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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Eicher Motors (EML), a leading manufacturer of two-wheelers and commercial vehicles, has reported financial results for Q1 FY2027, recording a 32 percent YoY increase in quarterly operational revenue to INR 66.32 billion.

The company's earnings before interest, tax, depreciation, and amortisation (EBITDA) rose 32 percent YoY to INR 15.91 billion from INR 12.03 billion in Q1 FY26; consolidated net profit grew 21 percent YoY to INR 14.63 billion from INR 12.05 billion a year ago.

Alongside the financial results, Eicher Motors's board of directors approved an investment of INR 12.25 billion for Phase I of a greenfield manufacturing plant in Tada, Andhra Pradesh. The facility is scheduled for completion during FY 2029-30 and will provide additional annual production capacity of up to 450,000 motorcycles at full utilisation.

During Q1, Royal Enfield recorded quarterly motorcycle sales of 332,940 units, representing a 27.4 percent increase from 261,326 units. Operational milestones during the period included the start of deliveries for the Flying Flea C6 electric motorcycle and the launch of the Bullet on the 650cc engine platform.

On the other hand, VE Commercial Vehicles (VECV) reported revenue from operations of INR 66.10 billion, up 16.6 percent from INR 56.71 billion a year ago. VECV's EBITDA rose 6.1 percent to INR 5.41 billion from INR 5.11 billion, while net profit reached INR 3 billion compared with INR 2 billion last year. The company sold a total of 24,815 commercial vehicles, up 14.8 percent YoY, as compared to 21,610 units a year ago.

B Govindarajan, Managing Director, Eicher Motors and Chief Executive Officer, Royal Enfield, said, "Building on a record-setting performance in FY26, we have sustained our strong momentum into the new financial year, with Royal Enfield recording its highest-ever quarterly sales and VECV recording its highest-ever Q1 sales. This quarter was historic for Royal Enfield as we commenced deliveries of the Flying Flea C6 electric motorcycle. The early response to the FF.C6 has been highly positive, reinforcing our vision of creating a new category of premium city+ electric mobility. We also strengthened our portfolio with the launch of the iconic Bullet on the 650cc platform. Globally, key markets continued to perform well, driven by new motorcycle launches. To support our growth over the long-term, we announced plans for a new greenfield manufacturing facility in Tada, Andhra Pradesh, to expand our capacity beyond the existing facilities in Tamil Nadu. Beyond these milestones, our global community remained at the heart of our journey, which was reflected in the growing participation numbers in our marquee rides and events. With a robust product launch calendar and diverse brand initiatives planned for the rest of the year, we are optimistic of maintaining our growth trajectory in the dynamic global environment."

B Srinivas, Managing Director and CEO, VECV, said, "We are pleased to have delivered our best-ever first quarter, with sales of 24,815 units, growing 14.8 percent YoY, while maintaining our number one position in the LMD truck market. Beyond the numbers, we continued to drive modernization in the Indian CV sector. The launch of the Volvo FMX Edge is set to transform mining productivity by combining optimized payload capability with superior safety, uptime and lifecycle value. Furthering our commitment to deliver superior uptime to Eicher customers, we added 30 new touchpoints during the quarter. We also signed a MoU with the Ministry of Road Transport and Highways under the PARIVARTAN fleet modernisation scheme for the NCR, signalling our partnership to support the transition towards a cleaner and more efficient commercial vehicle fleet. As we look ahead, we remain focused on building on this momentum and delivering sustained value for our customers in a rapidly evolving industry."

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KPMG, one of the leading accounting firms, has launched The KPMG Global Tech Report 2026: Automotive, which indicates that global automotive organisations are directing investments towards artificial intelligence (AI), data resilience and digital infrastructure to adapt to evolving mobility ecosystems.

The report surveyed 258 technology executives across 22 countries, representing original equipment manufacturers (OEMs), commercial vehicle manufacturers, Tier 1 suppliers, technology component vendors, and mobility providers with annual revenues exceeding USD 1 billion.

The survey metrics show that 88 percent of respondents express confidence in revenue growth over the next 24 months. Furthermore, 74 percent view advanced technology as the primary driver of competitive advantage, whilst 86 percent state that technology roadmaps become outdated quickly due to market changes. Additionally, 82 percent of executives report a requirement to take risks on technology investments, though 53 percent note that legacy processes reduce return on investment.

To address macroeconomic and geopolitical volatility, sub-sectors within the industry report distinct technical responses. Among vehicle manufacturers, 67 percent plan to enhance data sovereignty across partnership networks. Among truck manufacturers, 61 percent intend to hire onshore technology talent. Tier 1 suppliers report that 41 percent aim to upgrade data infrastructure for scenario planning, while 47 percent of component suppliers plan to tighten technology expenditure. Among mobility service providers, 40 percent plan to expand the number of innovation centres of excellence.

