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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Arete 22 Limited, an integrated precision aluminium mobility solutions provider, has submitted its Draft Red Herring Prospectus (DRHP) to the Securities and Exchange Board of India (SEBI) as it moves towards an initial public offering. The proposed issue consists of fresh equity shares with a face value of INR 10 each, aggregating up to INR 440 crore.

The company intends to deploy the net proceeds across several priorities. Working capital requirements would receive INR 150 crore, while INR 120 crore would go towards full or partial repayment and prepayment of certain borrowings. Approximately INR 34.82 crore has been earmarked for plant and machinery at existing manufacturing facilities, with the balance directed to general corporate purposes.

Incorporated in February 2021, Arete 22 acquired Unicast Autotech Private Limited in 2026. The company manufactures aluminium alloy wheels and precision aluminium high-pressure die-cast components for automotive original equipment manufacturers. Its core business centres on alloy wheels for motorcycles and scooters, while Unicast produces high-pressure die-cast components for engines, transmissions, powertrains and structural uses.

Operating on a business-to-business basis, Arete 22 supplies directly to two-wheeler OEM customers under a build-to-print model, producing wheels according to designs and specifications set by buyers. Two alloy wheel plants support this output: a Bilaspur, Haryana, facility with 3.60 million wheels of annual installed capacity and a Kolar, Karnataka, site with 2.40 million, together totalling 6.00 million wheels and spanning roughly 27,042 square metres near major automotive clusters.

Revenue distribution has widened considerably. Karnataka led in Fiscal 2026 at INR 144.29 crore, or 26.82 percent, followed by Tamil Nadu at INR 119.47 crore, Haryana at INR 110.85 crore and Uttarakhand at INR 91.60 crore. Andhra Pradesh and Rajasthan added INR 37.00 crore and INR 33.16 crore, respectively, a marked change from Fiscal 2024 when Tamil Nadu alone represented 76.85 percent.

Financial and operational metrics have climbed sharply. SKUs expanded from 9 to 49 between Fiscal 2024 and Fiscal 2026, wheels sold rose from 745,000 to 3,179,000 units and revenue per wheel grew from INR 1,457.58 to INR 1,671.46. Revenue from operations reached INR 537.95 crore from INR 112.46 crore, while profit after tax rose to INR 44.97 crore from INR 2.92 crore and EBITDA to INR 94.68 crore from INR 13.79 crore. Unistone Capital Private Limited is banker to the issue, with Bigshare Services Private Limited as registrar.

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Toyota Kirloskar Motor (TKM), one of the leading passenger vehicle manufacturers, has released its Sustainability Report 2026, titled 'Progress that Powers Everyone', outlining the company's environment, social and governance (ESG) performance and manufacturing operations in India.

The report was presented by Ramalinga Reddy, Minister of Forest, Ecology & Environment for the Government of Karnataka, alongside B. Padmanabha, Senior Executive Vice President of Manufacturing at Toyota Kirloskar Motor.

In its product operations, the company maintains a multi-pathway powertrain strategy encompassing hybrid electric vehicles, battery electric vehicles, hydrogen technologies and alternative fuels. Hybrid models from Toyota represent approximately 80 percent of total hybrid vehicle sales in India, while the company introduced the Urban Cruiser Ebella as its first battery electric vehicle in the domestic market.

In manufacturing operations, Toyota Kirloskar Motor operated its facilities using 100 percent renewable electricity for the fifth consecutive year, eliminating Scope 2 greenhouse gas emissions. The company reported avoiding over 594,000 tonnes of carbon dioxide emissions since FY2012-13, while recycling more than 95 percent of manufacturing waste and sourcing over 90 percent of its operational water through recycling and rainwater harvesting.

Ramalinga Reddy said, "Environmental protection cannot remain confined to policies alone; it must become a habit that is reflected in the choices we make every day. Whether it is conserving water, reducing waste, adopting clean energy or preserving biodiversity, every effort counts. Industries have a significant role in leading this transformation because their actions influence people, communities and future generations. TKM's Sustainability Report 2026 is a reminder that sustained commitment and collective action are essential for building a greener and more resilient India."

B Padmanabha said, "At Toyota, sustainability is an integral part of how we create value for society. Guided by the Toyota Way and our commitment to ‘Producing /spreading Happiness for All', we continue to balance sustainable business growth with environmental stewardship and social progress. This Sustainability Report reflects the collective efforts of our employees, suppliers, dealers, and partners in advancing carbon reduction, resource efficiency, community development, and responsible governance. While we are encouraged by the progress made, we remain committed to continuous improvement and to contributing to a cleaner, safer, and more prosperous future for all. We believe that true success lies not only in making ever-better products, but in creating lasting value for society and future generations."

On human capital and community development, Toyota Kirloskar Motor trained over 140,000 individuals through the Toyota Technical Training Institute and partnerships with 120 Industrial Training Institutes and 30 Government Tool Room & Training Centres. During FY2025-26, the company allocated over INR 1,047 million towards corporate social responsibility initiatives covering education, healthcare, sanitation, water conservation, road safety and environmental restoration.

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Maharashtra-based Abhijeet Dies & Tools and Italy's INEVO have signed an agreement establishing a joint venture entity, Abhinevo Technologies.

Headquartered in Pune, the new JV will develop, engineer, manufacture and commercialise moulds, tooling and manufacturing technology solutions for the automotive and plastics-processing sectors.

The agreement combines Abhijeet’s four decades of tooling and plastics manufacturing operations with INEVO’s European high-precision injection mould technologies. The new entity intends to localise manufacturing technologies in India across the value chain, covering product and process engineering, tool design, simulation, manufacturing, trials, validation and production support.

