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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Toyota Motor Corporation (TMC) has announced a major organisational restructuring, including the creation of a dedicated India & Middle East Region, as part of its strategy to strengthen regional management and accelerate its transformation into a mobility company. The changes will take effect from 1 January 2027.

Under the new structure, Toyota will split its existing India, Middle East, East Asia & Oceania Region into two separate entities – the India & Middle East Region and the East Asia & Oceania Region. The move is aimed at enabling closer engagement with individual markets, faster decision-making and business strategies better aligned with regional growth opportunities.

Masakazu Yoshimura will continue to lead the India & Middle East Region as its Chief Executive Officer, having previously headed the combined regional operations. The newly established region will focus on strengthening its business foundation for future growth, including the launch of a new plant in India and improved coordination of businesses and functions across the region.

The restructuring reflects Toyota's emphasis on regional autonomy, with market leaders expected to make faster decisions based on local customer requirements, operating conditions and business challenges. The company said the approach would strengthen its competitiveness while advancing its transition into a mobility company.

Takanori Azuma, currently associated with Toyota's accounting and regional operations, will head the newly created East Asia & Oceania Region as CEO. The new regional structure will allow both entities to focus more closely on their respective markets and manufacturing and sales operations.

Robotics Emerges As A New Business Priority

Among the significant organisational changes is the establishment of Toyota Robotics as a company-wide organisation under direct corporate oversight. The initiative builds on Toyota's manufacturing and engineering capabilities and positions robotics as a key pillar of its future business.

Takefumi Shiga, Operating Officer and Chief Production Officer, will also head the new organisation. Toyota plans to consolidate robotics-related expertise, personnel and functions across the company to accelerate the practical application, commercialisation and deployment of robots in manufacturing and other areas.

The company said its approach would focus on developing robots as partners that complement human capabilities rather than replace jobs.

Furthermore, Toyota will also establish a Toyota Philosophy and Education Group, headed by Chairman Akio Toyoda. The new group will focus on developing future leaders and passing on Toyota's manufacturing philosophy, technical skills and organisational values through practical, hands-on learning.

In another structural change, the Carbon Neutral Engineering Development Center will be dissolved, with its functions integrated into the Powertrain Company. The consolidation is intended to strengthen the connection between technology development and product implementation, particularly in hybrid systems, while supporting Toyota's carbon neutrality ambitions.

The Frontier Research Center will also be abolished, with its functions transferred to the Advanced R&D and Engineering Company and Software Development Center to bring future technology research closer to product development and commercialisation.

Toyota will additionally reorganise its External & Public Affairs Group by integrating selected public relations and investor relations functions to strengthen corporate communications and technology messaging across Toyota, Lexus and GAZOO Racing.

Leadership Changes Across Global Markets

The restructuring also involves changes to Toyota's regional leadership. Mark Templin will become CEO of the North America Region, Sukenaga Ota will head the China Region, while Masando Hashimoto will take charge of the Asia Region. Motonobu Kawamura has been appointed President of Business Planning & Operation.

Several existing regional leaders, including Tetsuo Ogawa, Tatsuro Ueda and Masahiko Maeda, will move into Senior Fellow positions.

The changes underline Toyota's wider organisational shift towards decentralised regional management, closer integration of engineering and business development, and greater emphasis on people and technology as it pursues its transformation into a mobility company.

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Axis Bank has unveiled a suite of festive offers spanning retail lending, business banking and credit card services. The initiatives encompass home, personal, auto, two-wheeler, commercial vehicle, construction equipment and education loans, alongside working capital solutions and merchant discounts.

Auto loan provisions include 30-minute instant disbursement, a 50 percent reduction in processing fees, a 10 basis points interest rate discount on select electric vehicle models, financing of up to 100 percent of on-road prices, loan tenures of up to eight years and a waiver of foreclosure charges after 24 months.

Two-wheeler financing includes rates starting from 10.75 percent for premium motorcycles and a 0.5 percent rate discount for electric models. Commercial vehicle and construction equipment loans carry a standardised processing fee of INR 5,999.

Munish Sharda, Executive Director, Axis Bank, said, "Festive spending is increasingly shaped by considered choices, whether it is buying a home, upgrading a vehicle, meeting personal needs or investing in a business. At Axis Bank, our focus is to give customers flexibility and value to act on these plans with confidence. Our festive propositions bring together competitive financing solutions across retail and business banking, helping customers make the most of opportunities that matter to them."

