Witnessing manufacturing modernisation since Maruti Udyog began producing cars in collaboration with Suzuki of Japan at Gurgaon in 1984, the Indian auto industry landscape has drastically changed. Opening up to automation with the installation of some of the best robots available at Kuka, ABB and others, the auto industry has left no stone unturned. Such has been the fervor that Tal, a Tata Motors company, launched a robot called Brabo in 2018 to make manufacturing processes involving the application of sealants, picking and placing of parts, welding and vision inspection reliable and easy to perform. Made with an eye on manufacturing process the world over, the Brabo was tested in over 50 work streams and has so far found use in sectors like lighting, aerospace, software, electronics, plastics, education and logistics sectors apart from the auto industry. Coming from an auto maker that installed 300 Kuka robots to automate the assembly of Sumo and Safari at its Pune plant in 2009, the Brabo has seen many rounds of development and application-preparedness since its launch.                

Smart manufacturing trend

Highlighting the smart manufacturing trend, the TAL Brabo robot with payloads of two and 10 kilos has also found favour with companies in Europe and other places. Highlighting the prowess of Artificial Intelligence (AI) and Internet of Things (IoT), the robot is an example of the fast-changing manufacturing canvas. Producing about 1,286 engines per day, the Igatpuri plant of Mahindra & Mahindra became India's first carbon-neutral manufacturing facility by adopting smart manufacturing practices under Industry 4.0 in 2019. It invested in energy efficient technologies among others. It invested in recycling of water and other waste. It invested in solar panels to power some of its processes in the plant. An industry source expressed that the rapidly changing business environment the world over is providing impetus to smart manufacturing. It is driving efficiency enhancements and collaborations, he added. Emphasising on efficiency enhancements and collaborative efforts as key smart manufacturing drivers, an industry expert stated that technologies like AI, Industrial Internet of Things (IIoT), automation, big data and 5G are the biggest triggers. They are touching every aspect of manufacturing, from sourcing of raw materials to final inspection, he quipped.  

Industry 4.0

As companies like Lincode (it has collaborated with Switzerland-based Global Automotive Alliance), specialising in AI-powered visual inspection with multiple patent-pending defect detection capabilities, find more and more takers in India, the smart manufacturing shift is continuing to take place despite disruptions. It has, in fact, gained speed in India with the race to successfully accomplish BS VI transition in the last few years. A source in the auto industry mentioned that BS VI transition led to manufacturers upping their global ambitions. Vinay Raghunath, Partner and Leader, Automotive Sector, EY India, averred in a report that automotive shop floors are evolving and adopting digital technologies. This, he added, is happening amid challenges like slowdown in demand, non-availability of labour, concerns on health and safety management on the shop floor. Witnessing disruptions relating to ROI among other factors, as Raghunath has informed, the Indian auto industry has been an early adopter of digital manufacturing techniques.  

Working to dial higher efficiency, expertise and superior productivity, the Indian auto industry has been overhauling existing assembly lines, erecting new ones and extensively re-evaluating its manufacturing processes and practices in view of smart manufacturing, especially from an automotive value chain point of view. Taking to Industry 4.0, it is leveraging AI and IoT-based manufacturing technologies to automate further – to engage in machine-to-machine communication (M2M) such that there is self-monitoring as well as self-diagnosing. Taking to Industry 4.0 to tackle unanticipated disruptions like the Covid-19 pandemic, which has put well-oiled supply chains and production lines to the test and made it painfully clear that they in their current form are not as agile or resilient as expected, the auto industry is shifting to smart manufacturing in a big way. It is exploring and experimenting; it is finding new ways. It is doing so as it absorbs a significant change in technologies and products like electrification and EVs.

Operator 4.0 and hyper-intelligence

Investing heavily in data analytics infrastructure and capabilities, the auto industry is leveraging opportunities to digitally transform itself. It is defining the boundaries of physics for data-driven model. It is focusing on digital skills development. It is supporting the rise of Operator 4.0. Taking to collaborative robots that coexist with humans in a workplace, it is transforming its ways of manufacturing significantly. Drawing attention to the semi-conductor shortage and how the auto industry was affected despite using only 10 percent of the production, Vipin Sondhi, Managing Director, Ashok Leyland, explained that the rapidly changing consumer psyche is dictating a move to a completely different technological aspect. Emphasising on material technology, he said smart manufacturing is about digitising and achieving cost competitiveness. It was some two to three years ago that the Chennai-based CV maker began implementing smart manufacturing technologies to mitigate challenges. It took to modernising and digitising existing workplaces to address quality issues that are difficult for human beings to detect and acquire made-to-order or mass customisation capabilities. It took to equipping itself with an ability to expand and contract in tandem with the market conditions even as it took to modularisation of product lines.  

