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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Mumbai-based automotive major Mahindra Group is preparing to test the waters of India’s nascent lifestyle pickup segment, while accelerating a deliberate international expansion and doubling down on its electric vehicle ambitions.

It was on 14^th August that Mahindra took the wraps off its much-anticipated global pickup truck christened – ‘Mahindra Lifestyler’ and ‘Scorpio Lifestyler’ (for India market), based on the popular Scorpio SUV. While the technical details and pricing have still been kept under wraps, what's known is that it will be available in three variants - Trail, Valley and Reef editions. It will be launched by April 2027 with prices starting under INR 1.95 million (ex-showroom). 

R Veluswamy, President - Automotive Technology & Product Development, Mahindra Group and Nalinikanth Gollagunta, CEO, Automotive Division, Mahindra & Mahindra, outlined a strategy rooted in what they describe as latent customer demand rather than existing market size.

“The latent demand, latent need is the most important thing,” Gollagunta said. “So far what we have seen is, it’s a compromise choice they make. Because they don’t have the right product at the right price point. So, they’re making either a compromise on the capability or making a compromise on the budget.”

He added, “We believe that the latent demand for an uncompromised choice means there’s an open space for us to play.”

Veluswamy reinforced the point by recalling the original Scorpio’s arrival. “When we first saw the car, we all were blown away, but no customer had expressed that they wanted such a car. So, to say that the pickup segment is not exist may be a statement that’s not representative of the customer. They may not know how to express it. The latent desires are always understood.”

He continued: “We have seen customers who want the pickup character and who want the SUV character and who want the 4x4 character at an affordable price point. If you put all of them together, Mahindra has the deep pickup expertise. Mahindra has the deep SUV expertise; we put all of them together, and we think it will click with the customer.”

The forthcoming Scorpio-badged Lifestyler pickup was originally conceived as a global product.

“You have to remember three years ago, this was a global pickup as we call it. This was for the global market. But in three years, we have had enough indications to tell us that there’s some latent demand in this market,” Gollagunta noted.

Responding to a query on the volume expectations, Gollagunta said, “I won’t get into the volumes to be honest. The way we are looking at it is we are the third largest automotive market in the world. We believe the market is evolving and maturing and becoming a lot more sophisticated. The problem we see is there are not enough of these choices in these markets.”

Veluswamy pointed to past surprises as evidence that the right product can rewrite expectations. “How many of us thought the 9E would have such volume? And the 9S when we launched, how many of us thought that would have that volume? It clearly tells if you have the right product for the right customer needs. They don’t look at the price. They look at the value proposition.”

He added of the XUV700: “Who in the earth would have imagined that this car will be selling at 9,000 units per month. Who would have thought?”

The Scorpio brand itself is viewed as elastic enough to support the new model. “Our sense is the Scorpio brand means a lot to different people,” Gollagunta observed.

“There are a lot of customers who have a Scorpio Classic, who tell us that I will not buy a Scorpio N. A lot of Scorpio N customers say that I don’t see myself in a Scorpio Classic. Yet the market has stretched and you have two distinct segments with very loyal customers on both sides. So, it’s hard to predict right now. Our view is there’s enough elasticity in the brand today to take a price that is very distinct in itself,” he said.

Pricing has been carefully signalled rather than fixed. “I’ve given one so that now I can have conversations,” Gollagunta explained. “The starting price is less than this, we said. It’s a conversation starter for me to have conversations with customers.”

Veluswamy clarified, “The starting price is less than that. We haven’t announced the price. We have just put a number.”

When queried about the production capacity for the upcoming Lifestyler, “Every new product comes, it comes with a capacity,” Veluswamy said. “So there is a capacity for the product, and there is an operationalisation based on the demand; you operationalise the capacity.”

The vehicle will benefit from body-on-frame technology, 4x4 expertise and technologies already proven elsewhere in the range. “We are riding on that high price point SUVs, which means high technologies that we already use in our ICE and EVs. That is what we are bringing to pickup,” he noted.

Beyond India, the company is pursuing a measured three-phase global approach.

“There is a three-phase strategy. The core markets where we have a strong legacy will continue to double down. Those markets: South Africa, Australia for sure. The second wave is the other LHD markets where we think there is significant potential for us. And we have talked about UK. If we go there, we want to go there to win. And if you are not convinced we cannot win, we will be careful about doing it. I am not in a hurry because I have a core market which is doing well. But we will go out there; the difference is we now have products which are built for the globe,” Gollagunta averred.

Veluswamy provided market context: “We sold about 235,000 units last year (2025) in Australia. And about 135,000 units in South Africa. But the majority of them are these mid-size pickups. The South African market is looking for versatility. Whereas the Australian market is looking for adventure, freedom, go anywhere, towing 3.5-tonne trailers, premium upmarket. So, it is really two different markets.”

The Indian market in the recent past has seen a slew of automakers in the passenger vehicle space introduce hybrid products. For Mahindra, the message has been clear: electrification was unambiguous.

“Our focus is electric, electric, electric. That’s it,” Veluswamy declared.

Furthermore, the company had no intention to dilute its SUV focus simply to chase EV volume elsewhere. “We play in the SUV market. So wherever there is an SUV market, we bring electric. You have to see multiple parameters. It’s not one-dimensional.”

