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.

Comments (0)

ADD COMMENT

Link Copied!

Hyundai Motor India Limited (HMIL) has facilitated a landmark achievement in accessible mobility through its ‘Samarth by Hyundai’ initiative. The company supported international para-athlete Chandeep Singh in completing a record-setting cross-country drive spanning over 7,000 kilometres. The expedition, undertaken in a specially modified Hyundai CRETA, saw Singh successfully traverse from Kashmir to Kanyakumari and back to the starting point.

This arduous journey stands as one of the longest transcontinental drives ever undertaken by a para-athlete in India. The customised vehicle proved instrumental as Singh traversed a vast array of challenging terrains and severe climatic conditions. His successful completion of the route not only demonstrated exceptional personal endurance but also served as a powerful testament to the principle that mobility solutions should enable all individuals to chase their goals without barriers.

Consequently, Singh’s feat has earned him a distinguished place in the Golden Book of Records. Beyond this personal victory, the expedition solidifies HMIL’s ongoing dedication to social progress and inclusive mobility. Through ‘Samarth by Hyundai,’ the company continues to champion interventions that improve accessibility, ensure equal opportunities, and empower persons with disabilities.

Virat Khullar, Head – Marketing, HMIL, said, “At Hyundai Motor India, we believe mobility is about empowering people and enabling possibilities. Through our ‘Samarth by Hyundai’ initiative, we are committed to creating a more inclusive and accessible ecosystem where every individual can dream bigger and achieve more. Chandeep Singh’s remarkable journey is a powerful testament to the indomitable human spirit, resilience and determination. We are honoured to have supported him in this historic achievement, which not only finds a place in the Golden Book of Records but also inspires millions across the country to redefine what is possible.”

Singh said, “Completing this 7,000+ km drive from Jammu to Kanyakumari and back, and securing a place in the Golden Book of Records, is a dream realised through years of relentless preparation, grit and belief. This journey was never just about setting a record; it was about showing every person that with determination, the right support and accessible technology, no destination is out of reach. The specially adapted Hyundai CRETA performed flawlessly across every terrain, truly becoming an extension of my body and spirit. I am deeply grateful to Samarth by Hyundai for believing in my vision and helping turn what seemed impossible into a reality for India. Furthermore, I am also grateful to Hyundai dealership network for their unwavering support throughout this remarkable journey.”

Comments (0)

ADD COMMENT

Link Copied!

The Automotive Skills Development Council (ASDC) has appointed Prasanna Pahade as its Chief Executive Officer. He comes with over 25 years of operational experience across the automotive, logistics, manufacturing and engineering sectors. He succeeds Arindam Lahiri, who held the post of Chief Executive Officer at the organisation from 2019.

Pahade graduated with a degree in mechanical engineering from the College of Engineering, Pune in 1996 and holds a postgraduate diploma in management from IIM Calcutta. His career includes management positions at Mahindra Logistics, Tata Strategic Management Group and Voltas, as well as founding the startup Making Champs.

Vinkesh Gulati, Chairperson of ASDC, said, “Prasanna Pahade brings a strong combination of strategic vision, business leadership and operational excellence. His diverse industry experience will help ASDC strengthen its role in preparing a future-ready workforce and deepen collaboration with industry, academia and government as India's mobility ecosystem continues to evolve.”

Prabhu Nagaraj, Vice Chairperson of ASDC, said, “The automotive industry is witnessing unprecedented technological change, and skilling will remain central to sustaining its growth. We are confident that Prasanna's leadership will accelerate innovation, expand industry partnerships and further strengthen ASDC's contribution to the Skill India Mission.”

Rama Shankar Pandey, Treasurer, ASDC, said, “Prasanna Pahade's extensive industry experience and leadership will further strengthen ASDC's efforts to build a skilled, future-ready automotive workforce. We look forward to expanding our impact through stronger industry collaboration and innovation in skilling.”

Pahade said, “I am honoured to join ASDC at a time when India's automotive industry is undergoing unprecedented transformation. My focus will be on strengthening industry-led skilling, fostering innovation, building stronger partnerships with industry and academia, and preparing a future-ready workforce that supports India's ambition of becoming a global leader in mobility and automotive manufacturing.”

Comments (0)

ADD COMMENT

Link Copied!

Sona Comstar, in partnership with Tata STRIVE, has opened a vocational training facility in Chakan, Pune.

The Sona Comstar–Tata STRIVE Skill Development Centre was inaugurated by Priya Kapur, Non-Executive Director of Sona Comstar and Chairperson of its Corporate Social Responsibility (CSR) Committee.

Located within the Chakan industrial cluster, the facility aims to train 220 individuals during FY2026–27. The centre offers instructional programs in computer numerical control (CNC) machine operations, electrical maintenance and banking, financial services & insurance (BFSI) roles to match workforce requirements in local manufacturing and service sectors.

The Chakan project expands an existing skill development initiative between Sona Comstar and Tata STRIVE, following the establishment of a similar facility in Chennai. The Chennai centre has provided training to 623 individuals, recording an 80 percent job placement rate and 42 per cent female participation.

Priya Kapur said, "Every young person I met had a different story to tell. Different struggles, different ambitions, but the same dream of building a better future. It was inspiring to hear their journeys and learn what brought them here. Skilling is about much more than employability. It equips young people with the confidence, dignity and practical skills to build better livelihoods. Partnerships like the one between Sona Comstar and Tata STRIVE demonstrate how industry can play a meaningful role in preparing young people for the jobs of tomorrow. I hope the Chakan centre becomes a launchpad for hundreds of such journeys."

The facility will conduct continuous technical training, faculty interactions and industry placement assistance to facilitate employment across manufacturing plants and corporate entities operating in the Pune region.

Comments (0)

ADD COMMENT

Link Copied!

Toyota Motor Corporation-owned luxury brand Lexus has introduced Lexus Flight, a helicopter transportation service operated by Aero Toyota Co, with operations scheduled to commence from 24 August 2026.

The service expands the brand's product offerings beyond ground vehicles and maritime vessels into air transport. The operational structure combines road transfers in Lexus vehicles between passenger departure points and heliports, flight connections between cities and resort locations aboard helicopters and marine transport options utilising the LY680 yacht.

The service utilises the Leonardo AW169 helicopter, manufactured in Italy, which accommodates seven passengers. The aircraft measures 14.65 metres in length, 3.21 metres in width and 4.56 metres in height, powered by two Pratt & Whitney Canada PW210A1 turboshaft engines. The twin-engine helicopter reaches a maximum cruise speed of 267 kilometres per hour and maintains an operational range of 785 kilometres.

Cabin specifications for the aircraft include Wi-Fi connectivity and an onboard tablet interface allowing passengers to control climate settings, interior lighting, flight map tracking, exterior camera feeds and entertainment systems.

Comments (0)

ADD COMMENT

Link Copied!