Introduction
Across a 700-acre campus, one of India’s leading automotive OEMs runs 30+ bustling production shops. With a monthly energy load exceeding 400,000 units sourced from grid, solar, wind, and diesel costs were high and climbing.
The plant had always prioritized efficiency. But despite their conventional Energy Management System (EMS), a familiar pattern persisted: Information was everywhere, but actionable intelligence was lacking. Teams were operating with partial visibility, unable to respond in real time.
To shift from monitoring to optimization, the plant partnered with Greenovative to deploy GreenErgy an AI-powered, real-time energy and water intelligence platform purpose-built for industrial environments.
Challenges
➤ Cost & Carbon Pressure Mounting
Corporate sustainability targets and rising utility bills created twin pressure points. There was no room for guesswork energy optimization was no longer optional.
➤ Data Blind Spots
Their EMS offered limited insight: manual audits, static charts, and lagging reports. For a plant of this size, that wasn’t enough. High-consumption zones like paint shops and utilities remained black boxes of inefficiency.
➤ Reactive Asset Management
Critical assets weren’t being tracked live. Failures were caught late, and inefficiencies like oven overshoots or idling bays went undetected until the cost had already been paid.
Baseline Snapshot
- Specific Energy Consumption (SEC): ~28.5 kWh/unit
- CO2e Intensity: ~620 tons/month
- Existing Setup: Energy and equipment data were managed through a legacy systems, largely reactive, focused on daily report logging rather than real-time decision-making.
Solution: Real-Time Intelligence, Deployed Without Disruption
Over a 12-week rollout, GreenErgy transformed the facility’s approach from observation to action. Here’s how:
l AI-Powered Root Cause Engine
The system absorbed telemetry from machines, utility profiles, and shift schedules to trace inefficiencies back to their source such as load imbalances or suboptimal runtime behaviors without needing manual analysis.
2 Energy Balance for Unmetered Zones
By applying energy balance models, the platform identified hidden losses in areas lacking physical sensors from compressed air systems to standby loads; revealing inefficiencies that standard monitoring missed.
3 Contextual Benchmarking
Instead of generic KPIs, the platform tailored benchmarks to each shop’s actual operating conditions shift load, line design, ambient heat enabling fair and actionable comparisons.
4 Adaptive Thresholds
No more static limits. AI tuned anomaly thresholds dynamically, learning from historical trends and day-to-day variability, minimizing noise and maximizing relevance.
5 KPI Automation & Asset Monitoring
Daily SEC reports and asset performance dashboards went live giving shop-floor experts the ability to act in real time. Energy saving drives could now be triggered not by instinct, but by data.
6 Seamless Integration
All of this ran on top of existing infrastructure from SCADA, PLCs, and BMS to enterprise systems like MES, IIoT platforms, and SAP ensuring zero disruption or production downtime.
Results and Impact
l Energy Efficiency
SEC dropped from 28.5 to 23.4 kWh/unit, delivering an 18% efficiency gain.
2 Carbon Reduction
CO₂e emissions reduced by 130 tons/month aligning with corporate net-zero goals without overhauling the facility.
3 Cost Savings
Operational savings crossed ₹ 70 lakh annually, thanks to targeted energy actions and reduced unaccounted usage.
4 Rapid ROI
Payback achieved in under 60 days proving quick wins are possible when intelligence is purpose-built.
5 Reliability & Compliance
Live equipment insights minimized downtime and reduced maintenance costs. ESG-aligned reporting was streamlined for audits and corporate disclosures.
Conclusion
This partnership shows what’s possible when industrial energy systems stop working in silos and start working with intelligence.
By making real-time visibility actionable, GreenErgy helped the Pune plant shift from fragmented tracking to holistic control without disrupting what was already working.
This transformation proves that with the right AI backbone, even legacy-heavy plants can unlock future-ready sustainability without much of a capital investment.
About Greenovative
Greenovative Energy specializes in next-generation energy management solutions, seamlessly integrating AI, IoT, and cloud technologies to redefine operational efficiency. Our flagship GreenErgy platform empowers organizations to navigate the complexities of energy management with precision and scalability.
Visit us at www.greenovative.com
