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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Rolls-Royce Motor Cars has reached a key milestone in the expansion of its Goodwood facility, officially declaring the new structure fully weathertight. This significant development paves the way for the next stage of the project.

To commemorate the achievement, CEO Chris Brownridge, accompanied by the Board of Directors, personally hand-signed the final wooden louvre installed on the building’s exterior. This element is one of 1,745 such features adorning the 40,000-square-metre structure. Each louvre, measuring 100 by 58 centimetres, is crafted from red cedar. This material was chosen for its durability and its natural ability to age gracefully, developing a soft silver-grey patina that harmonises with the landscape, mirroring the aesthetic of the original adjacent building, which also features red cedar cladding on its front elevation. This ceremonial signing follows a tradition established last year when the directors marked the installation of the final steel beam at the structure's apex.

With the exterior now complete, attention turns to the interior fit-out, managed by Rolls-Royce's specialist in-house teams. A central focus is the development of a new Surface Finish Centre, which will serve as a dedicated paint shop. Concurrently, work will progress on installing advanced equipment and establishing specialised areas tailored for Bespoke and Coachbuild projects.

Representing an investment exceeding GBP 300 million, this expansion is the most substantial financial commitment to the Home of Rolls-Royce since its inception in 2003. It is set to enhance the company's substantial economic contribution, which currently adds over GBP 500 million annually to the UK economy.

Chris Brownridge, CEO, Rolls-Royce Motor Cars, said, “This moment marks the point at which our new extension building becomes fully weathertight, meaning our specialist Technologies can begin the complex, exacting process of fitting-out, in readiness for full operation in 2029. It’s a really pivotal point in the project – a project that upholds the standards and vision of our founder, Sir Henry Royce, and his famous injunction to strive for perfection in everything we do. The Directors and I have also been inspired by his practice of personally inspecting and signing off each new component, giving them his own ‘seal of approval’. Having previously signed off the final element of the structural steelwork, we wanted to do the same for the last of the wooden louvres that now clad its exterior. It’s enormously exciting to see the work progressing with such pace and precision. To have that sense of personal connection with such a significant project through these signing ceremonies is very special for all of us.”

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Embracing the deep-seated passion for cricket in Kolkata, the Kolkata Knight Riders, in partnership with VIDA, powered by Hero, launched the VIDA Knights Electrifying Box Cricket tournament. This innovative three-day event, held from 19 to 21 February, represented the franchise's most ambitious fan-centric initiative to date, designed to immerse supporters directly into the professional cricketing environment.

The tournament was structured to deliver a premium competitive experience, reflecting KKR's dedication to nurturing talent at the community level. Over three days, 32 teams, each consisting of 10 players, engaged in intense group stage and knockout matches. The competition culminated with Joy Game Changers being crowned the first-ever champions, while Knights Dé Xtreme secured the position of runners-up. The event transcended traditional play by incorporating digital culture, as a special team composed of popular Kolkata content creators like Neel Bhattacharya, DaSoham, Rahul Dey, Saiket Dey and Nirit Datta participated, effectively merging online fandom with on-ground sporting spirit.

The tournament distinguished itself through a creatively reimagined format. Strategic elements, such as VIDA-branded bonus targets, rewarded players for precision and boldness, mirroring the innovative features of the brand. The excitement was amplified by unique rules, including the VIDA Electric Over, a phase where every run counted double and batsmen could not be dismissed, guaranteeing dramatic shifts in momentum. Furthermore, the introduction of an Impact Player rule allowed teams to introduce a strategic asset at a crucial juncture, ensuring that every match remained fiercely competitive and unpredictable until its conclusion. This event successfully transformed the streets into a vibrant, electrifying extension of the Knight Riders' universe.

Binda Dey, Group Chief Marketing Officer, Knight Riders Sports, said, “Cricket has always lived in the heart of Kolkata. With VIDA Knights Electrifying Box Cricket, we took the game back to the fans – in a format that’s fast, accessible and powered by participation. Featuring 32 teams competing over three high-octane days, this tournament celebrated community, competitiveness and the joy of playing the game. We’re proud to partner with VIDA, a brand that shares our belief in creating experiences that fans don’t just watch but truly live.”

Kausalya Nandakumar, Chief Business Officer, Emerging Mobility Business Unit, Hero MotoCorp, said, “Our association with Kolkata Knight Riders is rooted in the confidence, resilience and aspiration that define a new India. VIDA is driven by the idea of making electric mobility exciting, accessible and relevant to everyday India – much like how KKR brings people together through cricket. With VIDA Knights Electrifying Box Cricket, we are bringing cricket’s unmatched passion and pulse to the streets, creating an exciting platform where supporters not only watch but also play and engage with us.”

