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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UTAC, a prominent player in the automotive testing, inspection and certification sector, is significantly broadening its footprint in China. The company has unveiled plans for a cutting-edge proving ground in Huainan, situated in the central province of Anhui. This ambitious project is being developed through a collaboration with the Huainan City Government and is set to become the primary strategic hub for the UTAC Group’s operations within the country. By establishing this facility, UTAC aims to bolster the mobility industry with top-tier testing capabilities and specialised knowledge.

The new site will enable UTAC’s team of specialists to offer homologation and testing services that align with the most current international benchmarks and regulatory standards. This initiative is a direct continuation of the group’s overarching goal to foster a mobility landscape that is both safer and more environmentally friendly. The Huainan facility is designed to be comprehensive, featuring a variety of specialised tracks for vehicle testing, along with a technology park that includes rentable workshops and office spaces. It will also house a dedicated conference and exhibition centre and purpose-built laboratories outfitted with state-of-the-art equipment. These labs will be specifically geared towards testing the latest advancements in new energy vehicles.

Anhui province itself provides a rich environment for such an investment. Home to 70 million people, it hosts a dense and extensive mobility ecosystem. Major automotive manufacturers like BYD, Changan, Chery, JAC, NIO and Volkswagen, together with their extensive supply networks, are deeply embedded in the region. The province’s manufacturing prowess is underscored by its production of roughly 3.7 million vehicles in 2023, a figure that positions Anhui as China’s leader in overall vehicle manufacturing, new-energy vehicle production and vehicle exports. Consequently, the new proving ground in Huainan is poised to become a vital strategic component for UTAC, solidifying its presence in this central hub of the Chinese mobility industry.

Connor McCormack, CEO, UTAC, said, " We are extremely proud of our partnership with the city of Huainan, which is undergoing a significant transformation to support the future of the automotive industry. UTAC is delighted to contribute to this transformation and to bring our 100 years of specialist expertise, along with the European standards we have helped shape and validate, to China’s vital automotive sector.”

Mayor Zhang Zhiqiang of Huainan City said, “This represents a significant milestone in Huainan's efforts to accelerate the development of its intelligent connected vehicle industry. It is of great importance in bridging the critical gap in the regional automotive sector’s industrial chain of ‘testing-production-export' and establishing a specialised vehicle testing and certification platform with international recognition. The successful cooperation on this project will undoubtedly advance the high-end and intelligent transformation of the regional automotive industry, providing strong impetus for Anhui Province's efforts to foster a new energy vehicle industrial cluster with international competitiveness.”

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Gulf Oil Lubricants India, a Hinduja Group company, has announced a four-year extension of its partnership with the Chennai Super Kings (CSK). Gulf will serve as the Official Lubricants Partner for the franchise, continuing an association that has spanned 13 seasons.

The renewal maintains one of the longest-running brand partnerships in the Indian Premier League (IPL). The collaboration focuses on consumer engagement through marketing campaigns and fan-focused initiatives.

The 13-season history between Gulf and CSK has been a central part of Gulf’s brand strategy in India. The company uses the platform to reach cricket fans through digital activations and on-ground experiences.

This follows the recent announcement of fellow Hinduja Group company, Ashok Leyland, joining CSK as an official sponsor.

Ravi Chawla, Managing Director & CEO, Gulf Oil Lubricants India, said,“Gulf’s 13-season journey with CSK reflects a relationship built on trust, shared passion, and mutual success. This partnership has consistently delivered far beyond the commercial contract, forging a deep emotional connection with the loyal CSK fan base and cricket enthusiasts across the nation. Continuing this association is a proud moment for Gulf as it reflects our global heritage of supporting performance sports and iconic teams that inspire millions of fans.”

KS Viswanathan, Managing Director, Chennai Super Kings, stated, "We are pleased to continue our long-standing association with Gulf, a partner that has been with us through many memorable seasons. Over the years, Gulf has consistently brought creativity and energy to the partnership while engaging with our fans. We look forward to strengthening this relationship over the next four years. We are really pleased about how it has come together"

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Volvo Car UK is marking a major milestone in automotive safety this year, celebrating seven decades of pioneering seatbelt innovation with a groundbreaking new system in the EX60 model. This latest development represents the world’s first multi-adaptive safety belt.

