soft drinks, juices, water, beer and dairy. The company's installed base across India's Coca-Cola bottling network is substantial — and growing. But a world-class line is only half the story. The PLCs and HMIs at the heart of a Krones line are designed for live operation, not for the questions that come afterwards from the QA lab, the bottler's sustainability team, the franchise auditor or the plant manager preparing for next quarter's review. This case study describes what happens when Itanta's Core Platform is deployed on top of those Krones lines — turning them into observable, reportable, exportable assets for Krones' end customers. ## Challenges Faced by Krones A modern Krones beverage line is a marvel of process engineering. The data layer around it, traditionally, is a different story. - **Batch data was effectively write-only:** Live values were visible on the HMI, but historical batches lived inside the controller's local memory — gone by the time a QA query arrived. - **No way to investigate a deviation after the fact:** When a batch came in off-spec on Brix or density, there was no replayable record of where in the recipe the deviation crept in. Root-cause was guesswork. - **Pasteurizer audit trail was effectively manual:** Every flow-diversion valve event had to be logged for food-safety compliance. The data sat inside the PLC; the audit trail did not. - **Reporting was a person, not a system:** Batch reports for QA, bottler audits and the brand owner were assembled by hand from log sheets and PLC printouts — days of engineering time per cycle. - **No common language across stations:** Blender, pasteurizer, utilities skid and filler each spoke their own tag dialect. Cross-station questions couldn't be asked, let alone answered. - **World-class line, second-class record:** For a brand owner like Coca-Cola — with strict traceability requirements across a multi-bottler network — this gap mattered. Mechanical engineering alone couldn't close it. ## Highlights - Deployed across 5 Krones-equipped beverage lines in India - 501 unique signals continuously logged into the Itanta historian - Batch contextualization — every signal value tagged to its batch and recipe - One-click PDF and Excel batch reports for QA, audit and engineering - Pasteurizer phase log with flow-diversion-valve state and contact time - Read-only at the controller — preserves Krones OEM warranty and validation A repeatable, productized data layer on top of Krones equipment — not a custom integration project at each site. ## Background _The line was world-class. The record around it was not._ Krones lines are engineered to extraordinary tolerances. The Contiflow continuous blender doses up to eight ingredients with Brix-controlled accuracy. The juice pasteurizer's flow-diversion valve protects every bottle that leaves the line. The PLCs see everything: every flow rate, every temperature, every valve state, every kilogram of pulp transferred into a tank. For a brand owner like Coca-Cola, with strict quality and traceability requirements across a multi-bottler network, the gap between what the machine sees and what the plant team can later prove mattered. - Soft drinks, juices, water, beer and dairy production lines - Contiflow continuous blender with up to 8-ingredient dosing - Juice pasteurizer with flow-diversion-valve protection - CIP (Clean-In-Place) skid and utilities metering - Substantial installed base across India's Coca-Cola bottlers The framing from Itanta's customer-success team, in the words of the project intake form: "Unable to log batch data from plant." A short sentence for what was really a complete absence of a plant historian wrapped around the Krones equipment. ## How Itanta Sits On Top of a Krones Line ### Cyclic data logging from the Krones PLCs Itanta polls every signal of interest from the Krones controllers — process variables from the blender, the pasteurizer, the CIP skid, the utilities meters — at a regular cycle, and writes each value to a time-series historian with a timestamp. The PLC programmes themselves are not modified, which preserves Krones' OEM warranty and validation envelope. Itanta is read-only at the controller level. ### Batch contextualization Raw signals are not enough on their own. Itanta automatically slices the continuous data stream into batches — recognising when a batch starts, which recipe is running, which destination tank is in use, when the batch ends — and tags every signal value with that context. The result: an engineer can ask "show me batch 2509519" and get every relevant signal for that batch, neatly bracketed, instead of having to chase timestamps across raw historian dumps. ### Exportable batch reports On top of the contextualized data, Itanta generates batch