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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Kiwi General Insurance, a digital-native non-life insurer, has officially commenced operations in India's non-life insurance market. Backed by private equity firm WestBridge Capital, which holds approximately a 70 percent stake, the company begins its rollout targeting the private car motor insurance segment.

Co-founded by industry veterans Neelesh Garg (Former MD & CEO of Tata AIG General Insurance) and Saurav Jaiswal, Kiwi received its regulatory certificate of registration from the IRDAI in March 2026

The company is operating under the brand philosophy ‘Your Peace, Our Policy,’ the insurer aims to leverage a completely in-house, proprietary technology stack and AI to dismantle legacy pain points, targeting a gross written premium (GWP) of INR 2 billion to INR 3 billion in FY2027.

Kiwi General Insurance’s core operating model signals a structural shift away from traditional asset-based pricing toward personalised customer pricing, allowing it to reward safer drivers with lower premiums.

By starting with motor insurance – a mass product category historically tied to low consumer trust and complex claim friction – Kiwi said it has engineered its product ecosystem directly around minimising the anxiety associated with repair cycles and policy updates.

To address the hesitation consumers face when deciding whether to file an insurance claim, Kiwi has introduced several proprietary features designed to eliminate out-of-pocket stress and administrative delays:

• Super NCB (No Claim Bonus): Protects a customer's accumulated renewal discounts if they file a claim. Instead of resetting to zero, the driver drops only one level down on the bonus scale. The architecture allows policyholders to earn up to 40 percent higher discounts than standard market NCB structures.
• Flexi Repair: Allows policyholders to digitally ‘bank’ minor aesthetic or physical damages from minor incidents over time, later combining them into a single, comprehensive claim. This shields the customer from paying a compulsory deductible for multiple separate micro-claims, allowing them to wait until a complete workshop repair event is worthwhile.
• InstaCash: Provides instant cash support transferred directly to the customer’s bank account on the exact day their vehicle is checked into a workshop for repairs, removing the burden of managing upfront out-of-pocket expenses.
• ‘PayFirst’ Outside-Network Experience: If a customer prefers to utilise a trusted vehicle repair shop that falls entirely outside of Kiwi’s extensive cashless garage network, the PayFirst protocol triggers an instant digital payout directly to the user to maintain total freedom of choice.

Kiwi's simplified operating architecture extends across its hybrid distribution networks to empower its field partners and independent agents for same-day digital onboarding for new distributors, instant premium reconciliation & real-time performance dashboards and shared, interactive claim trackers that provide single-point ownership, completely removing internal communication bottlenecks between the client, agent and repair facility.

Neelesh Garg said, “The insurance industry has long been shaped by legacy processes that create customer apprehension. Our goal is to rebuild it from first principles using technology, data, and disciplined execution. We are focused on making insurance simple, fast and consistent. With Kiwi, we are building an institution that customers and partners can truly rely on.”

Saurav Jaiswal, Managing Director & CEO, Kiwi General Insurance, added, “Indian consumers have a real trust deficit in insurance. If someone has to make a claim, they are already having a bad day. We are building Kiwi to get them through it as fast as possible. Customers today expect clarity, speed, and reliability, especially in moments that matter. From instant policy issuance and real-time claim tracking to faster decisions and single-point ownership, every element is designed to reduce ambiguity.”

Image credit: Pexels Mikhail Nilov

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Palmer Energy Technology (PETL), a UK clean energy and battery technology group led by former Aston Martin CEO Dr Andy Palmer CMG, has confirmed its acquisition of Kleandrive’s business and assets as a going concern through administration. The acquisition preserves a specialist British engineering capability focused on heavy vehicle decarbonisation.

Based in Essex, Kleandrive specialises in retrofitting traditional diesel vehicles – specifically legacy diesel buses – by replacing their internal combustion engines with fully electric drivetrains. This approach allows fleet operators to transition to zero-emission running without the embedded carbon costs or high capital outlay associated with new electric bus procurement.

The acquisition integrates Kleandrive's repowering workflows into the PETL group's broader clean propulsion portfolio. PETL is a leading developer of battery and battery management system (BMS) technology, utilising capabilities from its wholly-owned subsidiary Brill Power, a University of Oxford spin-out.

The combined business establishes a vertically integrated structure with reach across multiple development phases:

• Battery cell selection and advanced management systems.
• Powertrain integration and heavy-duty electric vehicle (EV) conversion.
• Fleet deployment, live commercial relationships with major UK bus operators and aftermarket support.

This architecture provides PETL with a direct application channel for its proprietary battery and energy management technology in a high-impact segment of UK transit. Furthermore, it creates a foundation for future retrofit expansion into adjacent commercial sectors where the economics of repowering are increasingly favourable, including coaches, heavy goods vehicles (HGVs) and specialist commercial vehicles.

Heavy-duty buses represent an immediate opportunity within UK fleet electrification. Despite the UK government's end-of-sale date for new diesel buses and widespread operator commitments to zero-emission running, a significant portion of the national bus fleet remains heavily diesel-powered.

