Enertech UPS

Client Overview

Company

Enertech Pvt. Ltd.

Location

Pune, Maharashtra

Industry

Manufacturing (Electrical Equipment / Solar Components)

Duration

3 Months

Business Type

B2B Solar Equipment & Power Systems Manufacturer

The Challenge

Enertech’s QC testing process was completely manual, consuming excessive time and resources.

📋 Manual Testing Inefficiency

Manual testing using power analyzers and multimeters taking 50–60 minutes per unit

📦 High manpower dependency

Involvement of 2–3 operators for testing, comparison, and data entry

📄 Paper-based reporting errors

Paper-based reporting and high error rates

🏪 Lack of real-time data visibility

Lack of real-time visibility into test data or deviations

🏛️ Delayed production feedback

Delays in production feedback and decision-making

🏛️ Hardware/connection issue detection challenges

Difficulty in detecting hardware or connection issues across multiple systems

The Solution

AbhinavDCS developed an embedded software solution integrated with an IP-based web application to fully automate Enertech’s testing and reporting process.
The system enabled real-time communication between QC equipment and a centralized monitoring dashboard.

🎯

Automated QC Process

✓
Direct device integration via Modbus RS-485 communication
✓
Automated data capture and parameter comparison (voltage, current, power)
✓
Embedded code for standard value mapping and deviation alerts

📊

Real-time Monitoring

✓ LAN-based data transfer from Power Analyzer to centralized web dashboard

✓ Real-time display of test results across connected devices

📱

Reporting & Notifications

✓ Instant report generation with integrated email and WhatsApp sharing

✓ Centralized database for easy retrieval and traceability

📱

System Health & IP Tracking

✓ Integrated IP monitoring system to detect inverter or device faults instantly

🏛️

Government Compliance Integration

✓

Maharashtra State Electricity Board integration
✓

Automated data formatting & submission
✓

Application status tracking

🏪

Store & Dealer Management

✓

Real-time store-level visibility
✓Sales & transaction tracking
✓

Easy franchise onboarding

Results & Impact

Metric

⬇️

QC Testing Time
Manual Errors
Units Tested Daily
Data Access
Report Generation

Before

⬇️

50–60 mins/unit
Frequent
~10 units
Manual records
Manual & paper-based

After

⬇️

5–7 mins/unit
Almost eliminated
25+ units
Real-time dashboard
Automated & shareable

Additional Gains

✅ 80% improvement in operational efficiency

✅ Faster audits and better traceability

✅ Improved scalability across production

✅ Reduced manpower dependency

Project Timeline

Month 1

Process Mapping & Hardware Integration

Month 2

Embedded Development & Device Connectivity

Month 3

Dashboard, Automation, and Deployment

📌 Summary

Through AbhinavDCS’s embedded automation and real-time monitoring system, Enertech successfully transitioned from manual QC testing to a smart, connected, and fully digital process.
The solution now acts as the core of their production quality operations, ensuring speed, accuracy, and end-to-end visibility across the manufacturing floor.