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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French automotive major Renault India has further deepened its India commitment with strengthening of its design team in the country.

The company has roped in Jean-Philippe Salar as the new Design Director at Renault Design Centre India. He succeeds Julien Sabatier, who is set to take on the role of Head of Design Factory India and UI Management.

Sabatier led the Design Studio for the last three years and, on his part, was instrumental in setting up Renault’s Design Studio in India as part of the French automakers ‘renault. rethink’ strategy. He delivered over 10 projects for Renault for both India and Europe market and played a key role in the introduction of the new Duster SUV in India.

In his new role, he will focus on developing and industrialising future projects and implementing UI (User Interface) functions in India.

Salar is a Renault Group veteran having started his journey with the French automotive brand in 1996, and has extensive design experience across brands such as Renault, Dacia, LADA and Mobilize.

The design centre is part of the company’s ‘design in India’ and ‘make in India’ strategy. It functions as a hub of excellence, particularly due to its proximity to Renault Nissan Technology & Business Centre India (RNTBCI).

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China’s SAIC Motor-owned British marquee brand MG has unveiled its technology roadmap centred on its next-generation Plug-in Hybrid+ systems, SolidCore battery integration and advanced driver assistance systems (ADAS) at MG Tech Day at its UK headquarters in London.

The automaker unveiled its new Plug-in Hybrid+ system, which features 1.1-litre and 1.5-litre turbocharged petrol engines. The company states that it achieves thermal efficiencies exceeding 42 percent. The powertrain incorporates a hybrid transmission with two technologies: Power Split and Motor Decoupling. The latter isolates the generator during electric driving to improve energy efficiency.

The first model to feature this system will be the MG ZS Plug-in Hybrid+, scheduled for launch in 2027.

MG also confirmed the introduction of its SolidCore battery across future Plug-in Hybrid+ models. This semi-solid-state technology is designed to provide consistent power delivery and range stability across various temperatures and driving conditions. The battery will debut in three upcoming B, C and D-segment SUVs.

Furthermore, MG is refining its driving assistance technologies using data collected from over 1.2 million kilometres of driving across 24 European countries.

The One Touch iAD system for parking is production-ready, supporting scenarios such as kerbside parking, reverse paths of up to 100 metres and exit manoeuvres in tight spaces.

A highway assistance system capable of managing motorway entry, exit and lane changes is scheduled for a late 2027 debut in a new MG SUV. Urban NOA capabilities are planned for 2028.

Lastly, the company is conducting Level 4 Robotaxi trials across Europe, the Middle East and China to support long-term mobility research.

MG company stated that these developments reflect a focus on ‘making advanced technology more accessible, useful and relevant for everyday drivers.’

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Stellantis-owned Peugeot and the Strate School of Design have formed a partnership to focus on design and innovation within the automotive sector. Through this collaboration, students will work on projects related to mobility, user experience and technology under the guidance of Peugeot design experts and Strate faculty.

The initiative aims to provide Peugeot with access to student designers while offering students experience in the automotive industry. The projects are intended to act as a laboratory for mobility solutions.

Matthias Hossann, Design Director, Peugeot, said, "This partnership reflects our commitment to bringing academia and industry closer together, in order to foster innovative solutions to the challenges of sustainable mobility. It also enables us to engage with and support young design talents from the earliest stages of their educational journey."

Mike Levy, Head of the Transportation and Mobility Design Department, Strate School of Design, said, "This collaboration provides our students with an exceptional opportunity to confront the realities and ambitions of an industry undergoing profound transformation. By working alongside an internationally renowned automotive design team celebrated for its boldness, they gain first-hand experience of its methodologies, expertise, and high standards. In return, it offers PEUGEOT valuable insight into how this new generation of designers envisions its design practice, its perception of the brand, its relationship with mobility, and the future narratives that shape it."

The partnership is intended to combine academic and industrial perspectives to develop designers for future mobility and vehicle projects.