reports the plant's QA, audit and engineering teams can pull on demand. Each report covers the full Krones recipe execution — ingredient-level setpoints versus actual transferred volumes, the step-by-step progression through the recipe sequence, the pasteurizer phase log with flow-diversion-valve state and contact time — and exports cleanly to PDF and Excel. ## Solutions _How Itanta closes the data gap around a Krones line_ - **Continuous historian on top of the PLCs:** Itanta polls every signal of interest from the Krones controllers at a regular cycle and writes each value to a time-series historian — turning write-only batch data into a permanent, queryable record. Read-only at the controller, OEM warranty preserved. - **Batch contextualization & replay:** The continuous data stream is automatically sliced into batches — recipe, destination tank, start/end — so an engineer can pull up any past batch by ID and replay every signal that drove it. Deviations become investigable, not anecdotal. - **One-click batch reports:** QA, audit and engineering teams pull on-demand PDF and Excel reports covering ingredient setpoints vs actuals, recipe-step progression and the pasteurizer phase log — including FDV state and contact time. Days of manual assembly collapse to a click. - **Unified data across stations:** Blender, pasteurizer, utilities skid and CIP are reconciled into one consistent tag schema. Cross-station questions — the kind that matter most when something goes wrong — can finally be asked and answered. ## Krones Dashboards & Batch Reports Live batch parameters, historical batch lookup, and exportable batch dossiers — covering ingredient-level dosing, recipe-step progression and the pasteurizer phase log. - **SLMG Beverages — Juice Pasteurizer Batch Report:** Per-batch production report from the Krones juice pasteurizer at SLMG's Kursi plant. FDV state, flow rates and the full temperature profile across pre-heater, holding coil, cooling coils and product fill — every step of every batch, queryable after the fact. - **LBPL (Ludhiana Beverages) — Flash Pasteurizer Batch Report:** Same productized report at Ludhiana Beverages' Hoshiarpur plant. Identical schema, identical export — the report QA needs is one click away regardless of which Krones-equipped bottler produced the batch. - **MBPL (Moon Beverages) — Flash Pasteurizer Production Report:** Production-parameter report for Moon Beverages' Raninagar plant, including saver-tank dosing, return-product flow and hot-water flow — the variables that distinguish a clean pasteurization run from a marginal one. - **Enrich Agro Food — Blending Station Batch Report:** Ingredient-level dosing record for the Krones blender at Enrich Agro Food's Rohtak plant: every part of the recipe — water, sugar syrup, concentrate parts, pulp components — with start time, end time, set-point and transferred volume per batch. - **Enrich Agro Food — CIP Skid Batch Report:** Step-by-step record of each Clean-In-Place cycle on the Enrich line: program, step, forward and return flow, forward and return temperature, return conductivity. The audit trail the cleaning side of the plant never had. ## Results What changed once Itanta sat on top of the Krones lines across India's bottling network. - **Five lines, one playbook — Repeatable across India's Coca-Cola bottling network.** The same Itanta data layer now sits on top of Krones-equipped lines at SLMG, LBPL, MBPL and the Enrich blending site — a productized rollout, not a series of one-off integrations. - **Every signal, in context — 501 tags continuously historized and batch-tagged.** Process variables from the Krones blender, juice pasteurizer, CIP skid and utilities meters are polled on a fixed cycle, written to a time-series store, and automatically tagged to the batch and recipe they belong to. - **Batch reports on demand — PDF and Excel, in the formats QA already uses.** Engineers no longer assemble batch dossiers by hand. A complete record — ingredient-level dosing, recipe-step progression, pasteurizer phase log with flow-diversion-valve state — is one click away. - **OEM-safe by design — Zero changes to Krones PLC programmes.