OEMs are facing new challenges to improve the existing technologies and develop next-generation ones for the new mobility in shorter times. Reducing market responding time along with new complexities are paving the way for virtual simulation, which displaces physical tests and prototypes by virtually replicating product development, testing and manufacturing with simulations. Emmanuel Leroy, Executive Vice-President Industry Solutions at ESI Group, explains, “We enable our customers to drastically reduce every additional physical prototype by using our solutions. In the end, only one physical prototype is required to validate the whole concept. We envision that one day we may be able to virtually certify a product from end to end.” Excerpts:

Q) How did the Covid impact the software and services businesses of ESI Group?

The Covid pandemic has accelerated the need for more digitalisation within the industrial market. It has also somehow accelerated the readiness level of our customers and made solutions such as virtual prototyping even more relevant. Indeed, we enabled the continuity of our clients’ business. The use of virtual prototyping allowed them to continue designing, testing and prototyping their products. Our human-centric approach – one of ESI Group’s four outcome solutions – was particularly used by our customers to ensure the continuity of their businesses: using virtual reality to experience the product from home.

During pandemic times, we also provided our CFD (computational fluid dynamic) solutions to help investigating different scenarios to demonstrate the effect of occupant proximity, ventilation systems and contamination avoidance unique to each office and plant environment. ESI Group developed different virtual scenario, based on its facilities in India, to optimise the return to offices and on plant – especially on a car assembly line.

How the growing complexity of part process is influencing the virtual testing?

We notice that the automotive industry is facing more and more draconian regulations, disruptive technologies, intensifying competitions and shortening response time. Coupled with these, customers are getting more demanding on quality, reliability, safety and production deadlines in the business. Indeed, end users are no longer looking for products but for results (flight hours instead of engines, number of possible kilometres instead of electric car, etc.) and they seek for committed and responsible automakers to motivate their buys. At ESI Group, we have understood these preoccupations and we have defined four primary solutions answering our customers’ expectations.

The first one is the Pre-certification and Validation, enabling gains in performance and productivity. The purpose is double: meeting certification and validation requirements like crash, safety and fatigue issues in the first attempt and then increasing productivity with predictive models and process automation.

The second outcome is Smart Manufacturing, which enables to establish the right manufacturing processes to meet the performance indicators for industrial products and processes.

The Human-Centric Product and Process Validation, our third outcome, focuses on humans by implementing an operator-centric approach to ensure the efficiency of assembly, maintenance operation and the safety of human interactions.

The last one, Pre-experience, is the most advanced solution of ESI Group. Here, our customers and the operators do not look at the product itself, but virtually experience a product, component, subsystem or system under numerous conditions and environments.

Using these approaches, we identify industry challenges from the customer’s perspective and support them in achieving their results.

Finally, as products are getting more complex, one of our strengths is our end-to-end multi-material assembly solution with modelling of different materials (steel, aluminum, composite) and manufacturing processes, covering all the product development cycle.

What will be the growth drivers for the internal combustion engine-driven vehicles business?

Safety is essential and will remain a key driver in the future. Today, the active safety is gaining traction owing to the regulations and overall trends. There is an increasing demand for smart integrated safety, which caters to both active and passive what?

Alongside there are regulations on Co2. In Europe, the Worldwide Harmonised Light Vehicle Test Procedure (WLTP) Norm is challenging and will eventually be implemented in other countries. Regarding Co2 reduction, we focus part of our research and innovation around engine efficiency, aerodynamics and light-weighting, as we did with Bentley for instance.

OEMs are also looking to reduce the manufacturing cost and development time which are leading demand for virtual prototyping, digital twin and shifting OEMs’ investment from hardware to software. The end-to-end value and the digital continuity from the early design to the production is essential to achieve these goals.

OEMs are exploring possibilities to manufacture ICE vehicles and EVs on the same line. Being a solution provider for the smart manufacturing process, how do you see this as a challenge?

Some OEMs assemble EV and ICE vehicles on the same line and look for flexibility, while others use completely dissociated platforms. We, consequently, must find the right strategy regarding their requirements. The new upcoming challenges in CASE mobility manufacturing will bring even more complexities from components to manufacturing. We have to consider the complexity to train the operators: our virtual reality solutions are key here. We help our customers by providing training, on both ICE vehicles and EVs manufacturing processes to their team, even from different place around the world, gathered on the same interface. This solution gathers all stakeholders (from operators to QHSE officers and plant managers) around the same product. This immersive tool helps getting complementary feedbacks early on in the process.

