Trends: Smart manufacturing

Insurance: Tyred or just tired?

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.

 

Toyota Kirloskar Motor Secures 9 Medals At IndiaSkills National Competition

IndiaSkills National Competition

Toyota Kirloskar Motor (TKM), one of the leading passenger vehicle manufacturers, has announced that its participants secured 9 medals at the IndiaSkills National Competition 2025-26.

The cohort achieved 5 Gold, 3 Silver and 1 Bronze medal across seven vocational categories. The competition serves as the primary platform for vocational excellence in India, with participants progressing through district, state and regional levels before reaching the national finals held in Delhi, Bengaluru and Chennai.

In the Mechatronics category, Deepu M S and Jayanth K won gold, while Ganesh P B and Punith Kumar received silver. Shashank S and Abhishek S S secured gold in Robotic System Integration, followed by Chirag G and Vinay M H with silver. In Additive Manufacturing, Pavan B S achieved gold and Harshith K B took silver. Individual gold medals were also awarded to Tejas B S for Auto Body Repair and Punith P for Mechanical Engineering CAD, while Praveen Y H earned a bronze medal in Welding.

The winners will now enter selection rounds for the WorldSkills Competition 2026, which is scheduled to take place in Shanghai, China, from 22 to 27 September. WorldSkills involves young professionals from over 60 countries competing in more than 65 technical skills. Toyota Kirloskar Motors’ participation in these events is part of a broader strategy to train technicians through advanced infrastructure and curricula aligned with international manufacturing standards.

G Shankara, Chief Strategy Officer, Toyota Kirloskar Motor, said, “At Toyota, we believe manufacturing excellence begins with nurturing exceptional talent. The remarkable performance of TKM participants at these prestigious events reflects their ability to excel across diverse skill categories and compete at the highest level. Their achievements embody the spirit of the Skill India Mission – empowering youth, nurturing creativity and fostering innovation. With such milestones, TKM continues to set new benchmarks in skill development and plays a pivotal role in shaping India’s growing talent landscape”

MS Dhoni Joins Cars24 Road Safety Initiative As Goodwill Ambassador

MS Dhoni - Cars24

Cars24 has announced that former Indian cricket captain MS Dhoni has joined Crashfree India, a national road safety initiative, as its Goodwill Ambassador.

The partnership aims to address the high rate of traffic fatalities in India by shifting public focus towards driver accountability and discipline. India currently records the highest number of road deaths globally, with 180,000 fatalities reported in 2024.

Despite possessing approximately 1 percent of the world's vehicles, the country accounts for 11 percent of global road deaths.

The initiative highlights a demographic crisis, noting that 66 percent of those killed in 2024 were aged between 18 and 34. Data indicates that seven in ten fatalities were linked to overspeeding. Through this collaboration, Cars24 seeks to move the conversation beyond annual statistics and integrate safety into the daily mobility habits of Indian drivers.

The programme focuses on behavioural change, suggesting that improved judgment and patience on the road can prevent the majority of accidents.

MS Dhoni, said, “I have spent a big part of my life around cars, bikes, and roads. When you love driving and riding, you also learn to respect them. You understand that control matters, judgment matters, and patience matters. A vehicle gives you freedom, but it also gives you responsibility. On our roads, too many people still see safety as a rule to follow only when someone is watching. That mindset has cost us far too much. We already know what is going wrong. We know how many lives are being lost. We know the habits that put people in danger every day. What we need now is not more excuses. We need more responsibility, more discipline, and more respect for life. Roads may be beautiful, but they come with real risks. As much as we love them, they can be dangerous. We have the data. We know what the problem is. We know what needs to change. The only thing missing is the will to make it a priority. This isn’t something I was asked to do. This is something I decided to do.”

Vikram Chopra, Founder and CEO, Cars24, sad, “Some missions need encouragement. This one needs scrutiny. Crashfree India cannot be built by people who only know how to say the right things. It needs someone who sets a harder standard: someone strict, deeply observant, unwilling to indulge comfortable language and clear enough to call out the truth without softening it. Dhoni is exactly that. He does not mince words and that is one of the most valuable things about him. His understanding of Indian roads is grounded in lived experience rather than theory alone. Years of navigating them have given him insights into driver behaviour, road conditions and the split-second decisions that matter most. Every meeting with him has been inspiring, not in a superficial way, but in a way that leaves you sharper, more serious and less satisfied with easy answers. Dhoni holds us to a higher standard and his involvement challenges us to push this mission further. That changes the seriousness of the work. And that is exactly what this mission needs.”