** Itanta is read-only at the controller. The Krones validation envelope and OEM warranty stay intact, which is why the same deployment pattern works on both greenfield and brownfield Krones-equipped sites. ## Bottom Line Itanta gives the people who run Krones-built lines the one thing the lines themselves don't — a complete, searchable, exportable record of every batch they ever produced. - A productized data layer that bolts onto a Krones line the same way each time - Read-only at the controller — preserves OEM warranty and validation envelope - Batch-contextualized history replaces guesswork with replayable evidence - QA, audit and engineering teams pull batch dossiers on demand instead of building them by hand --- # Mahindra Electric Mobility Automates Energy Reporting with Itanta URL: https://itanta.ai/success-stories/mahindra-electric-mobility-energy-reporting-itanta Company: Mahindra Electric Mobility Ltd. Industry: Automotive > How Itanta's Core Platform replaced shift-by-shift Excel entry with automatic energy collection, kWh calculations, and consistent daily, shift-wise, and monthly reports ## Challenge Energy readings were manually collected and entered in Excel. The work required approximately two hours per shift, with one person dedicated to the activity during every shift. ## Outcome Itanta automatically collects energy data from WinCC SCADA, calculates kWh consumption, and generates daily, shift-wise, and monthly reports. ## At a glance - **~2 hrs** — Saved Per Shift - **2–4 wks** — Deployment Timeline - **Automatic** — Energy Reporting - **Core** — Platform Deployed ## About Mahindra Electric Mobility Ltd. Mahindra Electric Mobility Ltd. operates in the automotive industry, supporting electric vehicle manufacturing and battery assembly. Industry: Automotive · Size: Mid-size ## Introduction Mahindra Electric Mobility Ltd. supports electric vehicle manufacturing and battery assembly. Reliable energy information is important for understanding consumption across plant equipment and production operations. Before Itanta, the MEML team manually collected energy readings and entered them into Excel. The process required approximately two hours per shift, with one person dedicated to the activity during each shift. Itanta's Core Platform was deployed in 2–4 weeks to collect energy data automatically from WinCC SCADA, calculate kWh consumption, and generate daily, shift-wise, and monthly reports. ## The Challenge Before Itanta Manual meter readings consumed significant time during every shift - **Manual Energy Readings:** The MEML team had to collect energy readings manually before the information could be reviewed. - **Excel-Based Data Entry:** Every collected reading was entered into Excel, creating a repetitive manual step in each shift. - **Dedicated Shift Effort:** Approximately two hours per shift and one person during each shift were dedicated to collecting and entering the readings. ## Highlights - Automatic collection of energy data from the existing WinCC SCADA environment - kWh consumption calculated within Itanta's Core Platform - Daily, shift-wise, and monthly energy reports generated automatically - Approximately two hours of manual effort eliminated during every shift - Consistent energy information became available without manual Excel entry From two hours of manual collection and Excel entry per shift to automatically available, consistent energy reports. ## Energy Data Architecture ### Energy Meters Energy meters provide the source readings used to monitor electricity consumption across the operation. ### Siemens PLCs The supplied architecture shows energy meters connected through Siemens SIMATIC PLCs before the data reaches the SCADA layer. ### WinCC SCADA WinCC SCADA, shown as an OPC UA server in the supplied architecture, makes the collected plant energy data available to Itanta. ### Itanta Core Platform Itanta collects the WinCC SCADA data, calculates kWh consumption, and makes energy reports available to the MEML team. - Data flow: Energy Meters → Siemens PLCs → WinCC SCADA → Itanta Core Platform ## What Was Deployed Itanta connected MEML's existing energy-data environment to an automated reporting workflow. - **Automatic SCADA Data Collection:** Energy readings are collected automatically from WinCC SCADA instead of being gathered manually during each shift. - **kWh Consumption Calculation:** The Core Platform calculates kWh consumption from the collected energy data. - **Shift-Wise Reporting:** Energy information is organized into shift-wise reports for consistent operational review. - **Daily & Monthly Reports:** Daily and monthly reports make energy data available without repeated Excel preparation. ## Automated Energy Reports The supplied MEML report view organizes energy-meter readings and consumption values in a structured format for operational review. - **MEML Energy Report:** A structured energy report presenting meter-level information and consumption values, replacing the manually maintained Excel reporting process. ## Measurable Outcomes Less manual work and more consistent access to energy information - **~2 hrs — Saved Per Shift.** Approximately two hours of manual collection and Excel entry were eliminated during every shift. - **Eliminated — Dedicated Data Entry.