Arnika Dixit, Group Head of Cards, Payments and Wealth Management, Axis Bank, said, "Customers increasingly look for their cards to deliver value that is relevant to how and where they spend. During the festive period, as spending extends across different needs and occasions, relevance, choice and flexibility become even more important. Our focus is to make festive and planned purchases more rewarding, while continuing to strengthen our cards proposition around evolving customer needs. Through our wide range of festive offers, we are enabling customers to get more from their Axis Bank Credit Cards and make their spends work harder for them."

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IndiaTech.org has released India’s first Ease of Vehicle Ownership Index (EVOI), in partnership with Consumer VOICE, with Andhra Pradesh topping the rankings at 5.91 out of 10. Kerala ranked second at 5.74, while Uttar Pradesh finished last at 2.47, behind Bihar (2.51) and West Bengal (2.56). No state crossed 6.0, and 8 of the 15 assessed states clustered between 3.8 and 4.3, pointing to system-wide friction rather than isolated laggards. Together these states represent over 85 percent of India's organised used-car market.

The index scores states on six pillars – policy and regulation, digital infrastructure, process efficiency, transparency and accountability, institutional ecosystem and dealer support and cost and affordability – using a weighted geometric mean so strength in one area cannot mask weakness in another. It draws on a survey of over 1,000 buyers and sellers, interviews with dealers and RTO agents and a review of motor vehicle rules. Andhra Pradesh excelled in policy and regulation (7.90) but scored lowest on dealer ecosystem (2.22); Kerala's strength was digital infrastructure (7.02), its weakness transparency (4.86).

Cost was the weakest pillar nationally, with 12 of 15 states below 3.5. Manual verification and informal payments push transfer costs to nearly 10 times the statutory fee – INR 13,000 to INR 14,000 above the VAHAN fee in Bihar, and INR 7,000 to INR 8,000 against an official INR 800 at Tamil Nadu's border RTOs. Transfers take 7 to 10 days in Andhra Pradesh but over 30 days in Uttar Pradesh, and 13 states still demand physical copies despite online filing. Road tax on an INR 600,000 petrol car ranges from 3 percent in Uttar Pradesh to 14 percent in Karnataka and Telangana. Only Andhra Pradesh and Telangana run working interstate refunds; a CAG audit in Karnataka found a mean processing time of 436 days.

The 2022 Deemed Ownership framework has yielded 2,032 registered dealers, 875 in Kerala, while Delhi, Karnataka and Telangana have none. The survey found 39 percent of transfers still pending after sale, only 9.6 percent completed within two weeks, 61.5 percent unaware of mandatory in-person RTO visits, 62.7 percent unable to state total costs, 28.1 percent of sellers receiving challans afterwards and 52.5 percent willing to handle transfers themselves if fully online.

Recommendations include statutory timelines under Section 50 of the Motor Vehicles Act and Rule 55 of the CMVR, acceptance of DigiLocker and mParivahan documents as primary evidence, real-time bank-VAHAN integration, nationwide Deemed Ownership enforcement, a ‘One Bharat, One Road Tax’ framework, dealer authority to clear challans without owner OTP and automatic own-damage insurance carryover. IndiaTech.org will share scorecards with states and convene a national workshop, as the pre-owned market is projected to grow from USD 36.4 billion in 2025 to USD 73.5 billion by 2030.

Harsh Malhotra, Minister of State, Ministry of Road Transport and Highways, who launched the report, said, “The used car market in India is very big, and many people buy their first car as a second­hand or used car. I remember my first car, which was also a pre-owned car. While there are hassles and challenges in the transfer of ownership, the integration of policies and their implementation across states is very important, as differences in state-level governance often lead to problems. The Central Government is working on policies in this regard, and we are also taking steps such as setting up automated testing stations, which provide considerable relief, promote ease of doing business and help eliminate corruption. There is always scope for improvement, and we will discuss the recommendations basis this report findings to further enable ease of mobility.”

