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!

As part of its evolving global roadmap, French automotive major Renault Group is increasingly aligning its strategy around a select set of high-growth markets, with India emerging as a critical pillar for the company’s future competitiveness.

Senior leadership indicated that the carmaker now views India not merely as a domestic sales market but as a full-fledged industrial and sourcing hub capable of strengthening its global supply chain. With localisation levels already exceeding 90 percent, the company believes the Indian ecosystem can play a significant role in improving cost competitiveness and supporting exports to other regions.

To accelerate this transformation, the Group strengthened its leadership structure in the India by appointing a Stephane Deblaise as its first Chief Executive Officer (CEO) to oversee the entire India operation. The move reflects a broader intent to deepen local decision-making and integrate the market more closely into Renault’s global strategy.

India and South America drive future trade opportunities

The company is also exploring the potential benefits of free trade agreements (FTAs) that could further strengthen export flows from India and South America.

Executives indicated that improved trade frameworks could enhance the role of India as a competitive production and sourcing base, particularly as global automakers reassess supply chains and regional manufacturing footprints.

At the same time, the company remains cautious in other global markets. Chinese suppliers currently account for around five percent of Renault’s global sourcing, and the group has no plans to re-enter the Chinese market in the near term.

A key shift in the group’s strategy since 2019 has been a move away from aggressively chasing volumes toward building stronger brand value and profitability.

Instead of pushing for market share in every region, Renault says it is focusing on markets where it can build a sustainable and profitable business case. The emphasis is now on delivering differentiated products, stronger customer value and improved quality rather than simply expanding volumes.

This philosophy is shaping the company’s approach to India as well.

Rather than targeting the entire market, Renault plans to focus on specific customer segments, particularly middle- and upper-income families seeking value-driven mobility solutions. The company believes that strengthening product positioning and improving residual values will ultimately support stronger brand perception.

India’s passenger vehicle market remains highly competitive, especially in the price band of EUR 15,000–20,000 vehicles, where global and domestic manufacturers are battling for share.

Historically, Renault established its presence in the country through entry-level offerings such as the Renault Kwid. However, the company is now looking to shift its brand positioning toward higher-value products.

The success of the Renault Duster in the past continues to shape Renault’s product roadmap, with the company describing the nameplate as a brand in itself in several markets. Building on this equity, Renault plans to introduce new SUV offerings that combine stronger design, advanced technologies and multi-energy powertrain options.

One such upcoming concept is the Renault Bridger, which the company believes could be a game changer in its product portfolio. Designed around flexible powertrain architectures, the model is expected to support multiple energy options as part of Renault’s broader global push toward electrified and hybrid mobility solutions.

The company emphasised that it is not starting from scratch in India, pointing out that millions of customers already drive Renault vehicles across the country.

Another major focus area for the group is accelerating product development cycles.

According to Renault’s leadership, one of the biggest challenges facing the global automotive industry today is the ability to develop new vehicles in less than two years while keeping pace with rapidly evolving technologies.

The company has already demonstrated faster development cycles in China and is now working to replicate that agility in Europe by integrating engineers and suppliers more closely into the product development process.

This approach could also influence Renault’s India strategy, particularly as the company looks to launch new products more quickly and respond faster to market shifts.

Strengthening downstream ecosystem

Beyond manufacturing and product strategy, Renault is also placing increasing emphasis on downstream value creation, including dealership networks, customer services and vehicle residual values.

Management believes that stronger engagement with dealers and improved lifecycle value for customers will be critical differentiators in markets like India, where brand perception and resale value play a significant role in purchasing decisions.

The company currently maintains capital expenditure and R&D spending below eight percent of revenue, while maintaining tight control over inventory levels, which average around EUR 1 billion globally.

While Renault acknowledges that its current market share in India remains modest, the company sees substantial long-term potential in the country’s rapidly expanding passenger vehicle market.

With a renewed focus on SUVs, high localisation levels and a shift toward value-driven products, the French automaker believes it has a credible opportunity to rebuild momentum in the market.

For Renault, the strategy is clear: rather than chasing scale at any cost, the company intends to grow selectively and profitably, with India playing an increasingly central role in its global ambitions.

Comments (0)

ADD COMMENT

Link Copied!

French automotive major Renault Group, which unveiled its mid-term business strategy ‘futuREady’, will see India playing a huge role in its ambitious growth plan.

Fabrice Cambolive, CEO, Renault Brand, has stated that the company’s upcoming Bridger SUV, slated to be a key driver for growth, will go into production by next year.

What’s more, the sub-4-metre tech-loaded Bridger SUV touted as the company's flagship for the international markets with a spacious 400-litre boot, will see India as its first market before being exported to other countries.

As part of its future plans, the Bridger SUV will be a multi-energy vehicle, which means petrol, electric vehicle and a hybrid engine to enable transition towards EV.

While full details of the product will be revealed closer to launch, the company has clearly stated that outside Europe, India, South America and South Korea are key growth regions.

The high-growth markets with an estimated 50 million units per annum, represent 60 percent of total industry volume growth where Renault Group is present.

Comments (0)

ADD COMMENT

Link Copied!

