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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Hyundai Motor India Limited (HMIL) has launched a new brand campaign ahead of the ICC Women’s T20 World Cup 2026, featuring its brand ambassadors Smriti Mandhana and Jemimah Rodrigues. The campaign builds on the success of the earlier men’s World Cup initiative titled ‘Deewane India ka Deewana Humsafar’ but presents a distinct narrative focused on celebrating the rising support and admiration for women’s cricket in India.

The campaign directly challenges the traditional label of cricket as a gentleman’s game with the bold message that the ‘gentle’ has been removed from the sport. Through strong visuals, it highlights the determination, skill and barrier-breaking performances of women cricketers, showing how their passion is transforming the game and deepening India’s love for cricket.

As a Premier Partner of the ICC, HMIL plans to engage fans during the tournament with curated digital content and targeted outreach. These efforts aim to amplify the excitement of the Women’s T20 World Cup, bring fans closer to the action and strengthen Hyundai’s emotional connection with cricket enthusiasts.

Virat Khullar, Head – Marketing, Hyundai Motor India Limited, said, “At Hyundai, we believe sport has the power to unite communities, inspire dreams and create meaningful connections. The overwhelming response to our ‘Deewane India Ka Deewana Humsafar’ campaign reaffirmed the deep emotional bond between cricket and its fans. With the ICC Women’s T20 World Cup, we are proud to celebrate a new chapter of this passion by recognising the growing influence of women’s cricket and the millions of fans who continue to champion the game. This campaign aims to celebrate that shift and spotlight the incredible journeys of players like Smriti Mandhana and Jemimah Rodrigues, who continue to break stereotypes and inspire millions. As a proud partner of the ICC, Hyundai remains committed to supporting this new era of cricket and standing alongside the champions who embody the true spirit of ‘Deewangi’.”

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Vega Auto Accessories, a leading helmet manufacturer, has announced a strategic investment in Tageze Medical ID System, a Pune-based emergency technology platform operated by Techsocio Projects.

The transaction marks a direct entry for the traditional protective gear manufacturer into the connected safety and digital emergency response sectors, moving the brand's product ecosystem from pure accident prevention into active medical response coordination.

Tageze develops a decentralised, application-free medical identification platform. Utilising ruggedised, weather-proof QR-code tags integrated directly onto the helmet shell, the technology creates an immediate digital profile for first responders.

During a critical road incident (golden hour), bystanders, emergency responders, or healthcare professionals can simply scan the helmet-mounted QR code with any standard smartphone camera. The system instantly loads a secure, cloud-hosted medical profile outlining: primary and secondary emergency contact routing; blood group categorisation, known allergies, chronic medical conditions and current medications; health and vehicular insurance policy details to expedite hospital admission procedures.

Because app installation requirements often introduce friction during high-stress rescue operations, the platform operates entirely via a responsive mobile web interface. It supports multilingual localisation, dynamically translating medical profiles based on the browser settings of the first responder – a critical feature for long-distance touring riders navigating diverse linguistic states and countries.

The capital injection from Vega will be utilised to expand Tageze's technical infrastructure and scale its market footprint across India and its existing international distribution nodes.

For Vega, the alignment signals a broader shift occurring across the personal protective equipment (PPE) sector. As global motorcycling demographics demand higher technology integration, manufacturers are shifting beyond standard impact testing (such as ECE 22.06 or DOT standards) to capture the digital layer of post-crash telemetry and identity verification. The companies confirmed that the investment will fund a dedicated R&D pipeline aimed at embedding next-generation, hardware-level emergency tracking chips and intelligent response systems directly into future Vega and AXOR helmet lineups.

"At Vega, rider safety has always been at the core of everything we do. Through our partnership with Tageze, we are looking at safety beyond the helmet itself by enabling faster access to critical information during emergencies. We believe this is an important step towards building a more connected and responsive rider safety ecosystem," Vega said in a statement.

Deepak Gaikwad, Founder & CEO, Tageze Medical ID System, added, "Our mission has always been to make life-saving information accessible when it matters most. Partnering with Vega allows us to expand the reach of this technology and bring emergency preparedness closer to riders across India and global markets."

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Ireland-headquartered intelligent power management company Eaton has entered into a definitive agreement to separate its Mobility Group business and combine it with Dana Incorporated in a Reverse Morris Trust transaction.

The deal values the combined company at over USD 10 billion in enterprise value and values Eaton’s Mobility Group at approximately USD 5.1 billion. The transaction is scheduled to close in Q1 of CY2027, subject to approval by Dana shareholders and regulatory clearances.

Under the terms of the agreement, Eaton will receive a tax-free cash distribution of approximately USD 1.1 billion, which will be funded by newly issued debt from the mobility entity. Eaton shareholders will receive shares in the combined business, resulting in a post-transaction ownership structure where Eaton shareholders hold at least 50.1 percent of the outstanding shares and Dana shareholders own approximately 49.9 percent.

