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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As a key contributor to India’s rail modernisation, Pinnacle Industries has been selected as the official partner by Indian Railways to design and manufacture the sleeper berths and executive seating for the new Amrit Bharat Express. This partnership aligns with the train's role as a transformative, high-speed and affordable option for long-distance travel across the country.

The seating solutions developed by Pinnacle are the result of extensive ergonomic engineering, created to provide superior comfort, safety and longevity. They are specifically optimised to perform reliably in both air-conditioned and non-air-conditioned coaches. A primary focus has been placed on passenger well-being for extended journeys, achieved through enhanced cushion thickness in both seats and berths. The design also incorporates refined aesthetics with improved colour schemes and features like aluminium extrusions for the upper berths.

Safety is a critical component of the design, which includes specialised anti-injury fittings integrated into the seats and berths to minimise potential risks. Furthermore, all materials fully comply with the stringent fire safety standard EN45545-2 HL3, meeting Indian Railways' rigorous requirements for fire-retardant properties. Leveraging decades of expertise in mobility interiors, this project reinforces Pinnacle Industries' position at the forefront of developing world-class transportation solutions for India.

Arihant Mehta, President, Pinnacle Industries, said, “We are honoured to be a part of this visionary initiative by Indian Railways. Our seating solutions for the Amrit Bharat Express reflect our commitment to designing products that combine comfort, safety and innovation while being proudly Made in India. With this, we continue to drive India’s vision of modern, accessible and reliable public transport.”

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The Society for Automotive Fitness & Environment (SAFE), an initiative of the Society of Indian Automobile Manufacturers (SIAM), held its 26th annual convention today to address the urgent need for road safety and a transition to green mobility. Held at Bharat Mandapam, the event, themed ‘Together for Safe Roads and Green Mobility: Building a Sustainable India,’ brought together government officials, industry leaders and experts.

Rekha Gupta, the Chief Minister of Delhi, was the Chief Guest and emphasised that accidents are a result of driver behaviour, not vehicles. "We must shed the mindset that breaking rules is a badge of pride," she said.

She also highlighted Delhi's commitment to clean mobility, with a goal of electrifying 100 percent of its public transport by 2026. The Chief Minister also launched SAFE's new Road Safety Context Paper and a new initiative to involve college students in road safety.

In a video message, H D Kumaraswamy, the Union Minister of Heavy Industries and Steel, noted that the government has invested over INR 600 billion to boost domestic manufacturing and support clean energy adoption.

Sushant Naik, President of SAFE, stressed that safety must be a core part of design and manufacturing. "Over 173,000 lives are lost each year, a stark reminder that action should be urgent and collective," he said. He emphasised that road safety requires the collaboration of the five ‘Es: Education, Engineering, Emergency Care, Enforcement and Evaluation’.

Speakers, including Mahmood Ahmed, Additional Secretary of the Ministry of Road Transport and Highways (MoRTH), highlighted the need for a comprehensive accident database and a unified system to link driver licensing, vehicle registration and enforcement.

Sanjay Bandopadhyaya, a member of the Supreme Court Committee on Road Safety, pointed out that accidents rose in 2023 despite a goal to halve them, calling for stricter electronic enforcement to curb reckless driving.

Ajay Chaudhry, Special Commissioner of Police (Traffic) of the Delhi Police, noted that while the city has cut accident fatalities by 8 percent, speeding and violations remain a serious problem and he called for ‘zero leniency.’

The convention featured two plenary sessions focusing on ‘Education and Engineering’ and ‘Enforcement, Emergency Care and Evaluation.’ These sessions covered topics like promoting responsible driving, designing safer infrastructure and the importance of a swift emergency response to reduce accidents and save lives.

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Union Minister of Commerce & Industry, Piyush Goyal, inaugurated the Electric Vehicle (EV) Zone at the International Electrotechnical Commission's (IEC) 89th General Meeting in New Delhi on 15 September 2025. The exhibition, hosted by the Bureau of Indian Standards (BIS), runs until 19 September at Bharat Mandapam.

The EV Zone, organised by the Society of Indian Automobile Manufacturers (SIAM), showcases the country's progress in electric mobility. Goyal toured the pavilion, which features 31 production-ready electric vehicles from 14 major manufacturers, including Tata Motors, Mahindra & Mahindra and JSW MG Motor.

During the event, Minister Goyal emphasised that sustainability is a core pillar of India's growth strategy. He highlighted the importance of high-quality standards in protecting consumers and boosting the competitiveness of Indian-made products on the global stage. He also stated that ‘Design in India, Made in India’ products would soon be recognized globally for their reliability and excellence.

Prashant K Banerjee, Executive Director of SIAM, expressed appreciation for the government's vision, noting that the automotive industry is committed to this journey. The IEC GM 2025 has brought together over 2,000 global experts from more than 100 countries to discuss international standards, with the exhibition also featuring advancements in smart lighting, electronics, and IT manufacturing.

SIAM’s participation is part of its commitment to sustainable mobility and achieving India's Net Zero targets by 2070. Visitors to the EV Zone can also take a ‘Digital Sustainability Pledge,’ with BIS planting a sapling for each pledge made.

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The Federation of Automobile Dealers Associations (FADA) has released the results of its Dealer Satisfaction Study (DSS) 2025. The study, conducted in partnership with the Singapore-based consulting firm PremonAsia, was announced at the 7th Auto Retail Conclave on 10th September.

C.S. Vigneshwar, President, FADA, noted that the study provides a ‘true mirror’ to the relationship between dealers and OEMs. The study surveyed over 1,800 dealer principals, representing nearly 5,000 outlets across the country. For the first time, it was conducted in nine regional languages to ensure broader participation.

• JSW MG Motor captured the top position in the 4-Wheeler Mass Market segment with a score of 868 points.
• Royal Enfield led the 2-Wheeler segment with 852 points, followed by Hero MotoCorp. Both companies showed improvement from the previous year.
• Ashok Leyland retained its leadership in the Commercial Vehicle segment with 786 points.
• The 3-Wheeler segment was included again after three years, with Atul Auto topping the category with a score of 924 points.
• Volvo Cars topped the 4-Wheeler Luxury segment with 884 points.

The industry average dealer satisfaction score was 781, a 13-point increase from the previous year. Product continues to have the highest score across all categories, indicating dealers are largely satisfied with the quality, reliability and range offered by OEMs.

Rahul Sharma, Director and COO, PremonAsia, said, "close to two-thirds of dealer sentiment is shaped by after-sales service and viability factors. While after-sales service is the most important factor, Business and viability remains a key concern for dealers. Dealers cited issues such as buyback/write-off of unsold inventory, training cost-sharing arrangements and margins on vehicles and spare parts.”

Dealer satisfaction improved in the 2-wheeler segment compared to the previous year, but it declined in the 4-wheeler Mass Market and Commercial Vehicle segments. Vigneshwar stated that while the industry is performing well on product quality, structural issues like buyback policies, training costs and dealership viability cannot be ignored.

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