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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The Climate Pledge, co-founded by Amazon, has introduced a landmark evidence-based framework for converting India's diesel freight fleet to battery electric trucks, developed alongside the C40 Cities climate network. The National EV Highway Guidance Framework lays out a staggered timeline starting with 20 priority highways named by the Ministry of Heavy Industries, with an initial target of 2027. The plan extends to industrial zones and port connections, aiming for a fully integrated electric freight network nationwide by 2035.

India faces rapidly rising freight demand, projected to grow more than four times by mid-century. Roadways already handle nearly seventy percent of all goods moved, and despite medium and heavy trucks representing only three percent of vehicles, they generate roughly 53 percent of particulate emissions. Electrifying freight supports the national goal of reaching net-zero emissions by 2070.

The framework builds on the Laneshift pilot, a collaboration that united truck makers, fleet operators, logistics firms and financiers. On the Bengaluru–Chennai corridor, electric trucks logged over 200,000 kilometres across 600 trips, providing data on performance and operating costs while encouraging early adoption through multi-year contracts. A 6,500-kilometre trial along the Golden Quadrilateral further tested scalability. The pilot proved operational feasibility across all scenarios and commercial viability for daily runs above 400 kilometres, resulting in a 4.2-fold jump in electric truck orders and long-term commercial agreements.

The framework outlines priorities spanning charging infrastructure, demand generation and fleet operations. Aligned with the government's push for electrification, the roadmap offers a practical pathway to transform one of India's most emissions-intensive sectors.

Dr O P Agarwal, Distinguished Fellow, NITI Aayog, said, “India’s transition to cleaner freight will require strong collaboration across government and industry. The EV Highway Guidance Framework launched under the Laneshift programme today is an important step in this direction and will help create a scalable pathway for electric trucking in the country. Through the e-FAST India platform, NITI Aayog has been bringing together logistics operators, OEMs, energy providers and financial institutions to build an enabling ecosystem for freight electrification. Building on these efforts, partnerships led by C40 Cities, The Climate Pledge and private sector stakeholders such as Amazon and Ashok Leyland demonstrate how collaborative action can help move electric freight from pilots to large-scale deployment.”

Abhinav Singh, VP, Operations, India and Australia, Amazon, said, “We continue to invest in making our operations more sustainable, and electrifying our logistics is a key part of that effort. Through The Climate Pledge, we are also working with stakeholders to help scale electric freight solutions more broadly in India. The project findings and framework are encouraging and reinforce the importance of continued collaboration between government and industry to accelerate adoption.”

Naim Keruwala, Regional Director for South and West Asia at C40 Cities, said, “Decarbonising freight is not a future ambition; it is an immediate economic and public health imperative for the country. Laneshift has shown that zero-exhaust-emission trucks can operate commercially on long-haul corridors, that costs are coming down and that when the right stakeholders align their efforts, barriers give way. India has the scale, the policy momentum and the industry appetite to be the next frontier.”

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The share of electric buses in new bus sales in India is expected to reach 35-40 percent by FY2035, from the current level of around 7 percent states a recent report titled ‘Electrifying India’s Bus Industry – The Decade of Transformation’ by KPMG.

It indicates that the bus sector is entering a phase of structural change with the shift being driven by urbanisation, sustainability commitments and government-led mobility initiatives.

The report notes that the Indian bus market, which typically averages 35,000 to 50,000 units annually, is transitioning due to electrification and infrastructure investment. Buses currently account for nearly 57 percent of passenger-kilometres travelled in the country. Data shows that 16,300 electric buses were operational in India as of March 2026, and approximately 62,000 e-bus tenders have been issued to date.

Rohan Rao, Partner, KPMG India, said, “India’s electric bus transition is moving beyond a policy-led initiative to becoming a structural transformation opportunity for the broader mobility ecosystem. Public transport electrification has already created strong momentum, supported by government procurement programmes, improving cost economics, and increasing infrastructure investments.”

Raghavan Viswanathan, Partner, KPMG in India, added, “India’s e-bus ecosystem is entering a critical phase where scale, localisation and execution capabilities will become key differentiators. While public transport undertakings continue to lead adoption, the next phase of growth is expected to emerge from private intercity mobility, airport transport, platform-based mobility solutions and corporate fleets.”

The analysis finds that electric buses offer 70 percent higher energy efficiency and lower lifetime emissions than diesel equivalents. In public intracity operations, electric buses have reached total cost of ownership parity with diesel and CNG variants under high-utilisation scenarios.

Government schemes, such as PM-eBus Sewa, are projected to save between 1 and 2 million tonnes of CO2 and reduce oil imports by USD 2 to 3 billion over the concession period.

Projections suggest that India will tender nearly 40,000 additional electric buses by 2030. Within the public transport segment specifically, electric vehicle penetration is expected to exceed 85 percent by FY2035. Coordination between manufacturers, financiers and infrastructure providers remains a factor in achieving these targets.