French automotive major Renault Group has launched its new strategic roadmap, titled futuREady, marking the next phase of its corporate transformation following the 2021 ‘Renaulution’ plan. The strategy aims to establish the Group as a benchmark European carmaker through an offensive in products, technology and operational performance.

The Group has set medium-term financial targets including an operating margin between 5 percent and 7 percent and an average automotive free cash flow of at least EUR 1.5 billion per year.

Product Offensive and Global Growth

Renault Group plans to launch 36 new models globally by 2030. The strategy focuses on two distinct geographic tracks:

• Europe: 22 new models, of which 16 will be electric. The Renault brand aims for 100 percent electrified sales in this region by 2030.
• International: 14 new models targeted at growth hubs in India, South America, and South Korea. The Group expects 50 percent of Renault brand sales to come from outside Europe by the end of the decade.

A cornerstone of the plan is the RGEV Medium 2.0 electric platform. This modular 800-volt architecture is designed to reduce costs by 40 percent compared to current electric vehicles.

Technical specifications for the 2030 horizon include:

• Charging: Ultra-fast charging capability of 10 minutes.
• Range: Up to 750 km (WLTP) for pure electric versions and 1,400 km with a range extender.
• Software: Transition from Software Defined Vehicles (SDV) to Artificial Intelligence Defined Vehicles (AIDV), with 90 percent of functions updated via Firmware Over The Air (FOTA).
• Powertrain: A third-generation rare-earth-free motor (EESM) delivering 275 hp with 93 percent motorway efficiency.

Renault Group intends to halve factory downtime and reduce energy consumption by 25 percent through the use of an industrial metaverse – a digital twin of all manufacturing sites. The plan involves deploying 350 humanoid robots for low value-added tasks and using AI to supervise 1,000 manufacturing control points. These measures aim for a 20 percent reduction in production costs and a 30 percent reduction in logistics costs.

Francois Provost, CEO, Renault Group, said, “futuREady, our new strategic plan, is a crucial step in the future of Renault Group. In an environment that is even more competitive, we can build on solid fundamentals: our brands, our products and our financial results. Since my appointment as CEO last July, we have been working with the whole team worldwide to develop a plan that will set the Group on the path to robust and sustainable performance, whatever the challenges ahead.”

“Becoming Europe's reference carmaker means setting the ambition to design and produce in Europe products that are best in class in terms of desirability, technology and competitiveness. In an increasingly competitive environment, this means combining performance and innovation with resilience and robust strength,” added Provost.

Comments (0)

ADD COMMENT

Link Copied!

Rolls-Royce Motor Cars has marked the conclusion of its year-long partnership with Aldingbourne Trust by presenting the charity with a series of exclusive artworks. These pieces were created by the luxury marque’s in-house design team and inspired by a wooden model gifted to Rolls-Royce by the Trust late last year.

That model, named the ‘Sapele Shadow’ after the wood used in its construction, was made by the Wood@Aldingbourne team as a gesture of gratitude when Rolls-Royce delivered its final donation. Now displayed at the company’s Goodwood headquarters, the handcrafted vehicle prompted one of the marque’s designers to reinterpret it digitally using the same advanced rendering software applied for client commissions.

Only three framed prints of this original artwork have been produced, each signed and numbered by the designer. One is set to be displayed in the Aldingbourne Trust café, another has been presented to the Wood@Aldingbourne workshop and the third will be auctioned to support the charity during the Goodwood Members’ Meeting in April.

Wood@Aldingbourne is one of over a dozen social enterprises run by the Trust, which has supported more than 1,500 individuals with learning and physical disabilities since its founding in 1978. Operating as a self-funding environmental group, it collects and repurposes reclaimed wood from local sources, including the Rolls-Royce site. All materials are either transformed into handmade goods for sale or used to fuel the Trust’s biomass boiler.

The relationship between Rolls-Royce and Aldingbourne Trust extended beyond fundraising throughout 2024, with colleagues contributing both time and resources. This ongoing collaboration reflects the meaningful connections formed when employees engage with their chosen House Charity, often resulting in support that endures well beyond the official partnership.

Andrew Ball, Head of Corporate Relations, Rolls-Royce Motor Cars, said, “It was a privilege to work with Aldingbourne Trust as our House Charity in 2024. When we presented the final donation cheque, we received an unexpected gift – a model car made in Sapele wood by the Wood@Aldingbourne team. This delightful model inspired one of our designers to create a unique digital rendering, just as we would for a real client commission. We’re delighted that this artwork will be displayed in the Trust’s café and will also be offered as a significant prize in a fundraising auction. It’s a pleasure to extend our support for this wonderful organisation beyond 2024.”

Abigail Rowe of Aldingbourne Trust said, “We were so appreciative of the fundraising efforts by Rolls-Royce staff, and the tremendous awareness we were able to generate through being their House Charity. It’s wonderful that the relationship has continued through this collaboration, which meant so much to the client who created the original wooden model, and will help raise further money for us. We’d like to thank the whole Rolls-Royce team, and particularly the talented designer who created these images for us.”

Comments (0)

ADD COMMENT

Link Copied!