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.
Bajaj Auto Appoints Rakesh Sharma As Joint Managing Director
- By MT Bureau
- May 07, 2026
Pune-headquartered two-wheeler and three-wheeler major Bajaj Auto has appointed Rakesh Sharma as Joint Managing Director, effective from 1 June 2026 until 31 March 2029.
Sharma has over four decades of experience and is a graduate from the Indian Institute of Management, Ahmedabad. He joined Bajaj Auto in 2007 as President of International Business and became an Executive Director in 2019.
In his role as Joint Managing Director, Sharma will oversee business responsibilities, the Digital & IT function and the Legal function. He will continue to report to Rajiv Bajaj, Managing Director, Bajaj Auto.
Sharma previously served as Chief Commercial Officer and managed international operations for 10 years.
Furthermore, the company has also announced that it will buy back shares at an estimated INR 56.32 billion, representing 16.93 percent of the equity share capital and reserves on a standalone basis and 15.59 percent on a consolidated basis as of 31 March 2026.
PeakAmp Becomes Exclusive Recycling Partner For Stefen Electric’s EV Battery Waste
- By MT Bureau
- May 05, 2026
PeakAmp, a company specialising in battery circularity and lifecycle management, has entered into a partnership with Stefen Electric to handle end-of-life lithium-ion batteries from the latter’s electric mobility operations. Under the agreement, PeakAmp becomes the exclusive recycling and environmental compliance partner for Stefen Electric.
The collaboration places PeakAmp in charge of collection, reverse logistics, recycling and Extended Producer Responsibility compliance for battery waste generated by Stefen Electric. All processed batteries adhere to Central Pollution Control Board guidelines and the Battery Waste Management Rules of 2022, ensuring alignment with India’s regulatory framework for safe disposal.
This arrangement allows Stefen Electric to meet compliance standards while securing safe disposal and material recovery. It also improves traceability across the battery lifecycle. As India’s electric mobility sector expands, rising volumes of retired EV batteries are expected. Through this partnership, both companies aim to build scalable, compliant and environmentally responsible battery waste management solutions.
Aditya Sudhanshu, Co-Founder & COO, PeakAmp, said, “As EV adoption accelerates, establishing reliable systems for managing battery waste becomes increasingly critical. Our partnership with Stefen Electric enables a structured approach to collection, recycling and compliance, ensuring that end-of-life batteries are handled in a responsible and traceable manner. We look forward to contributing to a more transparent and efficient battery waste ecosystem.”
Vipin Nagar, Head – Commercials, Stefen Electric, said, “At Stefen Electric, we recognise that sustainable battery management is critical to the long-term growth of the EV ecosystem. Our partnership with PeakAmp allows us to build a robust and compliant framework for managing battery waste, ensuring responsible disposal and recycling while maintaining full traceability.”
Mahindra Outlines Ambitious EV Strategy, Capacity Expansion Following Robust FY2026 Results
- By Nilesh Wadhwa
- May 05, 2026
Mumbai-headquartered automotive major Mahindra & Mahindra (M&M) has signalled a bold new chapter in its global expansion, detailing plans for electric vehicle (EV) exports and significant production scaling following a ‘defining year’ of financial growth.
The Mumbai-based conglomerate reported a stellar performance for FY2026, with consolidated Profit After Tax (PAT) reaching INR 170.99 billion, a 35 percent increase over the previous year. Consolidated revenue for the year surged 25 percent to reach INR 1,986 billion, 25 percent YoY.
During the year, the company reported sales of 1.11 million units, up 19 percent, while tractor sales grew by 24 percent at 526,403 units.
Central to the company’s future is a phased entry into international EV markets. Rajesh Jejurikar, Executive Director & CEO (Auto and Farm Sector), told Motoring Trends, that Mahindra has planned a disciplined roadmap for global expansion.
"For exports, we would look at right-hand-drive markets in the world first. If we succeed there, then we will look at left-hand-drive markets". The company expects to begin seeing Mahindra EVs in a couple of new countries within the next 18 months.
Addressing potential competition from new Free Trade Agreements (FTAs), Dr Anish Shah, Group CEO & MD, Mahindra & Mahindra remains confident. He acknowledged that the government has structured FTAs to encourage local manufacturing. "We have already seen a lot of competition in the auto industry already and all the top players are here as well. FTA doesn’t change anything from that standpoint. It is important to emphasise that the government has done it (FTAs) very well to make sure that other players continue to make in India as well for the Indian market and to be able to export from around India. In that sense, they (automakers) have it set up well, and that should benefit the Indian government," Shah remarked.