Repowering serves as a critical bridge for local authorities and regional operators working under strict capital constraints and decarbonisation targets. By converting existing assets, operators can lower capital costs compared to buying new vehicles, extend the useful life of their fleets and eliminate the manufacturing emissions of new vehicle fabrication.

Palmer Energy Technology intends to invest in the newly acquired capability as part of its wider clean energy portfolio. Decisions regarding the future operating structure, long-term asset deployment, and brand identity of the acquired business will be finalised and communicated in due course.

Dr Andy Palmer CMG said, “Britain keeps losing its industrial base one company at a time. I have spent years making the public argument that the UK cannot meet its decarbonisation targets or build a credible clean transport sector without homegrown businesses leading the way. This acquisition of Kleandrive’s business and assets as a going concern is a small but practical example of acting on that argument. Repowering existing diesel buses is one of the most cost-effective ways for operators to decarbonise their fleets. It deserves to be built here, by British engineers and we intend to make sure it is.”

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The Society of Indian Automobile Manufacturers (SIAM) organised the 6th International Conference on ‘Climate Action: Accelerating India’s Transition to a Low-Carbon Future’, to mark World Environment Day.

The forum brought together automobile policymakers, industry CEOs, academic researchers and sustainability experts to detail decarbonisation pathways across the entire automotive value chain.

The conference emphasised that for a market as diverse as India, no single technology will satisfy the country's net-zero roadmap. Instead, progress relies on the parallel maturation of vehicle electrification, alternative bio-fuels, circular material economies and green factory manufacturing.

The transport sector was highlighted as a focal point for reinforcing India's domestic energy security and reducing its macro-economic reliance on volatile fuel imports. Government and industry speakers mapped out a multi-fuel ecosystem designed to transition the country toward localised and clean energy pathways.

While the three-wheeler category is experiencing a fast transition driven by favourable unit economics, panellists called for accelerated adoption curves within the four-wheeler and public transport segments, specifically via electric buses.

India is actively advancing a wide range of low-carbon fuel alternatives, including biofuels, ethanol and isobutanol blends, flex-fuel configurations, compressed biogas (CBG), liquefied natural gas (LNG/CNG), green hydrogen and synthetic fuels.

Technical pathways involving coal gasification-based fuels are being structurally explored to further diversify domestic supply lines.

Experts noted that tech adoption cannot be driven by immediate costs alone; long-term scale will naturally deflate pricing over the next decade. Crucially, vehicle deployment and localised charging/refuelling networks must expand in tandem.

The conference was segmented into three core technical tracks, evaluating circularity, fuel diversification and manufacturing supply chains.

The first thematic session, ‘Circularity in the Automotive Sector: From Materials to End-of-Life Vehicles,’ focused on circular economy practices across the automotive value chain, including sustainable sourcing, recycling, resource efficiency, and end-of-life vehicle management was addressed by Guest of Honour Dr. Virender Sharma, Member Technical (Additional Secretary to Government of India level), Commission for Air Quality management in National Capital Region and Adjoining Areas. The session was chaired by M S Anand Kumar, Chairperson, SIAM Recycling & Material Groups, and Assistant Vice-President, TVS Motor Company, the session included presentations by Dr. Rashi Gupta, Founder & Managing Director, Vision Mechatronics; Bhuwan Purohit, Executive Director, Rubamin; Dr Swati Singh, Head of Regional Standards, South Asia (UL Standards and Engagements) and Abhijit Sen Roy, General Manager (TS), Indian Oil Corporation Ltd. (IOCL), who shared perspectives on sustainable technologies, EPR frameworks, and circular resource recovery.

The session also included a panel discussion on ‘Building a Circular Automotive Value Chain,’ moderated by Sandeep Kumar Mohanty, Partner, PwC.

The second thematic session, ‘Alternate Fuels for Sustainable Mobility – Diversifying the Energy Mix: Pathways for Low-Carbon Fuels,’ focused on the role of alternate fuels in reducing transport emissions and supporting India’s mobility transition. Chaired by Vikram Gulati, Country Head & EVP – Corporate Affairs & Governance, Toyota Kirloskar Motor, the session included presentations by Dr. Santanu Gupta, Director Technical, Global Biofuels Alliance; Sumit Sarkar, Chief Executive Officer, Chhattisgarh Biofuel Development Authority and Santosh Gurunath, Chief Executive Officer, Umagine Hydrogen, who shared insights on global biofuel trends, agricultural residue-based fuels being developed, and elaborated on hydrogen as a pathway for low-carbon mobility.

A panel discussion on ‘Multi-Fuel Pathways to Achieve Sustainable Mobility,’ moderated by Atul Jairaj, Partner, Deloitte India, brought together Suruchi Bhadwal, TERI and Vedang Pittie, Harinagar Sugar Mills, along with the presenters and session chair. The discussion focused on the role of biofuels, hydrogen and other low-carbon fuels and the policy and infrastructure support needed to accelerate their adoption.