Representational image courtesy: Tata Motors

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On May 14, 2026, Japanese automotive major Honda Motor Co, unveiled a comprehensive roadmap to restructure its automobile business, prioritising a ‘multi-faceted approach’ to carbon neutrality that leans heavily on next-generation hybrid technology and strategic growth in three key regions.

Facing a challenging global environment and a slowing EV market, Honda is reallocating resources to ensure a return to record profitability by FY2029.

Interestingly, it has identified India as one of three ‘priority regions’ (alongside North America and Japan) central to Honda's future growth strategy. To address past limitations in the region, Honda is shifting away from standard global specifications toward a market-specific approach.

The Japanese automotive major has announced the establishment of a new subsidiary – Honda Digital Innovation India (HDII), which will be based in Bengaluru. This new subsidiary will build a digital platform to integrate motorcycle and automobile services, creating a unique mobility ecosystem.

Furthermore, in 2028, Honda will introduce strategic models tailored to Indian preferences, specifically targeting the high-volume ‘under 4 meters’ category and the mid-size segment.  

Leveraging its massive motorcycle footprint (nearly 6 million units sold annually), Honda aims to capture customers upgrading from two-wheels to entry-level automobiles.

Honda has announced its plans to increase its annual two-wheeler production capacity in India from 6.25 million to 8 million units by 2028, positioning the country as a primary global export hub.

In addition, a new financial services arm is scheduled to become operational by March 31, 2027, to bolster sales opportunities in India.

While Honda remains committed to carbon neutrality by 2050, it is strategically slowing some EV initiatives – including suspending a comprehensive EV value chain project in Canada – to focus on the immediate demand for hybrid vehicles.

The ‘Triple Half’ Approach

To compete with emerging OEMs, Honda is implementing a lean manufacturing and development strategy. The ‘Triple Half’ initiative seeks to reduce development costs, timeframes and workloads by 50 percent compared to 2025 levels.

Honda aims to improve production efficiency by 20 percent over the next five years through digital transformation and AI.

The company will move away from complete internalisation, instead leveraging external partnerships for batteries (such as the L-H Battery joint venture) and standardising components to mitigate tariff impacts and supply risks.

Honda anticipates that these structural changes will lead to a record-high operating profit of JPY 1.4 trillion by FY2029. During this period, the company plans to invest JPY 6.2 trillion in total resources, with JPY 4.4 trillion specifically dedicated to petrol and hybrid models. For shareholders, Honda has committed to stable and continuous dividend payments with a target 3 percent Dividend on Equity (DOE).

Toshihiro Mibe, Director, President and Representative Executive Officer (Global CEO), Honda Motor Co, said, “India is one of the few markets in the world where further expansion is expected in the future. However, currently, Honda is present in only a limited range of product segments and has not been able to fully expand sales volume due to an insufficient number of competitive models in each segment. One contributing factor is that we have not been able to deliver products fully aligned with the characteristics and preferences of customers in India. It has been our standard approach to develop all products based on global standard performance specifications, regardless of target countries and regions and to sell such products in different regions.”

“However, climate conditions, vehicle usage patterns, customer preferences and other factors vary significantly from country to country and region to region. As environmental regulations and other laws and rules are also different, in some cases, the global specifications of our vehicles have been somewhat excessive in the Indian market. Therefore, we will redefine the best specifications that are well aligned with the market environment and customer needs in India.

“Then, in 2028, we will begin introducing strategic models tailored to the Indian market that pursue an optimal balance of performance and price that satisfies our customers in India. To be more specific, we will launch our strategic models in two categories. One is for ‘vehicles under 4 meters in length’, which has the largest volume in India, and the other is the mid-size category. We will proactively utilise local development resources, including external resources, and introduce new models as quickly as possible. The solid foundation of our motorcycle business will become the key strength of Honda in this market," said Mibe.

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The Indian automotive industry continues to grow leaps and bounds. In fact, as per the latest data released by the Society of Indian Automobiles Manufacturers (SIAM), a total of 2.37 million vehicles were sold last month, up 28 percent YoY, as against 1.85 million vehicles sold in April 2025.

In April 2026, the two-wheeler segment at 1.87 million units, up 28 percent YoY, three-wheelers at 65,558 units, up 33 percent YoY and passenger vehicles at 437,312 units, up 25 percent YoY, all clocked high double-digit growth.

Notably, passenger cars segment grew at 33 percent, SUVs at 21 percent, motorcycles at 31 percent, three-wheelers e-cart at 55 percent and goods carrier at 45 percent, YoY, respectively, reported robust growth.

Rajesh Menon, Director General, SIAM, said, “Continuing with the momentum of the second half of FY 2025-26, the first month of FY 2026-27, posted high double-digit growth in passenger vehicles, three-wheelers and two-wheelers. In April 2026, the passenger vehicles recorded their highest-ever sales of 437,312 units with a growth of 25.4 percent, over April 2025. Three-wheelers also posted its highest ever sales of 65,558 units, registering a growth of 32.8 percent, compared to April 2025.”

“Though there are concerns of high commodity prices emanating from the disruptions in West Asia, Industry has been witnessing good demand,” he concluded.

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