JLR - Manufacturing Solil

The UK government is securing 4,200 jobs following an investment of more than GBP 700 million into the advanced manufacturing sector.

Business Secretary Peter Kyle announced the measures during a visit to Agratas in Somerset, where a GBP 380 million grant was confirmed to support the construction of a gigafactory. The facility, built using British steel, is projected to generate GBP 43 billion in economic growth over 25 years and will include a training unit to provide 300 apprenticeships.

Additional funding includes GBP 47 million for the Battery Innovation Programme to support research and development projects and GBP 190 million for the automotive industry. Of this, GBP 90 million in DRIVE35 funding has been awarded to firms including Nissan and Jaguar Land Rover for prototype development, while GBP 100 million is allocated to suppliers in the North East and West Midlands to assist in the transition to electric vehicle manufacturing.

The UK government is also providing GBP 115.44 million through the Made Smarter programmes to help small and medium-sized enterprises adopt digital technologies such as robotics and artificial intelligence. Furthermore, a GBP 182 million engineering skills package has been implemented to train the next generation of technicians, alongside GBP 1.4 million for autonomous freight and passenger service trials in UK ports.

Peter Kyle, Business Secretary, UK Government, said, “This government is backing the industries of the future by investing in auto firms, SMEs and battery manufacturers across the country - helping to boost economic growth and our resilience, secure jobs and put more money in people’s pockets. In an unstable world, our Modern Industrial Strategy is providing investors the stability and confidence they need to plan not just for the next year, but for the next 10 years and beyond. That is what sets us apart from the rest, and will help ensure advanced manufacturing remains a thriving sector in the UK for decades to come.”

Earl Wiggins, Vice-President of Manufacturing Operations, UK for Agratas, said, “We welcome the UK Government’s investment as we build a battery manufacturing facility that will play a vital role in delivering net zero and strengthening the UK’s position as a global leader in battery manufacturing. This funding will support the development of our Somerset facility, enabling us to produce battery cells for our anchor customer, JLR (Jaguar Land Rover). Over the next year we will have over 2,200 people working on the site, and that growth will continue over the coming years.”

Julian Hetherington, Automotive Transformation Director at the APC, said, “This globally significant investment by Agratas reinforces the UK’s accelerating position in pursuit of road transport decarbonisation through the production of vital high-performance batteries for electrified vehicles. I’m delighted that the ATF has been able to support Agratas in their investment in new facilities, creating secure and highly skilled jobs in this area and across the supply chain.”

Mike Hawes, Chief Executive, Society of Motor Manufacturers and Traders (SMMT), said, “Recent global events have highlighted the need for resilient supply chains, making this new investment in the sector both timely and important. The UK has a highly skilled and innovative automotive industry, but long‑term competitiveness depends on a policy framework that encourages investment. The modern Industrial Strategy provides that forward‑looking support, and today’s announcement demonstrates strong government backing for one of the UK’s most vital industries.”

Olectra Greentech Unveils New Brand Identity And Strategic Shift

Olectra Greentech

Hyderabad-headquartered electric vehicle company Olectra Greentech has launched a new brand identity and tagline, ‘Transforming Everyday’. The update marks the company’s transition from a specialist bus manufacturer to an organisation providing integrated mobility and energy solutions.

The brand repositioning is built upon three operational pillars intended to guide product development and market engagement:

  • Pragmatic Futurism: Developing platforms for real-world conditions.
  • Accessible Innovation: Ensuring technology remains scalable and usable.
  • Trusted Guide: Establishing the company as a partner within the electric vehicle (EV) ecosystem.

The mission statement accompanying the refresh focuses on delivering innovation and execution excellence to create value for stakeholders in the mobility and energy sectors.

The updated visual language reinterprets existing company elements – the Olectra Prism – a central triangle representing structural integrity and direction. The Olectra Universe – a surrounding circle symbolising the ecosystem of stakeholders, infrastructure and cities.

Olectra currently operates with a portfolio that has expanded to include electric trucks and tippers alongside its established bus manufacturing division. The company maintains a manufacturing pipeline primarily serving government sectors.

Mahesh Babu, Managing Director, Olectra Greentech, said, “Olectra’s new brand identity is not just a visual change – it represents our ambition, mindset and the direction we are heading. It ensures that our brand, organisation and long-term strategy are aligned. As we transform from a pioneering electric bus manufacturer to a future-ready, innovation-led organisation delivering integrated mobility and energy solutions, this new identity reflects our core values and our commitment to ‘Transforming Everyday’ across the mobility and energy ecosystem.”