Where do you find more competencies or comfortability — in the complete vehicle design or component design?

Clearly, we are positioning ourselves on the whole vehicle design as it gives the most significant benefit for the OEM and other customers. We are talking about an end-to-end value that we can demonstrate on full scale CAE demonstrators. When it comes to a standalone component, the complex interactions between components and environment are not well taken into account and can lead to reduced predictiveness. In this case, we come up with a holistic view of the problem itself. It is how we defined the four outcome solutions introduced earlier.

Do you think that virtual prototypes will, at a 100 percent, completely replace physical ones ?

Virtual prototypes are step by step replacing physical prototypes. Nevertheless, I think physical prototypes remain today essential to certify the product at the very end of the development phase. To give an example, in 2019 Renault succeeded a 5-star rating of its Clio 5 on the Euro NCAP safety certification test with a single physical prototype, the one needed for the consumer test. Virtual certification is a topic discussed within the automotive ecosystem, allowing to solely relying on the simulation from end to end. But we are not at that point right now.

Which is your largest market for automotive business?

The automotive industry is the most significant contributor to our total revenues. Today, Japan is the largest market for our automotive business. However, India has been an important market for ESI, and it has been growing quite well over the years.

Most of our engineering developments teams, for both our software and our platforms, are based in India.

What are the challenges in the business?

The increasing complexity I mentioned before is definitely a challenge, but it also brings opportunities to us. Our end-to-end multi-material, multiprocess solutions and chaining capabilities are key to overcome the challenges of the automobile market. Due to the ever growing content of electronics, system simulations and systems of systems techniques are improving as well. Our focus is to strengthen our collaboration with partners in the ecosystem to support the customers in solving their complex problems. (MT)

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Sona BLW Precision Forgings has signed definitive agreements with DENSO Corporation to establish two joint ventures aimed at developing, manufacturing and marketing electric and hybrid powertrain systems.

The partnership involves two strategic joint ventures tailored to different vehicle segments. The first joint venture focuses on high-voltage liquid-cooled traction inverters, traction motors and generators for passenger vehicles and commercial vehicles, with DENSO holding a 51 percent equity stake and management control and Sona Comstar holding 49 percent.

The second joint venture targets air-cooled traction inverters, traction motors, generators and e-axles for two-wheelers and three-wheelers, where Sona Comstar retains a 51 percent stake and management control and DENSO acquires 49 percent through a subsidiary structure.

Vivek Vikram Singh, MD and Group CEO, Sona Comstar, said, “We have always believed that the future of mobility will be defined by companies that continuously invest in innovation, product development and industrialization of advanced technologies. This partnership marks an historic milestone in Sona Comstar’s journey as a mobility technology company and reflects the capabilities we have built across advanced electric powertrain systems over the years. DENSO is a company we have immense respect for, as they have been at the forefront of automotive innovation globally for decades with deep expertise in electrification technologies. We are honored and delighted to partner with DENSO to bring together the complementary strengths of both companies and build advanced electric and hybrid powertrain solutions for four-wheelers and larger vehicle applications. This partnership will also accelerate the growth of our existing electric powertrain business for two and three-wheelers by strengthening our capabilities across the powertrain value chain and enabling us to serve a broader set of customers.”

Tsuneo Maebara, Head of Powertrain Systems Business Group, DENSO Corporation, said, “The electrification of mobility represents a major transformation that will continue to evolve in response to the diverse needs of customers and society across the world. India, in particular, is an important region where diverse forms of mobility coexist and electrification is advancing at significant scale. Sona Comstar is a mobility technology company with a global business presence, serving a broad range of customers, and having boldly transformed itself alongside the rapid evolution of the mobility market – from conventional vehicle technologies to solutions for both two- and three-wheelers and passenger electric vehicles. Through this partnership, we will bring together the respective strengths that both companies have built over the years to provide electrification solutions that address the diverse needs of customers in India. By harnessing new competitive strengths created through synergies across the two companies’ products, technologies and business foundations, DENSO will further advance and accelerate its electrification business. We will also build on the outcomes achieved in India to deliver value that meets a broader range of customer needs in the future.”

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Mumbai-headquartered JSW Group looks to double down on its ambition to become a formidable player in the Indian automotive industry with plans to acquire a majority stake in Volkswagen for its operations in the country, says a Bloomberg report.