** The team no longer needs one person dedicated to collecting and entering readings during each shift. - **Automatic — Report Availability.** Daily, shift-wise, and monthly energy reports are generated without manual Excel preparation. - **Consistent — Energy Information.** Automated collection and reporting improved the consistency and availability of energy data. ## Itanta's Impact The MEML team first saw clear value when energy readings and reports became available automatically, removing the need for manual Excel entry and significantly reducing the time required during each shift. - Approximately two hours of manual effort were removed from every shift. - Energy data now flows automatically from WinCC SCADA into Itanta. - Daily, shift-wise, and monthly reports are consistently available to the team. --- # Making Engine Quality Traceable Across 60 Pokayoke Sensors at Bajaj Auto URL: https://itanta.ai/success-stories/bajaj-auto-engine-quality-pokayoke-monitoring-itanta Company: Bajaj Auto Industry: Automotive > How Itanta's Core Platform turned raw sensor values into clear engine-wise quality statuses on a single dashboard ## Challenge Bajaj Auto faced difficulty tracing and tracking engine quality data across 60 Pokayoke sensors, where multiple engines were checked. Maintaining and managing machine-wise quality data across all sensors was challenging. ## Outcome A fixed-table dashboard was deployed to monitor all 60 Pokayoke sensors for each engine. Raw values were converted into meaningful NA, OK, NOT OK, and BYPASS statuses, with user access and a global Engine Code filter for fast engine-wise review. ## At a glance - **60** — Pokayoke Sensors - **4** — Meaningful Statuses - **1–2 wks** — Deployment Timeline - **1** — Centralized Dashboard ## About Bajaj Auto Bajaj Auto operates in the automotive industry and produces vehicle engines. This project was deployed in a mid-size organization with 3–10 plants. Industry: Automotive · Size: Mid-size (3–10 plants) ## Introduction Bajaj Auto operates in the automotive industry and produces vehicle engines. For engine quality checks, multiple Pokayoke sensors monitor conditions across each engine. With multiple engines moving through production, the quality team needed a dependable way to connect each engine with its inspection history and identify deviations early. When information is spread across numerous sensor checks, reviewing quality performance and tracing the source of an issue becomes more difficult. Itanta helped Bajaj Auto create a clearer operational picture of engine quality, making it easier for teams to review results consistently, follow quality history, and act with greater confidence. ## The Challenge Before Itanta Engine quality data was difficult to trace across many sensors and engines - **Fragmented Sensor Data:** Quality data from 60 Pokayoke sensors had to be traced and tracked while multiple engines were being checked. - **Machine-Wise Tracking Difficulty:** Maintaining and managing quality data machine-wise across all sensors was challenging. - **Raw Values Were Hard to Interpret:** Sensor values arrived as 0, 1, 2, and 3, requiring users to interpret the raw values before understanding the quality condition. ## Highlights - One fixed-table dashboard monitors the quality status of all 60 Pokayoke sensors for each engine - Conditional formatting converts raw values 0, 1, 2, and 3 into NA, OK, NOT OK, and BYPASS - A global Engine Code filter enables fast engine-wise review - User access was configured so teams could view the monitoring data through the system - Centralized monitoring improves data visibility, traceability, and issue identification From raw, difficult-to-track sensor values to a centralized engine-wise quality view with clear statuses. ## What Was Deployed Itanta created a centralized quality-monitoring view that makes every sensor condition understandable at the engine level. - **Fixed-Table Quality Dashboard:** A fixed-table dashboard displays the quality status of all 60 Pokayoke sensors for the selected engine. - **Meaningful Sensor Statuses:** Conditional formatting converts raw sensor values into four clear statuses: NA, OK, NOT OK, and BYPASS. - **Global Engine Code Filter:** Users can select an Engine Code and immediately review all 60 associated Pokayoke sensor statuses. - **Controlled User Access:** User access was configured to make the centralized monitoring dashboard available to the relevant team members. ## Dashboards & Reports The supplied report contains two full-page views from the Bajaj Auto project: the Engine Pokayoke quality-status report and the DC Tool report. - **Engine Pokayoke Report:** The report shows an engine-wise fixed-table view for SKU code JG501049 and an engine number, with Poka01 through Poka60 displayed as NA, OK, NOT OK, or BYPASS. - **DC Tool Report:** The DC Tool view presents engine-wise tool information, including SKU code, engine number, leak-test checks, oil-fill program fields, torque fields, and angle fields. ## Measurable Outcomes Centralized engine-wise quality monitoring with clearer, faster sensor review - **60 — Sensors in One View.