Automating its cab panel pressing plant at Hosur in 2019, which increased the output by up to 66 percent, Ashok Leyland has been one of the many automotive OEMs globally that are investing in hyper-intelligent automation. A confluence of AI and Robotic Process Automation (RPA), hyper-intelligent automation is redefining not just Industry 4.0 but also Operator 4.0. It is facing challenges like the high initial acquisition cost in terms of tools, but that isn’t worrying players involved like Tata Consultancy Services, Wipro, Mitsubishi Electric Corporation, Catalytic Inc and Infosys Limited among others. Estimated to grow at a CAGR of 18.9 percent as manufacturers strive to reduce energy consumption, up quality and reliability, and control costs through predictability and data-driven unique insights, hyper-intelligent automation is turning out to be yet another finer aspect of smart manufacturing. It is proving to be a big enabler for automating repetitive tasks – to enhance efficiencies, to take to cloud computing to ensure significantly more flexibility and to achieve scalability and the ability to collaborate and reduce costs.

Increasing visibility, predictability and enhancing control on operations and inventory, hyper-intelligent automation is aiding effective decision-making. Supported by development of new technologies such as 5G, which according to a domain expert, promises the need for speed and flexibility along with the capability to eliminate network instability or downtime, hyper-intelligent automation is helping automotive suppliers like Rane Madras Limited to make efficiency, reliability and cost control gains. In 2018, the company adopted automated solutions of Mistubishi Electric Corporation for its new plant in Gujarat. It led to a significant decrease in energy consumption. Aiding smart manufacturing, technologies like hyper-intelligent automation and 5G are helping the auto industry to achieve resilience and immunity against future uncertainties. They are helping to integrate Information Technology (IT) systems used for data-centric computing with Operational Technology (OT) systems – for data readiness and cyber security, and for the development of digital talent. Technologies like hyper-intelligent automation and 5G are helping to develop cross-functional profiles like engineering-manufacturing, manufacturing-maintenance and safety-security.

Tackling disruptions and smart working environment

Looking at productivity gains, emerging competition and risk aversity in the globalised world as per the EY report, the auto industry is taking to smart manufacturing to achieve significant technology transformations like electromobility as well. Apart from the creation of a smart working environment, it is also looking at the use of new materials, new process guidelines and practices. With health also becoming a disruptive factor in recent times, the auto industry is looking at automation in processes like inbound logistics, production planning, sourcing, press shop, body shop, paint shop, quality control and outbound logistics through data visualisation. With sensors and analytics shaping up, the smart working environment in a factory is coming to include AI-based alerts and fully automated work floors. This is increasingly getting compounded by data collection, historical data and high-quality extensive data mining. Helping to guarantee ROI, smart manufacturing is helping to lower the ‘takt’ time. It is also ironically undermining the involvement of humans on the shop floor.   

Reducing the cost of computation, storage and connectivity, smart manufacturing is coming of age with plummeting prices of sensors, 3D printers and robots. Empowering cloud-based manufacturing techniques and a gradual increase in the understanding of emerging technologies, smart manufacturing is providing an advantage in terms of the ability to respond to market changes quickly. Taking to develop a new light-duty truck platform with export ambitions and flexibility in terms of left-hand drive and right-hand drive orientation, VE Commercial Vehicles Ltd took to automating its welding line with robots at its Pithampur plant. It also took to robotising its windshield pasting station among others. Experiencing quality, consistency, efficiency and cost gains, the CV maker is also known to have reduced the takt time and energy consumption. As global ambitions and modularity strike in view of the ability to explore new export markets with a cost competitive BS VI product, the auto industry in India is using embedded sensors, RFID and GPS etc. for smart tracking. It is using smart manufacturing technologies to monitor parameters like temperature, pressure, vibration, machine rpm and flow rate.

Smart flexibility

As part of a shift to smart manufacturing, automakers and suppliers are resorting to flexible manufacturing and AR-based solutions to upskill. They are, in view of the technologies like connected vehicles and EVs, stressing on re-aligning their traditional manufacturing setups with that of the future. Emphasising on quality, resource optimisation, streamlining of business processes and adoption of new emerging technologies, they are closely evaluating the advantages of solutions like digital twins and rapid prototyping using additive manufacturing offer. With ROI on their mind, they are embracing smart manufacturing to move up the value chain.

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Bengaluru-based Micelio Mobility, which calls itself a catalyst for India’s clean mobility ecosystem, fostering innovation and collaboration across startups, corporates and academia successfully hosted its Global Clean Mobility Summit 2025.

The event saw discussions on the future of electric vehicles (EVs) in India with participation from leaders from industry, policy and academia.

Tarun Mehta, Co-founder and CEO of Ather Energy, received the ‘Individual Contributor of the Year 2025 Award’ for his work in India’s clean mobility sector.

