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.

Automate Energy Reporting Across Your Plant

See how Itanta's Core Platform can collect SCADA data, calculate kWh consumption, and replace manual Excel reporting with automatically available energy reports.