Power Apps Automation for an Industrial & Energy Infrastructure Company
Routine electrical testing and compliance reporting form the backbone of quality assurance for manufacturers of high-voltage components. When these processes rely on manual data entry, scattered master files and paper-driven approvals, they become slow, inconsistent and vulnerable to error — risks that carry real consequences in industries governed by strict safety and compliance standards. This case study covers how STS helped a client digitize that process end to end with a Power Apps-based automation solution.
Client Profile
Our client is a leading industrial and energy infrastructure company in India, specializing in engineering products and services such as heat-shrinkable components, power cable accessories, electrical insulation systems and specialty transformers. With manufacturing operations spanning Gujarat and Maharashtra, the company serves customers across utilities, transportation, oil and gas, and telecommunications, and places strong emphasis on research, quality and compliance in everything it delivers.
The Challenge
The client's routine test reporting process for high-voltage cable accessories relied heavily on manual effort, creating bottlenecks in an operation where speed and accuracy directly affect compliance and delivery timelines.
- Manual data entry: testers manually entered serial numbers, product details and test parameters — PD value, temperature, humidity, background noise — into Excel, adding time to every report.
- Dependency on multiple master files: Product Type, Ratings, Size and Backup Master files had to be manually cross-referenced for every test entry, adding complexity and room for mismatch.
- Manual validation: PD values and pass/fail determinations were assessed by hand, with no consistent logic applied across testers or shifts.
- Manual report preparation and approval delays: HVCA Test Reports were compiled manually, and borderline results requiring managerial approval added further delay.
- Risk of data entry errors: without automated checks, even small manual errors could affect the accuracy and traceability of compliance-critical reports.
Our Approach
Our team studied the client's existing routine testing workflow end-to-end, from manual data capture to report generation, and designed an automation approach centered on the Microsoft Power Platform.
Power Apps UI Development
Built a structured data entry form in Power Apps to replace manual Excel entry, covering test date, product details and all manually recorded test parameters.
Master Data Synchronization
Configured Power Automate flows to pull and synchronize values such as U0, High Voltage Test 2.5 U0, PD Test 1.5 U0 and Cable type directly from SharePoint-hosted master files.
Business Rule Implementation
Codified the client's testing logic into automated rules covering serial number generation, PD-based pass/fail determination, and approval escalation.
Automated Report Generation
Configured the solution to auto-populate the HVCA Test Report template with validated data and store the final report in SharePoint for traceability.
Our Solution
The team developed a Power Apps-based application, integrated with SharePoint and Power Automate, to digitize the client's entire routine test data entry, validation and reporting workflow — mapped directly against each manual bottleneck identified above.
Manual Data Entry → Structured Digital Form
Replaced Excel-based entry with a Power Apps form featuring dropdowns for Product Type, Ratings and Size, populated dynamically from SharePoint master data, alongside an auto-generated Product Number combining product type, rating, month, year and a running serial number.
Multiple Master Files → Automated Synchronization
Automated synchronization of U0, High Voltage Test 2.5 U0, PD Test 1.5 U0 and Cable values from the Backup Master using Power Automate, removing the need for manual cross-referencing.
Manual Validation → Codified Business Rules
Built PD-based validation logic that automatically classifies results as PASS when PD (ρC) falls between 1.0 and 3.5, triggers a Microsoft Teams approval request from the Test Manager for values between 3.6 and 5.0, and marks results as FAIL above 5.1.
Report Delays → Automated Numbering & Approval Routing
Automated report numbering by combining a fixed prefix, financial year and serial number, and routed borderline results through Microsoft Teams approval, removing manual follow-up.
Data Entry Errors → Auto-Populated, Auditable Reports
Eliminated manual computation and cross-checking by auto-populating the HVCA Test Report template with validated values and storing the final report in SharePoint for easy retrieval and audit traceability.
The solution has been live for over a year, consistently supporting the client's routine testing operations across its manufacturing facilities.
The Impact
Beyond the headline numbers, business rules ensured every test record followed the same validation and reporting logic, removing inconsistencies across testers and shifts, while centralized storage in SharePoint combined with Microsoft Teams-based approvals gave the client a clear, auditable trail for every test report.
Conclusion
By replacing a largely manual testing and reporting process with a standardized digital workflow on the Microsoft Power Platform, STS helped the client improve efficiency, data quality and compliance while minimizing manual intervention. The solution continues to support the client's day-to-day testing operations, with future enhancements under consideration — including Power BI-based KPI dashboards, digital signatures, mobile interface improvements, ERP integration, and predictive analytics for test trends.
This is the same discipline behind STS's broader Data and AI practice areas — automating the process, not just the paperwork.