The brand’s legacy began in 1956, when the Volvo Amazon prototype was fitted with a two-point diagonal chest belt, making it one of the first European vehicles to offer such a feature. Just three years later, Volvo made history by becoming the first manufacturer to fit three-point seatbelts as standard. This design, created by engineer Nils Bohlin, combined a lap belt with a diagonal strap anchored at a low point beside the seat, establishing the template for the safety belts found in every modern vehicle.

Volvo’s commitment to saving lives was further demonstrated when it made the three-point belt patent available to all competitors free of charge. This altruistic move accelerated the widespread adoption of seatbelts globally and helped fast-track legislation making them a legal requirement, ultimately saving millions of lives. The engineering principles established 70 years ago continue to inform modern Volvos, with the new EX60’s multi-adaptive belt representing the latest evolution.

This advanced system leverages real-time data from interior and exterior sensors to tailor protection for each individual occupant. It considers factors like height, weight and seating position, adjusting its response based on the specific crash scenario. For instance, a larger occupant in a severe collision would receive a higher belt load to mitigate head injury risks, while a smaller person in a minor incident would experience a lower load to protect against rib fractures. Crucially, the system is designed to learn. Through over-the-air updates, the vehicle can continuously refine its understanding of occupant dynamics and crash responses, ensuring the technology improves throughout the car's life. This landmark achievement arrives as Volvo prepares to celebrate its centenary in 2027.

Nicole Melillo Shaw, Managing Director, Volvo Car UK, said, “Volvo has always been at the forefront of safety evolution and innovation, and we’re pleased that we can continue to make new developments on such vital features like the seatbelt. The latest multi-adaptive seatbelt in the new EX60 is a testament to our pioneering technology and approach to safety that is continued today.”

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Toyota Kirloskar Motor (TKM) has taken a significant step in its ongoing collaboration with the Government of Maharashtra by completing the upgrade of the Government ITI Deogiri in Chhatrapati Sambhajinagar. This development is part of a broader Memorandum of Understanding aimed at enhancing the state’s network of Industrial Training Institutes. The company has already facilitated the modernisation of 16 ITIs across the Marathwada and Nagpur divisions. The core objective of this partnership is to uplift rural youth by providing them with advanced technical training, thereby preparing them to become skilled technicians ready to support India’s expanding industrial sector.

A structured three-pillar strategy has been established to drive this transformation. The first pillar concentrates on educator development through specialised training programmes and workshops, including sessions held at Toyota’s facility in Bidadi. The second involves equipping the institutes with modern tools and learning materials, such as fundamental skill training kits and visual aids, to create an industry-relevant learning environment. The third pillar is dedicated to instilling a strong work culture by integrating practices that promote discipline, safety and environmental awareness. This holistic approach aims to cultivate graduates who not only possess technical expertise but also demonstrate integrity and a sense of social responsibility.

The rollout is planned in three distinct phases. Following the completion of the first phase covering 17 ITIs in the Marathwada and Nagpur regions, the subsequent phases will extend the initiative to the Amravati and Nashik divisions and finally to the Mumbai and Pune divisions by 2030. With the upgrade of ITI Deogiri, the institution now serves as a blueprint for this scalable skilling framework. Starting this academic year, it will begin offering training in both manufacturing and service domains to align with current industry demands. This long-term project, which ultimately aims to uplift 45 ITIs across the state, reinforces the national Skill India Mission by leveraging global manufacturing insights to address local skill development needs.

Mangal Prabhat Lodha, Minister of Skill, Employment, Entrepreneurship & Innovation, Government of Maharashtra, said, “Our youth are the foundation of Maharashtra’s future, and by nurturing their skills and aspirations, we are building a self-reliant society. This collaboration with TKM reflects our commitment to providing young people with industry-relevant training that enhances their confidence, employability and contribution to nation-building. Such initiatives ensure that our students are ready for the future to drive the country's growth story."

Vikram Gulati, Executive Vice President – Corporate Affairs and Governance, Toyota Kirloskar Motor, said, “At Toyota Kirloskar Motor, we firmly believe that the youth in rural India deserve the same opportunities as those in urban centres. Our vision is to empower them with world‑class technical capabilities so they can excel in their careers and contribute meaningfully to the nation’s progress. Guided by our philosophy of ‘Grow India, Grow with India’ and our mission of ‘Producing Happiness for All’, this initiative underscores our commitment to strengthening skilling at the grassroots level. As India moves towards the vision of Viksit Bharat 2047, we are dedicated to enabling equitable access to industry‑relevant skills that uplift communities and build a more resilient future.”

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