It is no secret that despite investing billions in India, Volkswagen has been struggling to find a strong foothold in the country and has been aiming to attain a 3-5 percent market share without much success.

In FY2026, passenger vehicle sales in India touched 4.64 million units. During the same period, Volkswagen India and Skoda Auto India sold a total of 37,576 units and 75,556 units, respectively, translating to a combined market share of 2.5 percent.

The report further stated that the partners are in advanced discussions, wherein JSW will pick up a significant stake in Skoda Auto Volkswagen India, with the announcement expected in the coming few weeks.

For the unversed, Volkswagen has been scouting for a suitable partner in India, with previous reports indicating a potential partnership with Mahindra Group and Tata Motors, among others.

Interestingly, JSW Group has been aggressively looking to expand its presence and grab a meaningful share in the Indian automotive industry. It already has a presence in the passenger vehicle segment, being the largest shareholder in JSW MG Group India, in addition to its newly established JSW Motors, with the first model set to be introduced in the next few months.

As per media reports, the European automaker has also scaled down its investment plans from the earlier planned EUR 1 billion to EUR 700 million, as it looks to narrow down losses in the country.

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Chennai-headquartered two-wheeler and three-wheeler major TVS Motor Company is optimistic about delivering above-industry growth in the coming quarters, supported by robust structural demand drivers, replacement needs, improving affordability, and accelerating electric vehicle (EV) adoption.

In a post-earnings call, K N Radhakrishnan, Director and Chief Executive Officer, TVS Motor Company, said, “Structural demand drivers, replacement demand, affordability, and continued EV adoption. All these are going to be supportive and I’m pretty confident that TVS will do much better than the industry growth.”

The company continues to see strong momentum in its electric vehicle segment. Following the milestone of crossing one million iQube sales, EV penetration exceeded 10.6 percent in June.

TVS Motor Co’s manufacturing capacity for electric two-wheelers is being scaled from 40,000 units towards more than 50,000 units, while three-wheeler EV capacity is expanding to approximately 30,000 units.

Radhakrishnan sees demand for internal combustion engine (ICE) two-wheelers to remain solid in the domestic market, with the company’s scooter portfolio — including the Jupiter, Ntorq and Scooty ranges — registering robust retail offtake. This has been supported by targeted product upgrades and disciplined inventory management, with dealer stock levels maintained below 30 days.

TVS Apache Crosses 7 Million Sales Milestone, Launches Tu Race Laga Campaign

On the international front, TVS Motor achieved record Q1 sales of 4.68 million units, a 33 percent YoY increase. Growth was driven by a recovery in Africa, expansion in Latin America and strong demand for the HLX series. The company is targeting an increase in total two-wheeler capacity to 8.3 million units.

Despite commodity price volatility and supply chain challenges in April, TVS Motor delivered a healthy operating EBITDA margin of 12.8 percent through strategic price adjustments of approximately 1.5 percent in Q1, ongoing cost optimisation and benefits from scale.

With the festive season approaching in October and November, the company expects sustained momentum across both domestic and international markets, supported by new product introductions and an expanding global footprint.

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European auto major Stellantis has announced leadership changes for the Ram and Jeep brands. Matt VanDyke has been appointed CEO of the Ram brand, effective 20 July, succeeding Tim Kuniskis. Branden Cote has been named CEO of the Jeep brand, effective 3 August, succeeding Bob Broderdorf, who is taking medical leave and will assume a new role upon his return. Both executives will report to Tim Kuniskis, Head of American Brands, North America Marketing and Retail strategy, Stellantis North America.

VanDyke joins Ram following roles as President of Shift Digital, CEO of FordDirect and leadership positions at Ford Motor Company. Cote joins Jeep with industry experience across OEM and dealer retail operations, including roles with AutoNation, Aston Martin Lagonda, Canoo and Mercedes-Benz USA.

Tim Kuniskis, said, “Matt and Branden are proven leaders who will build on our successes and take these iconic American brands to the next level. Their skills and deep industry experience align with our simple – but very important – customer-centric objective: to provide people with the brands and products they love and trust. I also want to thank Bob Broderdorf for his exceptional leadership of Jeep. Bob is a dedicated and valued colleague, and a friend to many across the Company. I look forward to continuing our work together when he takes on his new role.”

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