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 the right insights at the right time.

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

Ready to Transform Your Manufacturing Data?

MAHLE Anand's success story shows how the right no-code analytics platform can revolutionize manufacturing operations. Your organization can achieve similar operational excellence with Itanta Analytics.