** All 60 Pokayoke sensor statuses can be reviewed for a selected engine from one dashboard. - **4 — Clear Statuses.** Raw values are presented as NA, OK, NOT OK, and BYPASS. - **Real-time — Data Visibility.** The team can access current engine quality data through the centralized dashboard. - **Reduced — Manual Effort.** Manual interpretation and machine-wise data searching are reduced. - **Faster — Issue Identification.** NOT OK and BYPASS conditions are easier to spot and act upon. ## Itanta's Impact The team can now select an Engine Code and quickly see the status of all 60 Pokayoke sensors in one dashboard, without manually interpreting each raw sensor value. - Engine-wise quality monitoring is available from a single fixed-table dashboard. - Clear OK, NOT OK, NA, and BYPASS statuses make sensor conditions easier to understand. - The global Engine Code filter speeds up engine-wise checking and helps the team identify potential issues faster. --- # Merck's Journey to Seamless 21 CFR Part 11 Compliance using Itanta URL: https://itanta.ai/success-stories/merck-21-cfr-part-11-compliance-itanta Company: Merck Life Science Private Limited Industry: Pharmaceutical Manufacturing > Real-Time SCADA Integration, Automated Reporting, and Regulatory Excellence in One Platform ## At a glance - **3,000+** — Tags Monitored - **18+** — Data Source Collections - **75%** — Audit Prep Time Reduced ## About Merck Life Science Private Limited Merck Life Science Private Limited, Bangalore, India — incorporated in 1986 as a JV with Millipore Corporation (USA), became a 100% Millipore subsidiary in 2009, which was then acquired by Merck Chemicals in March 2010. Headquarters: Bangalore, India · Industry: Pharmaceutical Manufacturing · Size: Enterprise ## Introduction Merck Life Science Private Limited, partnered with Itanta Analytics to revolutionize their pharmaceutical manufacturing reporting and analytics capabilities to standardize and automate critical batch manufacturing processes across multiple facilities. Merck required a robust, scalable solution that could handle complex pharmaceutical batch reporting while maintaining strict regulatory compliance. The implementation resulted in dramatically improved operational efficiency, enhanced data visibility, and streamlined compliance reporting across their downstream manufacturing operations. ## Challenges Faced by Merck - **Regulatory Compliance and Standardization Pressures:** Need for standardized reporting templates, comprehensive audit trails for FDA inspections, and 21 CFR Part 11 compliance with automated backup capabilities. - **Fragmented Reporting Systems:** Fragmented data collection from SCADA systems created time-consuming processes, inconsistent formats, and limited real-time visibility with poor audit trail maintenance. - **Complex Multi-System Integration:** Multiple systems, various pharmaceutical processes, and different equipment required seamless integration across WinCC SCADA, PLCs, and OPC UA systems. - **Data Visibility and Decision-Making Limitations:** Lack of real-time process visibility and unmanageable historical data analysis prevented optimization opportunities and proactive decision-making. - **Scalability and Resource Constraints:** Manual processes couldn't scale across global facilities, wasting engineering resources on routine tasks instead of value-added activities. - **Technology Integration and Modernization Needs:** Required bridging legacy SCADA with modern analytics while supporting digital transformation without disrupting critical manufacturing operations. ## Highlights - 3,000+ tags across 18 data source collections with centralized access - Built-in 21 CFR Part 11 compliance with electronic signatures and audit trails - Real-time monitoring with 1-second updates via OPC UA connectivity - Automated batch reporting with two-level digital approval workflow - HTML5 web interface with customizable dashboards and trend analysis - Scalable architecture supporting future expansion with minimal effort ## Merck Life Science Private Limited _Pharmaceutical Manufacturing Excellence_ - Global pharmaceutical manufacturer requiring strict regulatory compliance - Multiple downstream manufacturing facilities with complex batch processes - Infrastructure includes WinCC SCADA, Siemens PLCs, and OPC UA systems - Three Inline Buffer Dilution Machines feeding real-time manufacturing data - Requires 21 CFR Part 11 compliance