Shreyas Shibulal, Founder & Director, Micelio Mobility, said, “India stands at a decisive point where clean mobility must evolve from aspiration to acceleration. The collaborations and innovations we witnessed today reaffirm Micelio’s belief that sustainable transport will define not just the next decade of growth but the next era of progress. Micelio remains deeply committed to nurturing ideas that can power a cleaner, more connected and equitable mobility ecosystem for all.”

C V Raman, Member of Executive Committee, Maruti Suzuki India, spoke on the country’s journey toward self-reliance. He stressed that mobility will be a catalyst for the economy to become a developed economy by 2047.

Jan Kuenne, of Grundig Akademie fur Wirtschaft & Technik, highlighted the importance of integrated design, data and investment for infrastructure.

Kuenne said, “Every visit to Bengaluru reminds me why this city is so special; the innovation here is unlike anywhere else. The ideas coming out of India are shaping the future of clean mobility for the world. We’re not just talking about electric vehicles; we’re talking about reimagining how cities move. From digital twins to new mobility systems, India is showing that sustainability and progress can go hand in hand. Together, we can create a world where clean, smart and responsible movement becomes the new normal.”

The summit released Micelio’s report, 'Closing the Loop: Building a Roadmap for Battery Circularity in India'. A Knowledge Roundtable agreed that upskilling and reskilling are required to make India industry ready for EV scaling.

The event also highlighted the collaboration between Micelio Mobility and the Automotive Research Association of India (ARAI) on the Digital Twin Lab for EV testing.

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Fery Rides, an Indian mobility start-up focussing on women's transportation led by women, has raised INR 20.75 million in a seed funding round led by IAN Angel Fund, part of IAN Group, with participation from Hari Balasubramanian, Uday Chatterjee and Sri Prakash.

The funding will be used to strengthen the technology platform, expand operations beyond the NCR region and onboard more women drivers, which the start-up refers to as Sister Partners.

The start-up aims to provide safe and reliable transport for women passengers, with every ride operated by trained and verified women drivers. The platform is developed by Ajay Kumar, alongside Vindhya Mehrotra and Himanshu Chaubey, with a key focus on women's safety.

The all EV service uses an app for onboarding, real-time tracking with SOS alerts and WhatsApp-enabled customer support.

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Sterling Tools, a leading automotive component manufacturer, has announced its subsidiary Sterling Gtake, which focusses on electric vehicle, has been rebranded as Sterling E-Mobility Solutions.

The company stated that the strategic rebranding is part of its portfolio expansion and its aim to be an integrated solutions supplier for EV powertrains and power electronics.

Anil Aggarwal, Chairman, Sterling Tools, said, “We are proud to begin this new chapter as Sterling E-Mobility Solutions. This rebranding reflects our commitment to delivering integrated EV solutions powered by global innovation and local expertise. Our exclusive partnership with Gtake remains strong, and we’re excited to explore new collaborations that strengthen our leadership in the EV ecosystem. We thank our partners and customers for their continued trust and support as we work together to shape India’s e-mobility future.”

In May 2025, Sterling entered into a technology licensing agreement with Advanced Electric Machines (AEM), UK, to manufacture magnet-free motors in India. In Sep 2025, the company announced another key partnership with Landworld Technology Co., China, for their range of on-board chargers and DC/DC converters.

Furthermore, the company’s existing relationships with Jiangsu Gtake Electric Co., for the Indian market, remains strong and unchanged. This partnership continues to flourish, with multiple products being developed by Gtake and localised by Sterling to meet domestic requirements.

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Toyota Kirloskar Motor (TKM) has signed a Memorandum of Understanding (MoU) with Samagra Shikshana Karnataka (Department of School Education and Literacy), Government of Karnataka, to strengthen vocational education for students in Grades 9 to 12.

The collaboration aims to link education with industry, provide students with experience in automobile technology and address the demand for skilled workers. The initiative will also focus on the development of school students.

The programme will be carried out in eight government schools across seven districts of Karnataka, reaching more than 800 students. The schools are located in Kudur and Kanakapura (Bengaluru South), Peenya (Bengaluru Urban), Bagepalli (Chikkaballapur), Byadagi (Haveri), Harapanahalli (Vijayanagara), Turvihal (Raichur) and Haliyal (Uttara Kannada).

The MoU was signed in the presence of K Vidya Kumari, IAS, State Project Director, Samagra Shikshana Karnataka, MR Maruti, KAS, Director (Quality), SSK and A Ramesh Rao, Vice-President, External Affairs-Karnataka & Corporate Social Responsibility, Toyota Kirloskar Motor.

The partnership includes teacher training through a comprehensive Train-the-Trainer programme, which will give faculty members exposure to Toyota’s manufacturing and learning processes. TKM will also set up automobile skill laboratories in the schools to deliver practical, industry-specific knowledge. Students will also gain exposure to industrial environments and company practices, promoting discipline, a safety mindset and respect for people.

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