How Electrosteel Castings Limited (ECL) Achieved Zero Theft Over 3 Years with End-to-End Supply Chain Intelligence from Fleetx
How Electrosteel Castings Limited (ECL) Achieved Zero Theft Over 3 Years with End-to-End Supply Chain Intelligence from Fleetx
An ECL unit, importing coal through Krishnapatnam Port, was facing a multi-layered logistics challenge. The absence of end-to-end monitoring created serious operational vulnerabilities. By deploying Fleetx solutions, the plant transformed its imported coal supply chain from an opaque, high-risk operation into a fully monitored, tamper-proof logistics corridor.
Business Challenge
The plant faced three core challenges:
Coal Theft and Adulteration
No Fleet TAT Visibility and Poor Utilisation
Transporter Disputes and Freight Settlement Gaps
Fleetx Intervention
Fleetx deployed a comprehensive, layered solution tailored to the high-risk, high-value nature of imported coal logistics.
- Every vehicle in the dedicated coal fleet was onboarded onto the Fleetx platform
- Operations teams gained a centralized dashboard for every active vehicle.
- Automated alerts were triggered for unauthorized halts, route deviations, and overspeeding — enabling immediate intervention
- Electronic seals were applied to vehicle containers and cargo hatches
- Any physical breach of the seal during transit generated an immediate alerts
- E-Seal status was logged for every trip, creating an auditable record of cargo integrity
- Tampered seals flagged suspicious consignments for inspection upon arrival at the plant, preventing adulterated coal from entering the grinding process
- Geofences were established at crucial points
- The system automatically computed TAT for each journey stage
- Fleet managers could view TAT benchmarks, identify outliers, and track utilization across the 50–60 vehicle pool
- Reverse TAT (return journey from plant to port) was tracked with equal rigour
- Freight bills were reconciled against GPS-verified actual kilometres travelled per trip
- This eliminated over-reporting of distances, a common source of freight cost inflation
- Transporters could also validate their claims using the same data
- A structured Standard Operating Procedure (SOP) was implemented
- 100% SOP adherence was tracked through the platform
- Risk analysis configurations were set up within the Fleetx system to proactively identify behavioural patterns indicative of pilferage or adulteration
Client Voice
"Fleetx helped us reduce adulteration of inbound coal movement and provide real-time visibility, better coverage, and monitor SLA adherence"
Mr. Rajesh Kumar Balouria, Dy. Chief Security Officer
Measurable Impact
The results of the Fleetx deployment were tangible, measurable, and directly tied to the core operational risks -
Coal Theft Incidents in Last 2 Years
Complete elimination of theft from an environment where pilferage was a persistent, uncontrolled risk.
Adulteration Detection
Fleetx risk analysis flagged a suspicious consignment in the first year of deployment, preventing further damage and creating accountability.
Machine Damage from Adulterated Coal
No further grinding machine damage attributed to coal quality post full-platform rollout.
Fleet TAT Visibility
Full visibility across loading, transit, and unloading stages for all 50–60 vehicles in the dedicated fleet.
Freight Settlement Accuracy
Freight costs aligned to actual travel — reducing over-billing and resolving transporter disputes with objective data.
Transporter Dispute Resolution
Timestamped TAT records replaced verbal disputes with factual, auditable data accepted by all parties.
Strategic Outcomes
Beyond the quantifiable operational improvements, the Fleetx deployment delivered lasting strategic value across five dimensions:
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