with comprehensive audit trails ## Itanta System Architecture ### Data Acquisition The data acquisition process begins with three Inline Buffer Dilution Machines, feeding real-time manufacturing data to Siemens PLCs. - These controllers continuously capture critical parameters including pressure, temperature, valve positioning, and cycle codes, providing comprehensive operational data from the manufacturing floor level. ### Data Aggregation Data flows from individual PLCs through an Industrial Ethernet Switch to the IBD WinCC RT SCADA system, which serves as the central aggregation point. - The SCADA system consolidates data streams from all three buffer dilution systems, converting raw sensor data into structured manufacturing information while maintaining real-time synchronization across connected systems. ### Data Visualization The Itanta platform transforms aggregated SCADA data into intuitive web-based dashboards accessible through standard browsers. - This layer provides real-time monitoring with 1-second updates, historical trend analysis, user configurable views, and comprehensive alarm management with visual alerts for immediate process visibility. ### Data Distribution The system automatically generates standardized batch reports for pharmaceutical processes and delivers information through multiple formats including PDF exports and direct printing. - This lets all your factories access the same system, while keeping a full record of every action to meet regulatory requirements. ## How Itanta Solved These Challenges - **Comprehensive Data Integration Architecture:** Multi-connector approach with OPC UA (1-second intervals), SQLite (10-second intervals), and Mongo-to-Mongo connectivity handled 3,000+ tags across 18 data source collections with centralized access. - **Automated Batch Reporting System:** Built-in 21 CFR Part 11 compliance with electronic signatures and comprehensive audit trails. Implemented two-level digital approval workflow: Operators mark batches "Done" and Supervisors/Engineers provide "Review". - **Redundant Engineering Station Setup:** A central server monitors all three buffer dilution systems with high availability, same-domain network setup, and a scalable design that supports future expansion with minimal effort. - **Advanced Dashboard and Analytics Features:** Deployed an HTML5 web interface with customizable dashboards showing real-time trends for pressure, temperature, and valve positions, along with detailed alarms, event logs, and flexible data display options for detailed analysis. - **User Experience and Operational Tools:** Developed IA Launcher application for dedicated SCADA integration, page selection printing functionality, direct printer integration, configurable PDF download paths, and pre-login functionality with SCADA user credentials for seamless workflow. - **Scalable and Future Ready Architecture:** Centralized monitoring of multiple systems with flexible templates, built-in redundancy for high availability, and API-ready integration for future growth. ## Snapshots of Reports - **1. Alarm Data Report:** - **2. Events Data Report:** - **3. Trends Data Report:** ## Conclusion The Merck-Itanta success story demonstrates that with the right technology partner and strategic approach, even the most complex manufacturing environments can achieve rapid digital transformation while maintaining the highest standards of quality, compliance, and operational excellence; the real-time visibility into critical process parameters, standardized reporting across multiple facilities and comprehensive audit capabilities have positioned end-users to make more informed decisions and respond proactively to process variations. The scalable architecture ensures that this digital foundation can support future growth and technological evolution. --- # Smart Monitoring Transforms Eden Renewables India's Solar Operations URL: https://itanta.ai/success-stories/eden-solar-operations-itanta Company: Eden Renewables India Industry: Renewable Energy > How Itanta's platform improved efficiency and performance at a massive 450 MW solar facility in Rajasthan ## Challenge Eden Solar's 450 MW facility with nearly 800,000 panels and 24 block inverters required manual visits to each control room for readings. Over 11,000 data tags generated massive volumes that were manually processed into Excel reports across multiple time intervals. ## Outcome Itanta automated data collection from ABB Symphony Plus SCADA, processed 11,122 monitoring tags with minute-by-minute precision, delivered 75+ dashboards and 253 automated reports—eliminating manual monitoring and enabling real-time visibility. ## At a glance - **11,122+** — Data Tags - **253** — Automated Reports - **75+** — Dashboards ## About Eden Renewables India Eden Renewables India is a joint venture between EDF Renewables and Total Eren, present in India for 25+ years. Operating solar and wind farms generating 476 MW from commissioned plants with 2,366 MW in the pipeline, including this flagship 450 MW solar facility in Rajasthan. Headquarters: Rajasthan, India · Industry: Renewable Energy / Solar Power · Size: 476 MW Commissioned / 2,366 MW Pipeline ## Introduction The Eden Renewables India's Solar Plant in Rajasthan represents one of India's largest solar power installations, generating power through nearly 800,000 solar panels across four operational sections. With 24 block inverters and multiple monitoring systems generating vast amounts of operational data, the facility faced significant challenges in real-time monitoring and comprehensive reporting. Itanta Analytics supported Eden Solar's operations with an integrated monitoring platform and real-time findings. By connecting to existing SCADA systems and processing over 11,000 data tags, Itanta delivered dashboards and automated reporting that enhanced operational efficiency and supported data-driven decisions across the solar facility. ## Challenges and Requirements Eden Solar's massive 450 MW facility faced critical monitoring and reporting challenges across its vast infrastructure of nearly 800,000 panels and 24 block inverter control rooms. - **Manual Data Collection:** Staff had to physically visit 24 block inverter control rooms daily, each housing four individual inverters (96 total), to manually take readings on an hourly and daily basis—an extremely time-consuming and error-prone process. - **Multi-System Monitoring:** Infrastructure required simultaneous monitoring of diverse operational components including 24 block inverters, primary and secondary Weather Monitoring Stations (WMS), each demanding unique parameter tracking with different aggregation methods. - **Drowning in Data:** With over 11,122 data tags generating information every minute across 26 different collections, Eden Solar faced the challenge of processing and making sense of massive operational data volumes, leading to delayed decisions. - **Time-Intensive Reporting:** Comprehensive Excel-based reports were required spanning multiple time intervals—1-minute, 15-minute, hourly, daily, monthly, and yearly analysis across more than 25 operational sections. Manual report creation was extremely time-consuming. - **Real-Time Optimization Gaps:** With nearly 800,000 solar panels and complex electrical infrastructure, Eden Solar needed immediate visibility into system performance, efficiency metrics, and fault detection capabilities to prevent significant energy losses. ## Highlights - Automated data collection from 96 inverters across 24 block control rooms - 11,122 monitoring tags processed with minute-by-minute precision - 75+ comprehensive dashboards for real-time operational visibility - 253 scheduled reports auto-generated across multiple time intervals - Real-time monitoring of nearly 800,000 solar panels and equipment - Centralized MongoDB architecture replacing fragmented data silos This implementation delivered measurable impact for one of India's largest solar facilities, enabling operators to focus on maximizing clean energy production and profitability. ## Eden Renewables India _Powering India's Energy Transition_ Eden Renewables India has been present in India for over 25 years as a key partner in the country's energy transition, operating solar and wind farms generating 476 MW from commissioned plants with 2,366 MW in the pipeline. - 450 MW solar facility in Rajasthan utilizing 795,168 solar panels from thin-film and polycrystalline technologies - Joint venture between EDF Renewables and Total Eren, established for the Indian solar market - 24 block inverters with multiple monitoring systems generating over 11,000 data tags - Annual production of over 2,300 GWh, serving nearly 2 million people's electricity needs - Awarded in 2020 as part of three major contracts totaling 1,350 MWp Eden Renewables India's partnership with Itanta demonstrates how intelligent automation can transform complex solar operations at massive scale. ## System Architecture ### Data Acquisition Real-time operational data captured from the facility's vast infrastructure. - Real-time data from 24 block inverters, weather monitoring stations, and transformer voltage monitors. - Raw data collected from nearly 800,000 solar panels and associated infrastructure with continuous transmission to central monitoring. ### Data Aggregation ABB Symphony Plus SCADA consolidates all field data into a unified system. - Symphony OPC-DA Server standardizes information into a common format accessible to external platforms. - Real-time