Gollagunta added that electric powertrains are already on the roadmap for future platforms: “We did have the NU_IQ we launched last year, and we said that there is going to be electric powertrains on NU_IQ. But if we do it, it has to be in a way that we believe taps into a platform architecture.”

Veluswamy highlighted the recently introduced BE6 for its intelligence layer.

“The intelligence of the car is different from intelligent driving. Naturally, it can speak to you. You can ask many questions. It is like a teacher, a tuition teacher. That is phenomenal. It understands the context, the context reasoning. It understands natural language reasoning. You do not have to be as accurate as Alexa. That is why we say it is unmatched.”

He detailed the system’s architecture: “It goes to the cloud, and it has 17 agents, and 17 agents are working in tandem. If they have to get it from the LMM, the Gemini model, then it directly gets it.”

Simple commands remain local and immediate, while contextual or knowledge-based queries draw on the cloud. “Our electric vehicle is one of the best cyber security certified. Without cybersecurity, you cannot even bring this in,” he added.

Going forward, it will be interesting to see whether the Scorpio Lifestyler remains a niche experiment or becomes another volume surprise will depend on the next six months of customer conversations.

What is already clear is that Mahindra intends to treat both the Indian opportunity and its wider global and electric ambitions with the same methodical, brand-first discipline that has underpinned its recent growth.

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Honda Motorcycle & Scooter India (HMSI) Director of Sales and Marketing Yogesh Mathur has exited the company after more than two decades, sources familiar with the matter have confirmed.

Mathur joined the Japanese two-wheeler major in June 2001 and rose through the ranks to become one of its longest-serving senior leaders. At the time of his departure, he held end-to-end responsibility for sales, distribution, logistics, customer service and business planning across HMSI’s network of more than 6,500 dealer and customer touchpoints nationwide. Under his oversight, the company managed annual volumes exceeding 5 million units and a turnover of approximately INR 500 billion, spanning rural, semi-urban, urban, metro, premium and electric vehicle segments

Mutsuo Usui, Director – Sales at Honda Motorcycle & Scooter India, has succeeded Mathur, according to people aware of the development. The company has not issued any official statement on the leadership change.

Mathur’s career at HMSI progressed from executive roles to regional head across every geography in India, followed by stints as division head for marketing and business planning, operating head of sales and marketing, and ultimately senior-level expert. He also served on the company’s CSR Committee, Business Ethics Committee and Information Security Management System (ISMS) Committee.

As HMSI’s official spokesperson, he represented the company in national media for over five years.

At present, there are no further details on Mathur’s next move or the exact effective date of the transition were immediately available.

The move comes at a time when Honda Motorcycle & Scooter India is gearing up to unleash one of its most aggressive product launch roadmap compromising of 10 motorcycles and scooters, which includes 7 models and 3 refreshed variants.

The lineup spans internal combustion engine, electric and flex-fuel mobility, featuring models such as the ADV 160, CB 500, Rebel 300, Rebel 500, XR 300L, XR 300 Rally and QC3 EV. Production utilises local sourcing and manufacturing capabilities to support market expansion

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German automotive supplier Brose has appointed Chetan Lagu as the President of its Indian operations, effective 1 August 2026.

Lagu brings over three decades of experience in the automotive and supplier sector to the role. Prior to joining Brose, he served as Country Manager for Adient in India, a position he held from May 2019. His previous career history includes positions at American Axle & Manufacturing and over a decade of tenure at SKF Group, where he held roles including General Manager of the Car Chassis Business Unit in India.

In his new role, Lagu will oversee the execution of Brose's strategy in India, manage market expansion and direct regional business operations. He succeeds Vasanth Kamath, who served as the head of Brose India from June 2019.

‘India is an important growth market for our company. In his new role, he will drive the execution of our India strategy, strengthen our market presence, and support the continued development of our business in the region. We welcome him to the Brose team and wish him every success in his new role. We look forward to working together and driving the next chapter of growth in India,’ said the company in a statement.

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The automotive industry in India continues to reap the benefits of the revised GST 2.0, new product launches and positive consumer sentiment to drive sales growth in the country.

As per the latest wholesale data shared by the Society of Indian Automobile Manufacturers (SIAM), a total of 2.47 million vehicles were sold in July 2026, marking a 25 percent YoY growth, as compared to 1.97 million units sold a year ago. Interestingly, even compared to the previous month, the industry wholesales grew by 7 percent YoY.

In segment-wise performance, passenger vehicle sales grew by 34 percent YoY to 457,810 units, registering double-digit growth across categories.

Three-wheeler sales at 92,560 units were 33 percent higher YoY, as compared to 69,403 units sold a year ago.

Two-wheeler sales at 1.92 million units managed a 23 percent uptick, as compared to 1.56 million units sold last year.

Rajesh Menon, Director General, SIAM, said, “India’s auto industry delivered its strongest-ever July sales, with robust double-digit growth across Passenger Vehicles, Three Wheelers and Two Wheelers. Passenger Vehicle sales rose 34.3 percent to 458,000 units, Three-Wheeler sales grew 33.4 percent to 93,000 units and two-wheeler sales increased 22.6 percent to 1.92 units compared with July 2025. This positive momentum, sustained over several months, has continued as the industry enters the festive season with expectations of strong consumer sentiment.”

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