Jayamurugan Thangavel, CEO, Abhijeet Group, said, “This joint venture marks an important step towards technology-led manufacturing. By combining INEVO’s specialised European technology with Abhijeet’s engineering and manufacturing capabilities, we aim to build advanced capability in India and create a platform serving Indian and global customers.”

Abhijeet Raut, Director, Abhijeet Dies & Tools, said, “The real value of this partnership will be in taking advanced technologies from concept to industrialisation. Through Abhinevo, we aim to give customers access to sophisticated tooling and manufacturing solutions with closer engineering collaboration, faster development and globally benchmarked quality – converting technology into robust, repeatable and commercially viable manufacturing solutions.”

INEVO, spun off from the mould division of INglass in 2020, exports over 80 percent of its output globally, producing more than 100 injection tools per year. Its specialisation covers multi-material and multi-colour moulding, automotive lighting tooling, In-Mould Decoration (IMD), In-Mould Labelling (IML), injection on decorative and functional foils and surface technologies.

Roberto Fagarazzi, Managing Director – Sales, INEVO, said, “India is becoming increasingly important in the global automotive manufacturing landscape, and customers are looking for greater localisation without compromising technology, quality or manufacturing performance. We see a strong opportunity to bring INEVO’s experience in advanced moulds, multi-material technologies, smart surfaces and industrialisation closer to this market.”

“Abhijeet has a strong tooling and manufacturing foundation, engineering resources and an established automotive presence. The combination of INEVO’s specialised technology with Abhijeet’s manufacturing expertise creates a strong platform for long-term development. Our ambition is to develop solutions together in India, build local technical competence and progressively create opportunities that can serve customers both in India and internationally,” he added.

The initial technology scope for Abhinevo Technologies will encompass 2K and multi-component mould technology, polyurethane-based surface applications, IMD, IML, In-Mould Coating, film integration and process simulation. These processes target automotive interior and exterior components, functional panels, and smart surfaces for domestic automotive OEMs, Tier-1 suppliers and international export markets.

Nikhil Raut, Director, Abhijeet Dies & Tools, said, “This partnership is more than a business agreement. It brings together two companies, cultures and capabilities with a shared ambition to create something meaningful and long-lasting, built on trust, teamwork and mutual respect. The true success of Abhinevo will be measured by what our teams create together, the value we deliver to customers and the trust we build over the years ahead.”

Consultancy firm Crescendo Worldwide facilitated the partnership process, initiating partner identification in early 2025, which led to a Memorandum of Understanding in June 2025 prior to the final joint venture execution in September 2026.

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Chinese automotive companies NIO Holding Co, and Zhejiang Geely Holding Group Co, have entered into a strategic agreement covering technology, operations and capital investments across their charging and battery swapping businesses. The partnership includes cross-equity investments, joint technology development and network integration.

As per the agreement, Geely Holding Group will acquire a 30 percent equity stake in NIO Power. The transaction involves Geely transferring a 100 percent equity interest in its battery-swapping subsidiary, Yiyi Power, to NIO Power, alongside a cash investment of RMB 640 million.

Following the completion of the deal, Yiyi Power's commercial fleet swapping operations will be integrated into NIO Power's infrastructure. In exchange, NIO will acquire a 10 percent equity stake in Geely's charging subsidiary, Haohan Energy, establishing interconnected charging networks between the two companies.

The agreement includes provisions for the co-development of unified battery swapping technologies and standards for passenger vehicles. Geely will design battery-swappable models compatible with NIO Power's swapping stations, while NIO Power will provide battery swapping services for these vehicles.

William Li, Founder, Chairman and CEO, NIO, said, “Over the past decade, China’s smart EV industry has made remarkable progress, driven by rapid advances in technology and continued innovation. Looking ahead, the industry needs not only to keep innovating, but also to become more efficient at turning innovation into value. This partnership brings together the strengths the two sides have built over the years, with closer collaboration across technology, standards, operations, assets, and capital. It represents an important exploration and innovative step toward addressing involution-style competition and building a more open and mutually beneficial industry ecosystem where automakers can work together to achieve high-quality growth. The collaboration between NIO and Geely in charging and battery swapping is open to the broader industry. We welcome and look forward to more industry peers joining us in creating a better recharging experience for users, supporting the industry’s transition to low-carbon, green energy, and shape a sustainable and brighter future.”

Andy AN Conghui, CEO, Geely Holding Group, said, “High-quality development of the automotive industry is not about scale alone. It calls for more resilient supply chains, higher quality and greater efficiency, safer and greener development, and a more open and collaborative ecosystem. Recharging networks are public infrastructure that serve society as a whole. They should be built together, shared openly, and connected across networks, so that users ultimately benefit the most. Geely Holding Group has long driven innovation in core new energy vehicle technologies, building an all-scenario recharging network that combines charging and swapping. This partnership marks another step toward the high-quality development of China’s intelligent connected new energy vehicle industry. With an open approach and a long-term commitment, Geely Holding Group will work with NIO and other industry partners to build a denser, more reliable, and safer recharging network, making mobility more seamless and worry-free for users.”

As of September 2026, NIO operates a network of 9,433 infrastructure sites in China, comprising 4,126 swapping stations and 5,307 charging locations housing 30,598 charging connectors. The company has set a target to operate 10,000 swapping stations by 2030.

Geely's charging unit, Haohan Energy, currently operates 2,500 charging stations with 12,000 connectors across 232 cities, with plans to expand to 22,000 stations containing over 100,000 connectors by end-2027.

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