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Just four months after a celebratory opening, the USD 5.8 billion BlueOval SK battery plant has hit a dramatic standstill. The facility, a joint venture between Ford Motor Company and South Korea’s SK On, is now sitting idle, leaving approximately 1,600 workers jobless and sparking a heated political debate over the future of American manufacturing stated news reports.

The 1,500-acre site was positioned in mid-2025 as the crown jewel of Kentucky's economic development, promised to be a ‘lifeline’ for the region's workforce. However, by December, the optimism vanished as Ford and SK On dissolved their partnership. Ford has confirmed the plant will remain idle for roughly 18 months as it undergoes a total strategic pivot.

Rather than powering the next generation of electric cars and trucks, the facility is being retooled to produce battery energy storage systems (BESS). These industrial-sized batteries are intended for power grids, data centres and commercial utilities.

Ford executives cited a ‘harsh operating reality’ for the pause, specifically:

• Slowing Demand: US EV sales projections for 2030 have been slashed from 45 percent of the market to as low as 9 percent.
• Regulatory Shifts: The administration has moved to rescind federal EV tax credits of up to USD 7,500, which many argue has cooled consumer interest.
• Supply Chain Pressures: New requirements for 100 percent US-made components for charging infrastructure have further complicated the transition.

The shutdown has become a lightning rod for political finger-pointing. Kentucky Governor Andy Beshear has blamed federal policy shifts – specifically the rollback of EV incentives – for draining the market momentum that justified the plant's massive scale.

Conversely, some industry critics and workers, like maintenance technician Joe Morgan, suggest the failure also lies in corporate strategy, arguing that Ford may have overestimated the public's immediate appetite for all-electric versions of flagship models like the F-150.

Image credit: Ford Motor Co

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India has pledged to reduce road fatalities and serious injuries by 50 percent by 2030 following the launch of the New Delhi Road Safety Declaration. Hosted by the Bharat Association of Road Safety Volunteers (BARS) at IIT Delhi, the initiative sets a long-term goal of zero preventable road deaths, aligning with the WHO Decade of Action for Road Safety (2021–2030).

The National Road Safety Confluence brought together the Ministry of Road Transport & Highways (MoRTH), the World Health Organization (WHO), state governments, insurers and vehicle manufacturers. The framework identifies three primary pillars for cooperation – Samaaj (Society), Sarkaar (Government) and Bazaar (Industry).

The Declaration adopts a Safe System Approach, prioritising human life in mobility decisions. Implementation will focus on five pillars:

• Governance & Accountability: Shifting metrics from road construction distances to lives saved and ensuring independent monitoring.
• Infrastructure & Blackspot Management: Continuous data-driven mapping of high-risk zones and safety audits of design.
• Safer Vehicles: Eliminating sub-standard components and integrating AI-enabled enforcement.
• Road User Behaviour: Mandatory practical driver training and stricter penalties for repeat violations.
• Post-Crash Response: Optimising the 'Golden Hour' through trauma care and standardised crash investigation.

India records the highest number of road fatalities globally. The confluence identified systemic gaps, including under-utilised crash data, fragmented accountability across agencies and inadequate emergency response integration.

The Declaration marks a transition from awareness campaigns to measurable implementation. Signatories have committed to time-bound action plans and the strengthening of district-level enforcement capacity.

Dr Mats-Ake Belin, Global Lead – Decade of Action for Road Safety, WHO, said, “Road safety is now firmly on the global agenda, with strong political and media attention. Our responsibility is to move beyond awareness and ensure consistent, evidence-based implementation so that no country is left behind in preventing road traffic deaths.”

V Umashankar, Secretary (Road Transport & Highways), MoRTH, added, “As a nation, we cannot accept road fatalities as inevitable. Each accident is personal, each loss preventable. Awareness is not enough - what we need is organised, district-level action, backed by certainty of enforcement and supported by strong institutions. When compliance becomes habit and accountability becomes certain, road safety will move from intention to impact.”

Rama Shankar Pandey, Chairman – BARS, stated, “Road safety is not merely a transport issue; it is a governance responsibility and a moral obligation. The New Delhi Declaration shifts the national conversation from fragmented initiatives to coordinated, time-bound, accountable action.”

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