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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German luxury and high-performance vehicle manufacturing company Porsche is reducing its Executive Board divisions from 8 to 7 as part of a strategic realignment. The Car-IT division will be suspended and integrated into the Research and Development division effective 1 July 2026. Dr Michael Steiner, Member of the Executive Board for Research and Development, will lead the expanded department.

Sajjad Khan, who managed the Car-IT division for two and a half years, will step down from the Executive Board on 19 June. He will continue to work with the company through a software partnership model.

During his tenure, Khan led the development of connectivity and infotainment systems, including the introduction of the Porsche Digital Interaction design language in the Cayenne electric. These technologies are being rolled out to other models, with specific versions for the Chinese market being developed in Shanghai.

The restructuring is intended to adapt the company to current market conditions and increase the speed of software development.

Dr. Wolfgang Porsche, Chairman of the Supervisory Board of Porsche AG, said, “Porsche is in a challenging phase of transformation. We need to realign the company and are consistently adapting our structures under the leadership of Dr. Michael Leiters to the changed circumstances — including at Executive Board level. I would like to thank Sajjad Khan for taking on responsibility for the company. We will continue to benefit from his professional expertise and in-depth knowledge of our structures in the future.”

Sajjad Khan, stated, “I am proud of what we have achieved as a team over the past two and a half years. In a constantly evolving market environment, however, it is essential to continuously review and adapt structures and processes. Porsche’s outstanding engineering expertise, combined with agile, results-driven software development, provides an excellent foundation for the future development of software components.”

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The 47th International Vienna Motor Symposium concluded at the Hofburg Palace, gathering 1,000 industry professionals and 50 exhibitors to discuss the future of propulsion. The event featured 100 presentations focused on achieving carbon neutrality through a range of technologies rather than a single solution.

A highlight of the symposium was the European premiere of China SAE’s Roadmap 3.0, a strategy charting China's automotive direction through to 2040. Professor Xiangyang Xu of Beihang University detailed the plan, which anticipates that 1/3rd of new vehicle registrations in 2040 will still feature electrified combustion engines.

Madame Ruiping Wang of Geely Auto supported this view, stating that every technological solution is required to reach neutrality goals.

In the electric vehicle segment, Mercedes-Benz demonstrated the range of the new EQS, completing a 620-kilometre journey from Stuttgart to Vienna with 21 percent battery charge remaining.

PowerCo SE, the battery subsidiary of Volkswagen, reported that serial production of its ‘standard cell’ began in Salzgitter in December 2025.

Stefan Pischinger of RWTH Aachen University projected that battery electric vehicles (BEVs) could reach a 45 percent global market share by 2035 under favourable conditions.

The symposium also highlighted advances in internal combustion engine efficiency and alternative fuels:

AVL List presented an engine achieving 48 percent thermal efficiency.

Porsche detailed a direct oil-cooling system for high-output electric motors in the Cayenne Electric Turbo.

Horse Powertrain introduced a petrol engine platform designed specifically for range-extended electric vehicles (REEVs), a segment that saw 1.2 million sales in China last year.

Alpine CEO Philippe Krief discussed the potential revival of in-wheel motors.

Hydrogen remains a focus for both direct combustion and fuel cell applications. Professor Helmut Eichlseder of Graz University of Technology emphasised the importance of hydrogen research for industrial resilience.

Industry leaders expressed concerns regarding European competitiveness. Niklas Klingenberg of TRATON noted the need for harder work to remain competitive in Europe, while Matthias Zink of Schaeffler and CLEPA spoke on the challenges of navigating EU legislative environments. The 48th International Vienna Motor Symposium is scheduled for 21–23 April 2027.

Professor Bernhard Geringer, President of the organising Austrian Society of Automotive Engineers (OVK), and host for the annual symposium, said, “The big picture – from cradle to grave in terms of energy and propulsion – is what matters most.”

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Ferrari has secured the highest distinction from Germany’s Red Dot Award organisation, as the Ferrari SC40 earned the Red Dot: Best of the Best honour within the Product Design category. Additional triumphs for the Ferrari Amalfi, 849 Testarossa, 849 Testarossa Spider, 296 Speciale and 296 Speciale A further reinforced the manufacturer’s design prowess.

Now in its 72nd year, the Red Dot Award stands as a premier industrial design competition celebrating breakthrough work. Ferrari’s cumulative tally over the past 12 years has reached 35 Red Dot wins, a feat no other automaker has matched since the prize was established in 1955. Since 2015, the jury has presented Ferrari with 13 Best of the Best awards, including for the FXX-K, 488 GTB, Ferrari J50, Portofino, Monza SP1, SF90 Stradale, Daytona SP3, Purosangue, Vision GT, Roma Spider, 12Cilindri and 12Cilindri Spider, F80 and the SC40.

This year’s Best of the Best accolade also draws attention to the exclusivity and remarkable value of the Special Projects programme, where a limited number of clients work directly with Maranello’s designers and aerodynamicists to create a personalised One-Off Ferrari.

Visitors to the Museo Ferrari in Maranello can currently view the car’s full-scale styling buck, a key artifact from the design process. The display reveals how the model’s proportions and surfaces took shape before production, emphasizing the defining volumes and graphic details that give the vehicle its identity. The buck serves as a tangible bridge between the initial design phase and the final One-Off creation.

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Kia Europe has appointed Dante Zilli as Marketing Director, effective 1 May 2026. He will report to Pablo Martinez Masip, Vice President of Product, Brand and Customer Experience. The move supports Kia’s ongoing electrification transformation.

Zilli will lead brand strategy and integrated campaigns across key customer touchpoints. His responsibilities include product launches, brand consistency and customer engagement. He brings international leadership experience in marketing, commercial operations and customer experience, having worked in six countries and several regional headquarters, offering strong insight into European market dynamics.

Zilli joined Kia Europe in 2021 as General Manager of Communications and then Customer Experience. He succeeds David Hilbert, who returned to Kia UK as Sales Director. Hilbert helped implement Kia’s brand transformation and ‘Plan S’ strategy in Europe, including campaigns for the EV6, Car of the Year 2022, and the PV5, International Van of the Year 2025, which also set a Guinness World Record.

Zilli said, “I am honoured to take on the responsibility of continuing to build the Kia brand in Europe, building on a period of strong product launches and sustained momentum. I look forward to further advancing our ‘Movement that Inspires’ philosophy to strengthen customer engagement and deliver increased value and relevance across European markets.”

Masip said “Dante combines international marketing expertise with a strong record within Kia Europe. His proven leadership across communications and customer experience ensures continuity in our marketing approach while further strengthening the alignment between brand, product and customer engagement across Europe.”

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