The third thematic session, ‘Decarbonising the Automotive Value Chain: Green Manufacturing and Sustainable Supply Chains,’ chaired by Suneet Deshmukh, Head Operations Excellence, Hero MotoCorp, discussed strategies for reducing emissions across manufacturing operations and supplychain.

The session included presentations by Chaitanya Kanuri, Director E-Mobility, WRI India; Mayur Karmarkar, Managing Director, International Copper Association India and Mohit Jauhari, Head SCM, Shriram Pistons and Rings, who shared insights on copper, critical minerals, rare earth magnets and elaborated on sustainable supply chain practices.

The session also included a panel discussion on ‘Accelerating the Transition to a Low-Carbon Automotive Value Chain,’ moderated by Pratik Shah, Partner, EY Parthenon. The panel brought together Parag Sharma, Stellantis; Lt Col Monish Ahuja (Retd), Punjab Renewable Energy Systems along with the session presenters. They discussed green manufacturing, renewable energy, sustainable sourcing and supply chain decarbonisation.

To actively support India's target of carbon neutrality by 2070 and the Viksit Bharat vision by 2047, SIAM formalized its long-term actions under six targeted environmental and structural initiatives – विद्युतीकरण (Electrification), जैविक पहल (Bio-Initiatives), चक्रीयता (Circularity), गैस गतिशीलता (Gas Mobility), हरित हाइड्रोजन (Green Hydrogen) and सुरक्षित सफर (Safe Journey).

Tarun Kapoor, Advisor to the Prime Minister of India, stated during the opening session, "The transport sector must play a central role in strengthening India's energy security. We cannot continue to depend on large-scale fuel imports and, over time, must move towards fuels that can be produced within the country. While three-wheelers are ready for rapid electrification, we need much faster adoption in the four-wheeler segment as well."

Prashant K. Banerjee, Executive Director, SIAM, added, "We are living through a time of unprecedented challenges, from climate change and air pollution to energy security concerns. But every challenge also creates an opportunity and as the world's largest market for two-wheelers and three-wheelers, India has already demonstrated remarkable progress in sustainable mobility."

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Green SM, the electric vehicle ride-hailing service company of Vietnamese conglomerate Vingroup has officially launched Green SM Limo service in New Delhi, marking its strategic entry into the Indian market.

India represents the company's fifth international territory, following active deployments in Vietnam, Laos, Indonesia and the Philippines.

The inauguration ceremony was attended by prominent dignitaries, including Rao Narbir Singh, Minister for Industries & Commerce, Environment, Forest & Wildlife, Foreign Cooperation, and Sainik & Ardh Sainik Welfare for the Government of Haryana and Dr. Virinder Sharma, Vice-President of the Commission for Air Quality Management. Representatives from the Embassy of Vietnam in India and various strategic industrial sectors were also present.

In its initial phase, Green SM Limo will operate exclusively within key areas of the Delhi National Capital Region (NCR), with plans to scale service coverage incrementally in response to consumer demand. The service features a specialised, single-model electric fleet tailored for premium passenger transport.

The fleet consists entirely of the VinFast Limo Green, a fully electric, 7-seater SUV that produces zero tailpipe emissions. To optimise passenger comfort during business commutes, family trips, or airport transfers, each vehicle is stocked with complimentary drinking water, wet tissues and essential travel amenities. Vehicles are integrated with a proprietary Secure-to-Safe system, which features interior and exterior monitoring cameras, AI-powered driving assists and dedicated emergency support buttons accessible by both the driver and passengers.

Operating under the core service commitment of ‘Ride 5 Star,’ Green SM Limo utilises a team of professionally trained ‘Green Drivers’ instructed in specialised electric vehicle mechanics, defensive driving and hospitality workflows.

Passengers within the active Delhi NCR zones can secure rides through three primary channels:

• The Green SM mobile application (available on the iOS App Store and Google Play).
• A dedicated telephone service hotline.
• Direct street-hailing within valid Green SM operating parameters.

To celebrate its market entry, Green SM is offering a 50 percent discount (up to INR 250) for all rides booked via its official app from 5 June to 11 June 2026.

Coinciding with the brand launch, Green SM inducted five local Indian partners spanning the mobility, travel, technology and service sectors into its Green Alliance Frontier. This global platform is designed to connect eco-conscious commercial enterprises to encourage collaborative cross-market innovation and accelerate localized green transformations.

Nguyen Van Thanh, Global CEO, GSM, said, “India is one of the most important mobility markets in the world. Its scale, rapid growth, and strong spirit of innovation are opening up many opportunities for the future of green transportation. We come to India with respect for the market, confidence in its long-term potential, and a commitment to working closely with local partners. Green SM hopes to bring high-quality fully electric rides to customers, while contributing to broader access to safe, reliable, and more sustainable mobility choices."

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