New product launches & Capacity enhancement
Furthermore, the Mahindra management acknowledges that there has been a gap between demand and supply, especially for its new range of electric vehicles, which is why it is ramping up and unlocking capacities to meet the consumer demand.
It has already enhanced its SUV ICE capacity from 54,000 units per month to 56,500 units per month at the end of FY2026, with plans to scale it up to 60,000 units.
Similarly, for battery electric vehicles, it has enhanced the capacity from 5,000 units a month at the end of FY2025, to 8,000 units per month by 31, March 2026.
Furthermore, to support the potential EV uptick growth, Mahindra is aggressively expanding its manufacturing footprint. The company is in the process of land acquisition for its Nagpur facility, which is intended to eventually take capacity up to 500,000 units per annum.
Going forward, it has revised its earlier plans to launch 4 new ICE SUVs and 3 new electric vehicles by 2031, to 10 new ICE SUVs and 6 new BEVs by 2031. This includes 1 new mid-cycle enhancement and 9 new SUV nameplates in the ICE category.
In the EV segment, Mahindra is targeting an 18-20 percent penetration rate over a five-year period. Monthly production for the popular XEV 9S model is slated to rise from 6,000 to 8,000 units this year, with plans to reach a total EV capacity of 12,000 to 14,000 units per month as they enter FY2028.
When questioned on how Mahindra will compete with new entrants, Jejurikar pointed to ‘design and the tech’ as primary differentiators. He highlighted their unique seven-seater EV offerings and long-range capabilities (450-500+ km) as key advantages that ‘reduce charging rate’ anxiety for customers.
Market Leadership and Financial Resilience
The company’s traditional strongholds continue to dominate the Indian market. Mahindra remains No. 1 in SUVs with a revenue market share of 25.3 percent, No. 1 in Light Commercial Vehicles (LCVs) and No. 1 in Tractors with a 43.6 percent market share.
"FY26 has been a defining year marked by strong execution and breakthrough performance," said Dr Anish Shah. He emphasised that the Group is ‘well poised to accelerate in these uncertain times,’ supported by a strong balance sheet and a net cash generation exceeding INR 1,600 billion.
FY2027 outlook
Despite global ‘geopolitical headwinds,’ the company maintains a disciplined approach to capital allocation, focusing on high-growth ‘Growth Gems’ and exiting non-performing international farm businesses to ensure a 20.1 percent Return on Equity (RoE).
It expects FY2027 to see the tractor sales to grow in mid-single digits, while SUVs will see mid to high teen growth. Mahindra's aim is to focus on ramping up manufacturing capacity to meet volume growth aspirations.
On the LCV (upto 3.5-tonne segment), where Mahindra holds the lion’s or 52 percent market share, it expects the industry growth volumes to come in high single digits.
April Sees Robust Record Automotive Retail Sales In India
- By MT Bureau
- May 05, 2026
The positive momentum for the Indian automotive industry continues to accelerate in the new fiscal year. In what comes as a record retail sales registration across categories, the total automotive sales in April 2026 reached a whopping 2.61 million units, up 12.94 percent, as compared to 2.31 million units last year.
The record retail sales were witnessed across two-wheelers, which saw retail registrations at 1.91 million units, up 13 percent YoY, three-wheelers at 106,908 units, up 7.19 percent YoY, passenger vehicles at 407,355 units, up 12.21 percent YoY, tractors at 75,109 units, up 23.22 percent YoY and commercial vehicles at 99,339 unit, up 15.02 percent YoY.
Barring construction equipment at 6,348 units, down 2.25 percent YoY, all categories were in the green.
Sai Giridhar, President, FADA, said: “This clearly underlines that the structural demand momentum which defined the second half of FY2026 has carried into the new financial year. The sequential MoM softness of -3.01 percent reflects the customary post-March seasonal reset rather than any erosion in underlying demand.”
He stated that the demand engine remained broad-based with Urban markets growing 14.07 percent YoY and Rural markets growing 12.30 percent YoY.
The industry body attributed this performance to improved rural liquidity following a healthy rabi season, the extended marriage-season tailwind that runs through May and June, and continued affordability gains carried over from the GST 2.0 framework. Furthermore, the performance could have further grown, if the industry did not witness supply constraints for selective models in certain commuter and premium variants.
In terms of electrification in the two-wheeler segment, it saw moderation at 7.76 percent, as compared to 9.79 percent last month.