Dhiraj Gyani, CEO, IndiaTech.org, said, “A vehicle may travel seamlessly across state boundaries, but the administrative processes governing its ownership often do not. As India's pre-owned vehicle market becomes an increasingly important part of our mobility and consumer economy, the systems governing ownership transfers must evolve in step with the market. The EVOI 2026 findings highlight significant variations in state-level processes, as well as considerable scope for improvement across the country. Our objective is to encourage greater harmonisation, digital integration and administrative efficiency, enabling citizens and businesses to experience seamless and predictable vehicle ownership transfers, irrespective of where they are located. We believe that a more integrated national framework, including progress towards the vision of ‘One Bharat, One Road Tax’, can play an important role in unlocking the sector's full potential.”

Mohit Gupta, COO & Co-Founder, Spinny, said, “Every Indian deserves the opportunity to own a quality car. A car is an aspiration, the promise of new beginnings, freedom and possibilities for individuals and families. Buying one should be an exciting milestone, not weighed down by paperwork and complex processes. As an industry, we have a responsibility to help consumers understand existing processes and work closely with policymakers to drive meaningful reforms – support state-wise implementation of ADRV, simplify hypothecation addition and removal and advance end-to-end digitisation of processes. The Ease of Vehicle Ownership Index (EVOI) is an important step towards bringing Central and State Governments and industry players together to address these challenges and make car ownership simpler and easier for people across India.”

Vikram Chopra, Builder Cars24, said, “A car may change hands, but ownership and liability do not always follow. At Cars24, we see this firsthand: sellers remain exposed to liabilities long after handing over their vehicles, while buyers wait to be recognised as legal owners despite completing the purchase. This is not just a procedural delay but a gap in consumer protection and accountability. The Ease of Vehicle Ownership Index brings these challenges to light, identifies systemic gaps and gives states a framework to drive reforms through competitive federalism. Ownership transfer must be an integral part of every car transaction, ensuring that ownership, responsibility and liability move together, giving both buyers and sellers complete peace of mind.”

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German tier 1 supplier Schaeffler has announced a performance improvement programme aimed at eliminating overcapacity, reducing organisational complexity and lowering personnel costs in response to challenging conditions in the European automotive sector.

The measures follow the completion of restructuring initiatives announced in November 2024 and the execution of 1,800 partial retirement agreements in October.

The plan involves a net reduction of 3,460 positions across Europe, with approximately 2,660 cuts located in Germany, representing 9 percent of its domestic core workforce by 2028.

Furthermore, 50 percent of the affected positions are in production, 30 percent in research and development and 20 percent in functional areas. The programme includes the closure of five European facilities, encompassing four German sites in Dortmund, Morbach, Berlin and Schwalbach, alongside a site in Herstal, Belgium.

Operations at additional locations in Germany, France and Slovakia will undergo structural adjustments. The restructuring is projected to generate annual earnings improvements of approximately EUR 300 million by 2030, against one-time expenses of around EUR 480 million, the majority of which will be recognised as restructuring provisions in 2026. The job cuts will be accompanied by a solidarity contribution involving a temporary compensation reduction across management levels.

Klaus Rosenfeld, CEO, Schaeffler, said, "With the performance improvement program announced today, we want to demonstrate that, despite the challenging operating environment, it is both possible and sensible to develop and manufacture in Germany and Europe in a way that is competitive and cost-efficient over the long term. This requires that we consolidate locations, bundle technological expertise in selected regional clusters, and optimize costs per employee. At the same time, we intend to further streamline the organization and reduce hierarchical levels. The most important element of the program – also in comparison to previous programs – is the solidarity contribution, which is intended to include, among other measures, a temporary compensation reduction across all hierarchical levels. Based on our strategic goal of becoming the leading Motion Technology Company, we view the Schaeffler Group’s broad cross-sector diversification as an important opportunity. We will do everything in our power to tap into new growth areas and, as far as possible, replace declining activities with new business "

Dr. Jochen Schröder, COO, Schaeffler, said, "In addition to our focus on further developing our core business, the Schaeffler Group has promising growth opportunities in future-oriented fields, particularly in the areas of humanoid robotics and defense. Here, we can draw on the technological expertise we have developed in our core business."

Dr. Astrid Fontaine, CHRO, Schaeffler, said, "As a family-owned company, it is particularly important to us that we implement the necessary measures in a socially responsible manner and in close dialogue with employee representatives. We have repeatedly found good solutions together in the past, and we want to build on that. We invite our employees to contribute constructively and actively support the necessary transformation."

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