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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JSW MG Motor India, one of the leading passenger vehicle manufacturers, has announced the eight winning startups selected for the 6^th edition of the MG Developer Program.

The startup engagement initiative, centred on the theme 'Innovation in Automotive', evaluated over 130 applications before selecting the finalists for pilot deployment consideration.

The selected startups comprise Nayan Technologies, Technod8.AI, LiveNSense, LW3, Smaartbrand by Acquink Solutions, Fitsol, Cautio and Meta Materials Circular Market.

The chosen entities specialise in artificial intelligence (AI) platforms, industrial software, battery supply chain tracking, mobility intelligence, supply chain decarbonisation and automotive circular economy systems.

The winners will collaborate with the vehicle manufacturer and program partners to test and implement pilot projects across industrial operations, manufacturing, customer experience and mobility services.

Anurag Mehrotra, Managing Director, JSW MG Motor India, said, "We are entering an era where the boundaries between mobility, data, and artificial intelligence are rapidly converging. The next wave of transformation in the automotive industry will be driven by innovators who can connect these ecosystems and create solutions with real-world impact. Through the MG Developer Program, we are committed to providing startups with a platform to collaborate, experiment and scale breakthrough ideas. The winning startups of Season 6.0 represent some of the most promising innovations across automotive technology, sustainability, industrial intelligence, and mobility services. We look forward to partnering with them to explore pilot deployments and unlock new possibilities for the future of mobility."

The sixth season was conducted in partnership with DPIIT, Startup India, JSW, NCPI BHIM, Jio, Gulf Oil India, TiE Delhi NCR, iCreate, Allianz Partners India, TERI, BSES Rajdhani Power Limited, LICO Materials and Pulse Energy.

The program saw more than 40 startups shortlisted for presentations, with 18 reaching the final jury stage. Since its launch in 2019, the program has evaluated over 1,680 startup applications covering connected vehicles, electric mobility, artificial intelligence, and manufacturing technologies.

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Cummins India has announced the appointment of Gbile Adewunmi as Managing Director and India Regional Leader, effective 1 November 2026. Adewunmi will assume the position alongside his current role as leader of Industrial Markets within Power Systems, where he will continue to direct business operations for the division.

In his current role as Vice-President, Power Systems Industrial Markets, Adewunmi oversees customer and partner operations across industrial segments, including mining. His work in the division has focused on hybrid-electric retrofit systems, mining technologies, and power solutions aimed at operational efficiency and emissions reduction.

Jenny Bush, President of Power Systems, Cummins, said, “Gbile is a respected global leader with deep experience across Cummins and a strong track record of delivering customer-focused growth and business performance. His enterprise perspective, ability to build high-performing teams and commitment to our customers make him exceptionally well positioned to lead Cummins India Limited and the India region while continuing to advance our Industrial Markets strategy.”

Adewunmi said, “I am honoured to take on this expanded role and to work alongside the talented teams across Cummins India, the India region and Industrial Markets. “India is a critical market for Cummins, and I look forward to partnering with our employees, customers and stakeholders to build on our strong foundation and continue powering a more prosperous world.”

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Birla Carbon is pushing deeper into speciality materials, positioning a suite of conductive carbon solutions aimed at tough applications that include next-generation batteries and other high-value conductive uses.

Within battery electrodes, conductive carbon creates the electron pathways that keep performance steady. Selecting the correct conductive additive can translate into quicker charging, stronger high-rate capability and a longer cycle life, while also making battery manufacturing more efficient. At The Battery Show North America 2026, Birla Carbon will put this portfolio on display. The event runs 12–15 October at Huntington Place in Detroit, Michigan, with the company located at Booth 3029.

Showcased products will include Conductex i conductive carbon black grades, Nanocyl carbon nanotubes and blend formulations combining carbon black with CNTs, all built for a broad spread of conductive applications. They offer high purity, leading conductivity and consistent dispersibility, while Conductex i grades additionally cut solvent and energy use during electrode production, bringing down customer costs. The additives address industry priorities such as charge acceptance, battery capacity, dry coating and solid-state, helping manufacturers keep pace with rising demands without giving up quality, consistency or dependable supply.

Shashank Awasthi, President, Speciality Materials, Birla Carbon, said, “Electrification is creating new performance demands across the materials value chain, and advanced carbon materials have an important role to play in meeting them. At Birla Carbon, we are combining our expertise in carbon materials with an expanding specialty portfolio to help customers address these evolving requirements. Established lithium-ion battery manufacturers need to showcase supply chain resilience, extended cycle life and ever-increasing fast charging requirements, which Birla Carbon’s portfolio enables. Next-generation cell technologies, like LMFP, sodium-ion, solid-state and metal-air, are rapidly improving by incorporating ConductexTM i carbon blacks and NanocylTM carbon nanotubes into their formulations.”

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Automotive tier 1 suppliers FORVIA and Anand Group have established a new joint venture to manufacture seat frames and complete seats for the Indian automotive market.

The new entity, named Faurecia Anand Seating India, will be controlled by FORVIA with a 50 percent plus one share stake, while Gabriel India, Anand Group’s flagship listed firm, will hold 50 percent less one share.

The partnership aims to combine FORVIA’s seating technologies and engineering portfolio with Anand Group’s operational network and customer relationships with domestic automotive manufacturers.

The JV aims for a 10 percent market share in India over the next five years as part of its regional expansion strategy. The collaboration expands on an existing relationship between the two companies that began in 1991 in the clean mobility segment.

The joint venture will utilise localised manufacturing footprints to support supply chain, industrial and talent capabilities for supply contracts across Indian vehicle manufacturers.

Jaisal Singh, Vice-Chairman, Anand Group, said, "This partnership is a natural extension of Gabriel India’s transformation into a broader mobility solutions enterprise. As vehicle systems become more integrated and technology-intensive, the ability to participate across a wider spectrum of the automotive value chain assumes strategic importance. The venture strengthens our portfolio with a globally proven capability, while reinforcing our commitment to building scalable, technology-led businesses that create enduring value."

Anjali Singh, Executive Chairperson, Anand Group and Gabriel India, said, "At Anand, we have always believed that long-term relevance is built through thoughtful partnerships, technological excellence, and a deep understanding of customer needs. This venture strengthens our longstanding partnership with FORVIA, building on complementary strengths and a shared commitment to innovation. By bringing together FORVIA’s global expertise and Gabriel India’s strong market presence, it creates a platform that is both strategically significant and future-ready."

Martin Fischer, CEO, FORVIA, said, "When we unveiled our IGNITE strategy earlier this year, we highlighted India as a key growth driver for FORVIA. Following the award of our first complete-seat program a few months ago, today’s agreement marks another important milestone in our development in the country. Building on our long-standing relationship with Anand Group, the joint venture will help accelerate FORVIA Seating’s growth in India."

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