In India, automotive firms are focusing on transitioning AI implementations from pilot stages to operational deployment across engineering, manufacturing, supply chain management and customer operations.

Jeffry Jacob, Partner and National Sector Leader, Automotive, KPMG in India, said, "For India’s automotive sector, the findings reinforce that competitiveness will increasingly depend on how effectively organisations scale AI, data and digital technologies. These capabilities must move beyond pilots and into engineering, manufacturing, supply chains and customer-facing operations. Strong data foundations, clear governance and disciplined execution will be essential to convert technology investments into measurable value. As vehicles become more connected, software-enabled and intelligent, resilient digital capabilities will be critical to sustaining growth and remaining competitive in the Intelligent Age."

The report concludes that industrialising machine learning operations (MLOps), enforcing data governance and implementing standardised digital architectures remain key operational priorities for sector participants aiming to manage software updates, cybersecurity and regulatory compliance.

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European automaker Stellantis has signed an agreement with private equity firm Mutares SE & Co. to sell its entire shareholding in the Free2move car-sharing business. The transaction is expected to close by the end of 2026, subject to regulatory approvals and employee consultation processes.

Free2move operates free-floating short- and long-term car-sharing services across 14 cities in Europe and the United States via a mobile application platform. Following the acquisition, Mutares plans to establish the business as an independent mobility entity, focusing on fleet management, transitioning to battery-electric vehicles and operational adjustments for municipal transport requirements.

The divestment aligns with Stellantis' capital allocation strategy under its FaSTLAne 2030 business plan, which prioritises resource allocation towards core automotive operations and high-return technologies.

Virgilio Cerutti, Head of Business Development & Partnerships at Stellantis, said, “By sharpening our focus on core automotive activities, we strengthen our capacity to deliver long-term performance. We are committed to working closely with all stakeholders to support a smooth transition process for customers, partners, and employees.”

Johannes Laumann, Chief Investment Officer, Mutares, added, “Free2move’s car-sharing business combines a strong, internationally recognised brand with clear potential for operational improvement following an intended carve-out from Stellantis. Together with the management team, we look forward to strengthening Free2move’s operating model and further developing the company into an independent leading platform in the mobility sector.”

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ZF Commercial Vehicle Control Systems India Limited (ZF CVCS India) has finalised multi-year supply agreements with three major Indian truck manufacturers for its ESCsmart Electronic Stability Control (ESC) solution. The deals cover 12-volt and 24-volt architectures and are tied to new model launches developed to align with upcoming safety legislation. Local assembly will occur at ZF CVCS India's domestic production hubs, with series manufacturing scheduled to start in the third quarter of 2027.

The regulatory landscape is the primary driver, as Indian authorities have set an October 2027 deadline for mandatory ESC installation on all trucks. With that compliance date approaching, OEMs are securing proven technology partners well in advance, and the nominations reflect a broader industry shift towards active safety adoption ahead of the mandate.

Electronic stability control is globally regarded as a critical tool for preventing rollovers and loss-of-control incidents, with many developed markets already enforcing similar requirements. India's forthcoming regulations represent a meaningful convergence with international norms, and observers anticipate measurable improvements in commercial vehicle accident statistics once the technology becomes standard.

The ESCsmart system is tailored for heavy commercial use, automatically modulating braking and engine torque when sensors detect instability. Its effectiveness in Indian conditions has been validated through deployments on over 60,000 vehicles, while ZF's pedigree includes 20 years of innovation and more than three million global deliveries. The company is providing validation and pre-certification support, positioning the solution as fully compliant with both current and stricter 2027 rules.

Paramjit Singh Chadha, Managing Director, ZF Commercial Vehicle Control Systems India Ltd, said, “As the Indian commercial vehicle industry prepares for the next phase of safety regulations, vehicle stability technologies are evolving from being a differentiator to becoming a fundamental requirement. These business nominations reflect the growing momentum towards advanced active safety systems across the market. With a proven ESC platform, dedicated validation capabilities at our ESC test track and strong local engineering and manufacturing expertise, ZF CVCS India is ready to support OEMs in meeting the upcoming safety requirements with scalable, India-ready solutions.”

Akash Passey, Non-Executive Chairman, ZF Commercial Vehicle Control Systems India Ltd and President – ZF Group in India, said, “We are proud of the confidence our customers have placed in ZF CVCS India and the partnerships we have built. As India enters a defining phase in commercial vehicle safety, OEMs are increasingly prioritising proven technologies that enhance vehicle stability and deliver meaningful safety outcomes at scale. These nominations reinforce ZF CVCS India's leadership in active safety and our readiness to support the industry's transition through proven technology, local manufacturing, advanced validation capabilities and ZF's global expertise in electronic stability control.”

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