data integrity maintained while making information available for processing and analytics. ### Data Processing & Storage Itanta's DS Manager processes and organizes the massive data streams. - OPC-DA Connector interfaces with Symphony server, organizing, validating, and storing data in structured MongoDB databases. - Intelligent calculations and aggregations applied based on each parameter's specific requirements. ### Visualization & Distribution Processed data flows into dashboards and automated reports for stakeholders. - Itanta Platform transforms data into intuitive dashboards and real-time monitoring screens. - 253 automated reports generated and delivered to stakeholders with user-friendly interfaces enabling informed decision-making. ## Itanta's Approach _Solutions Provided by Itanta_ Itanta deployed a comprehensive monitoring and reporting platform that automated Eden Solar's manual processes and delivered real-time visibility across the entire 450 MW facility. - **Automated Data Collection System:** OPC-DA connector automatically gathering real-time data from ABB Symphony Plus SCADA systems, processing all 11,122 monitoring tags across 26 collections with minute-by-minute logging - **Unified Dashboard Platform:** 75+ comprehensive dashboards bringing all operational data into a single interface, organizing complex multi-system monitoring from block inverters to power quality meters in one centralized location - **Intelligent Data Processing:** Aggregation methods tailored to each system's requirements calculate averages, min/max, and absolute values for operational findings. - **Automated Reporting Engine:** 253 scheduled reports automatically generated and saved as Excel files across multiple time intervals for over 25+ operational sections, delivered daily to dedicated folders and eliminating manual downloads - **Real-Time Monitoring:** Live monitoring dashboards showing real-time performance data from all 800,000 solar panels and equipment, allowing the team to spot and fix problems quickly before they reduce power production - **Centralized Data Management:** Centralized MongoDB architecture storing all operational data in organized collections, replacing fragmented data silos with a unified information system supporting both real-time operations and historical analysis The result was a complete digital transformation—from manual monitoring workflows to an intelligent, automated platform providing real-time visibility across the entire solar facility. ## Sneak Peek of the Dashboards Eden Solar's operational dashboards provide comprehensive monitoring views across the facility's vast infrastructure, from weather monitoring stations to individual inverter performance. - **Primary WMS Dashboard:** MCR WMS 1-Minute Report tracking 112 parameter tags including GHI, POA, rainfall, ambient temperature, and wind speed with minute-by-minute precision across all weather monitoring stations. - **SCB Report Dashboard:** Inverter current monitoring with data recorded every 1 minute across 1,537 parameter tags, providing detailed per-inverter performance tracking for fault detection and efficiency analysis. ## Results Itanta Analytics delivered transformative results across Eden Solar's massive 450 MW facility, eliminating manual processes and enabling real-time data-driven operations. - **11,122 — Tags Monitored.** Monitoring tags processed with minute-by-minute precision across 26 collections - **253 — Reports Automated.** Scheduled reports auto-generated across multiple time intervals for 25+ sections - **75+ — Dashboards Deployed.** Comprehensive dashboards for real-time operational visibility - **96 — Inverters Automated.** Manual visits to inverter control rooms eliminated through automated collection - **800K — Panels Monitored.** Nearly 800,000 solar panels with real-time performance tracking ## Conclusion The Eden Renewables India project with Itanta showcases how intelligent automation can transform complex solar operations. Itanta's platform eliminated manual monitoring across 800,000 solar panels, automated critical reports, and provided real-time visibility into thousands of data points. - Eliminated time-consuming manual data collection across 24 inverter control rooms - Automated generation of 253 comprehensive reports spanning multiple time intervals - Processed 11,122 monitoring tags with minute-by-minute precision - Delivered real-time operational visibility through 75+ unified dashboards - Reduced operational costs while improving response times and decision-making This implementation demonstrates that the right technology partnership doesn't just solve problems—it enables renewable energy operators to focus on maximizing clean energy production and profitability.