Commenting on the commercial vehicle performance, Giridhar said, “From a market mix standpoint, Rural markets grew a striking 20.25 percent YoY versus Urban at 10.22 percent YoY, highlighting that logistics-led demand is no longer concentrated in metros. Dealers across regions reported sustained freight movement, infrastructure-linked goods activity, school-bus replacement demand, and steady single-owner operator confidence as the principal drivers. The MCV sub-segment continued its standout run at 27.07 percent YoY, while LCVs grew 17.76 percent and HCVs 8.25 percent — reflecting participatory growth across sub-segments. Some dealers, however, flagged elongated financing turnaround time, sporadic variant-level supply gaps and a degree of caution induced by external geopolitical developments as monitorables.”
Coming to the passenger vehicle segment, the segment has seen demand firing on all cylinders. Interestingly, Rural PV growth at 20.40 percent YoY, was nearly three times the Urban pace of 7.11 percent YoY.
“This confirms the structural broadening of personal mobility into Tier-3 and rural India, supported by a small-car revival, sustained SUV demand and a richer alternative-powertrain product mix where CNG share held firm at 22.62 percent and EV share improved further to 5.77 percent. Dealers cited improved affordability post-GST 2.0, the Reserve Bank of India's supportive rate stance, which has translated into stronger EMI comfort, and a healthy marriage-season pipeline as the principal demand drivers. PV inventory levels have moved up modestly to a range of 28–30 days, marginally above March'26's around 28 days but well within the healthy band that we view as constructive. We continue to encourage PV OEMs to maintain disciplined dispatches in the coming weeks so that channel inventory stays anchored close to FADA's recommended 21-day benchmark, particularly as we move into the seasonally softer May-June window,” added Giridhar.
The near-term outlook for May 2026 is cautiously optimistic, with over 55 percent of dealers expecting continued growth. Momentum is expected to be maintained by the peak of the marriage season and residual buying from festivals like Akshaya Tritiya. However, monitorable factors include potential heatwaves, geopolitical tensions in West Asia that could impact fuel prices, and selective supply constraints. Over the next three months, dealer confidence remains steady as the industry transitions toward its mid-year phase.
Going forward, the industry body expects that demand for CVs, two-wheelers and passenger vehicles will continue to be positive. For CVs, he attributes the same to residual buying triggered by Akshaya Tritiya in select northern and western markets, the new financial-year OEM scheme cycle and sustained replacement demand in the CV segment.
The two-wheeler segment will continue to reap the benefits of improving rural cashflows, agri-cycle preparation purchases and continued post-GST 2.0 affordability in the rural market, while passenger vehicles are likely to benefit from healthy booking pipelines, refreshed product launches and improving small-car traction.
“That said, the India Meteorological Department's forecast of an above-normal heatwave across several states, the geopolitical situation in West Asia and its potential pass-through to fuel prices, selective supply constraints on running models remain factors to watch,” he concluded.
| AUTO RETAIL SALES IN INDIA | ||||||
| Category | Apr '26 | Apr '25 | Change (in units) | Change (in %) | Mar '26 | Change (in %) |
| YoY | YoY | MoM | ||||
| Two-wheeler | 1,916,258 | 1,695,638 | 220,620 | 13.01% | 1,951,006 | -1.78% |
| Three-wheeler | 106,908 | 99,741 | 7,167 | 7.19% | 109,777 | -2.61% |
| E-Rickshaw (P) | 28,154 | 39,504 | -11,350 | -28.73% | 28,946 | -2.74% |
| E-Rickshaw with Cart (G) | 7,742 | 7,447 | 295 | 3.96% | 7,425 | 4.27% |
| Three-wheeler (Goods) | 13,133 | 10,322 | 2,811 | 27.23% | 14,006 | -6.23% |
| Three-wheeler (Passenger) | 57,767 | 42,326 | 15,441 | 36.48% | 59,283 | -2.56% |
| Three-wheeler (Personal) | 112 | 142 | -30 | -21.13% | 117 | -4.27% |
| Passenger Vehicle | 407,355 | 363,028 | 44,327 | 12.21% | 440,144 | -7.45% |
| Tractor | 75,109 | 60,956 | 14,153 | 23.22% | 82,080 | -8.49% |
| Construction Equipment | 6,348 | 6,494 | -146 | -2.25% | 6,906 | -8.08% |
| Commercial Vehicle | 99,339 | 86,364 | 12,975 | 15.02% | 102,536 | -3.12% |
| LCV | 55,949 | 475,120 | ###### | -88.22% | 59,379 | -5.78% |
| MCV | 9,177 | 7,222 |
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