The study focuses on Fuel Monitoring & Fleet Visibility for large construction companies in India. The client of the project is Simplex Infrastructures Ltd. from Kolkata, India, a construction company involved in building bridges, highways, and other infrastructures as well as other industries, and CallComm is the system integrator for this activity. The project started in April of 2017 and had an implementation timeline of 4 years.
Challenges Faced
- Theft of fuel by drivers, draining of fuel tanks from machinery, and under-filling of fuel tanks by operators.
- Simplex Infrastructure Ltd. lacks the ability to constantly see or track how much fuel is used along with the amount of time each piece of equipment has been running.
- Simplex Infrastructure Ltd. also struggles to effectively monitor and control heavy construction machines as well as high-capacity diesel generators.
- Simplex Infrastructure Ltd. finds it challenging to relate fuel utilized to productivity gained from the equipment used.
Solutions By Manaviya Tech
Fleet Size & Equipment Deployed
There are currently 500+ vehicles and machines installed with Simplex Infrastructure Ltd. There is fuel monitoring for all vehicles and equipment as complete coverage of Simplex Infrastructure Ltd fleet with an ‘FMS’ (Fuel Monitoring System) is in place.
Hardware Selection
Monitoring Systems Equipment: TD150
The TD150 was selected due to:
- Compatibility with multiple sensor configurations
- Reliability for heavy-duty and industrial fleet use
- Seamless integration with advanced fleet management platforms
Software Platform
Fleet Management Platform: Wialon
Key Functionalities Used:
- Real-time fuel level monitoring
- Accurate fuel consumption and refuelling reports
- Engine-hour analysis
- Comparative fuel usage reports (before vs after installation)
- Alerts for fuel theft, drainage, and abnormal fuel behavior
Wialon provided all required analytical reports and dashboards, enabling actionable insights for management.
Installation Scope & Machinery Covered
The fuel monitoring system was successfully deployed across a wide range of equipment, including: Pavers, Transit Mixers, Dumpers, Hydraulic Rotary Rigs, Diesel Generators (DGs – including 1010 kVA units), Bitumen Concrete Mixing Plants, Excavators, Backhoe Loaders & Light Motor Vehicles (LMVs)
Performance & Operational Impact
Fuel Cost at Time of Installation
- Diesel Price: Approx. ₹74 per litre
Fuel Monitoring Results (Initial Months)
Detailed Excel-based analysis was conducted on:
- Engine hours vs fuel consumption
- Refuelling patterns
- Detection of underfilling and drainage
Fuel Savings Identified:
- 1st Month: ₹8 lakh savings
- 2nd Month: ₹9 lakh savings
- 3rd Month: ₹12 lakh savings
Financial Performance & ROI
Annual Fuel Expenditure
- Before Implementation: ₹100 crore
- After Implementation: ₹94 crore
Net Savings
- Monthly Savings: ₹0.5 crore
Cost Breakdown
- Installation Cost per Unit: ₹16,000
- Total Installation Cost (Entire Fleet): ₹96,00,000
- Maintenance / Subscription Fee: ₹200 per sensor per month
Maintenance Cost for 6 Months:
₹200 × 500 sensors × 6 months = ₹6,00,000
Overall Expense (First 6 Months)
- Installation + Maintenance: ₹1.02 crore (approx.)
Outcome
TD150 fuel sensors integrated with Wialon enabled Simplex Infrastructures Ltd to:
- Monitor their fuel usage with complete transparency.
- Reduce their fuel theft and fuel misuse by a substantial amount.
- Improve operator and site team accountability.
- Analyze the productivity of their machines with greater accuracy.
- Achieve sustainable fuel cost savings through the optimal use of fuels on large-scale construction sites.
Conclusion
This Project demonstrates that through implementing an integrated solution for monitoring fuel and managing fleets can have a direct positive financial effect on your bottom line in even the most complex and demanding heavy construction environments. The collaboration between CallComm and Simplex Infrastructures Ltd serves as a prime example of how to utilize technology to improve operational efficiencies within the Indian construction industry’s infrastructure sector.
