Early Fault Detection Across 21 Site Locations
UltraTech Cement standardized electrical health monitoring across 21 manufacturing sites with a unified Innvendt deployment—enabling cross-site benchmarking and portfolio-level risk management for the first time.
The Challenge
“UltraTech Cement's engineering leadership had long struggled with inconsistent electrical safety and maintenance practices across its 21 manufacturing locations. Each site operated independently, with different monitoring approaches, different alert thresholds, and different maintenance standards. Corporate engineering had no consolidated view of electrical asset health across the portfolio and no basis for identifying which sites carried the highest electrical risk. An internal audit found that 7 of 21 sites had no electrical condition monitoring beyond annual manual testing.”
The Solution
Innvendt deployed a standardized E5 monitoring system across all 21 sites, with a unified cloud platform providing individual site dashboards and a corporate portfolio dashboard. Standardized sensor configurations, threshold policies, and maintenance workflows were defined at the corporate level and deployed consistently across all sites. The corporate engineering team gained, for the first time, a portfolio-wide view of electrical asset health with cross-site benchmarking capability.
Implementation
Corporate Standard Configuration Development
Before deployment, Innvendt worked with UltraTech's corporate electrical engineering team to develop a standardized monitoring configuration for cement manufacturing facilities: a defined set of monitoring points (earth pits, transformer neutrals, motor control center busbars), standardized sensor types and installation procedures, uniform threshold policies with tiered alert levels, and a standard incident response workflow. This standard configuration was documented as a deployment specification applied consistently across all 21 sites.
Phased Site Deployment
Sites were deployed in four cohorts over six months, prioritizing the seven unmonitored sites in the first cohort and completing with the previously-monitored sites (where existing monitoring was replaced with the standard platform) in the final cohort. A deployment quality checklist verified that each site met the standard configuration before being brought live on the corporate platform, ensuring consistency across the portfolio.
Portfolio Risk Dashboard and Benchmarking
The corporate portfolio dashboard ranks all 21 sites by electrical health score—an aggregate metric computed from earth resistance compliance rates, leakage current deviation from baseline, and alert frequency. Sites in the bottom quartile of the health score receive enhanced monitoring cadence and priority capital allocation for grounding system upgrades. Monthly cross-site reports compare maintenance intervention rates, fault detection rates, and false alarm rates to identify sites where the monitoring program is underperforming and requires operational attention.
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