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
• 2–4 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.

Make Engine Quality Data Easier to Trace

See how Itanta's Core Platform can centralize sensor monitoring, translate raw values into clear statuses, and simplify engine-wise quality review.