The transaction allows Eaton to alter its corporate focus toward its electrical and aerospace divisions, which align with market trends in electrification, data centres, infrastructure modernisation and aerospace defence.

The combined entity will merge Dana’s portfolio of axles, driveshafts, thermal management and sealing products with Eaton’s commercial vehicle transmissions, clutches and engine emissions technologies. The merged entity will target internal combustion, hybrid and electric vehicle platforms across commercial and light vehicle manufacturing sectors.

The combined entity will retain the name Dana Incorporated and continue its public listing on the New York Stock Exchange under the ticker symbol DAN. The business is projected to generate approximately USD 11 billion in pro forma revenue and USD 1.7 billion in pro forma estimated 2026 adjusted EBITDA. The integration plan targets USD 250 million in annual run-rate cost synergies to be fully achieved within 24 months of closing.

Furthermore, Byron Foster will become the Chief Executive Officer of the combined company and Timothy Kraus will assume the role of Chief Financial Officer. R. Bruce McDonald will serve as Executive Chairman, while Erin Rowse is named as the incoming Chief Human Resources Officer. Dana’s board of directors will expand from eight members to include three additional directors appointed by Eaton.

Paulo Ruiz, Chief Executive Officer, Eaton, said, "We are pleased to have reached this agreement, which delivers significant value to Eaton and its shareholders and represents a major milestone in Eaton’s 2030 growth strategy to lead, invest and execute for growth. Eaton shareholders will benefit from the meaningful upside created by the combined company, and the transaction will provide substantial cash value for Eaton to deploy to our highest-growth and highest-margin opportunities. Looking ahead, our portfolio will be closely aligned with the powerful megatrends driving generational growth in our Electrical and Aerospace businesses, and we look forward to continuing our momentum to drive meaningful value for our customers and shareholders."

R. Bruce McDonald, Dana Chairman and Chief Executive Officer, said, "We are excited to bring together Eaton’s Mobility Group with Dana. The addition of Mobility Group’s leading positions in commercial vehicle transmissions, clutches and power management technologies, combined with Dana’s strengths in axles, driveshafts, electrification, thermal management and sealing products, will create a truly differentiated global platform. Together, we will be better positioned to serve our customers, invest in innovation and drive long-term value creation for shareholders of the combined company.”

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Bajaj Auto Foundation, the CSR arm of Bajaj Auto Limited, has announced a significant INR 4 billion commitment over the next decade to support women engineers through the Rupa Rahul Bajaj Scholarship for Women in Engineering (RRBSWE). The initiative is aimed at increasing female participation in core technical fields.

The scholarship, recognised as India’s largest such programme for women in core engineering, targets meritorious students pursuing disciplines like Mechanical Engineering, Electronics, Industrial Instrumentation, Mechatronics and Robotics. Scholars at 40 leading institutes, including IITs, NITs, IIITs and reputed state and private universities, can receive up to INR 800,000 in financial aid throughout their engineering education.

Beyond monetary support, the programme focuses on holistic leadership development. It offers structured mentorship, industry immersion and professional networking opportunities to cultivate future women leaders in engineering and manufacturing sectors. The launch event at Bajaj Auto Ltd.’s Pune headquarters also celebrated the first cohort of 506 scholars, with chief guest Kiran Mazumdar-Shaw and Rajiv Bajaj in attendance.

The foundation highlighted that this effort tackles the persistent underrepresentation of women as advanced manufacturing and deep technology grow critical for India’s economy. Unveiling its overarching proposition, ‘Where there’s a skill, there’s a way’, the foundation reaffirmed its dedication to skilling and education for the nation’s future workforce.

Rajiv Bajaj, Managing Director, Bajaj Auto Limited, said, “Women possess inherent skills of patience, empathy and diligence, which are very strong attributes to excel in core engineering jobs. We identified this long back and made women engineers a significant part of our workforce. In fact, from virtually no women in our operations till around a decade back, today they account for nearly 20 percent of our workforce. This has brought a meaningful difference to our way of working and contributed to Bajaj Auto’s global scale, thereby making us the World’s Favourite Indian. This programme would extend our learning with the larger manufacturing industry.

“The Rupa Rahul Bajaj Scholarship for Women in Engineering holds a special place in my heart, as it carries the name of my beloved mother, Rupa Rahul Bajaj. Her dedication to education and her belief that women can drive change in their communities inspire this programme. The Rupa Rahul Bajaj Scholarship is an investment in talent, ambition and the belief that opportunity can unlock extraordinary potential. We are deeply committed to ensuring that women play a far greater role in shaping the future of engineering and manufacturing.”

Kiran Mazumdar-Shaw, Executive Chairperson, Biocon Limited, said, “The future of science, engineering and manufacturing must be built on inclusion and equal opportunity. Encouraging more women to pursue core engineering disciplines is not just a social imperative but an economic one. Initiatives like the Rupa Rahul Bajaj Scholarship can help create a stronger and more diverse innovation ecosystem for India.”

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