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BMW Group India has surged to the top of the luxury car retail charts in the first half of CY2026, overtaking its closest rival in a significant milestone for the company. The company sold a total of 9,075 vehicles  between January and June 2026, a 17 percent YoY increase.

In an interaction with Motoring Trends, Hardeep Brar, President & CEO, BMW Group India, attributed this success to a potent combination of new product launches and shifting consumer preferences towards electric vehicles amid global fuel price volatility.

“A couple of factors played very well for us. So firstly, we launched 11 new models and second thing, because of the West Asia crisis, an increase in fuel prices, a lot of narrative got shifted towards EVs; a lot of people are preferring to buy EVs versus diesel now,” said Brar.

The company’s aggressive product offensive has been central to its performance. With 11 models already launched in the H1 against the planned 25 product offensive for the year, BMW is capitalising on both traditional and emerging powertrains. Brar expressed strong confidence for the remainder of the year, noting an even more exciting pipeline ahead.

“So that gives us more confidence and EV story is only getting stronger with every passing day. I think we have reached an inflection point; people are really loving the EVs that we are introducing,” he remarked.

BMW’s EV penetration stands at an impressive 26 percent within the luxury segment, significantly ahead of the luxury average of around 14 percent and the broader industry’s 6 percent.

Brar highlighted that removing ‘BMW from the luxury equation drops the segment’s EV share to 8-9 percent, underscoring the brand’s leadership in electrification.’

Responding to the key factors driving EV adoption in the luxury space include near price parity between petrol and electric variants, ranges exceeding 500 km (with next-generation models targeting 800 km), and innovative customer assurances.

“EV customers have a lot of anxiety in terms of residual resale value. So, we have a program where we give an assured buyback to the customer that after three years you will get 60 percent of the value. And that is really playing and that is giving them confidence,” Brar explained.

MINI’s Remarkable Revival

On the other hand, the MINI brand has also delivered exceptional results. After selling approximately 730 units last year, BMW India launched the locally produced Countryman C last month at INR 4.75 million, passing on cost benefits to customers. The response was overwhelming, with 150 units sold in the first month alone.

“We are growing at almost 70 percent for MINI in H1 CY2026 and we want to double the volumes of 730 units last year and are looking at 1,500 units for MINI in CY2026,” Brar stated.

Localisation, Dealer Dynamics and Manufacturing Focus

On localisation, the company maintains an average of 50 percent, slightly higher for internal combustion engine (ICE) models than EVs, with ongoing efforts to deepen content in battery technology as more local players emerge.

Addressing dealer profitability concerns around EVs, which typically require less aftersales maintenance, Brar noted strong upfront margins due to high demand. “Dealer doesn’t lose any money on selling the new car. Whereas petrol and diesel have an oversupply and thus they are able to make far more money on the electric vehicle.”

He confirmed that discounting remains absent on EVs, with waiting periods stretching to three months owing to robust demand.

India’s rising importance in BMW’s global portfolio was a recurring theme. “India is one of the fastest-growing markets for BMW across the globe. This year, India is at No. 1 in terms of growth globally,” Brar said.

The company has moved into the global top 20 markets, prompting increased focus from headquarters.

Going forward, BMW Group India plans to produce 20,000 cars this year, up from 18,000 units last year, with ongoing investments in production lines and AI for efficiency. A significant INR 4 billion investment is earmarked for the retail network across CY2025–2027.

The second half of 2026, will see BMW Group India introduce 14 additional launches, including electric vehicles, sedans and SUVs, maintaining strong momentum.

Sharing his views on the sedan segment, Brar said that it continues to hold a robust 35 percent share of BMW’s sales, far above the industry’s 9-10 percent, reflecting enduring customer preference for the brand’s driving dynamics.

When asked about key challenges and opportunities, Brar outlined a balanced view.  “In terms of headwinds, forex is an issue because it is deteriorating. And with every one rupee deterioration, it impacts our bottom line by 1 percent.” He also flagged the risk of sudden shifts away from diesel potentially creating inventory challenges.

On the flip side, “The accelerating EV transition, rapidly growing demand from Tier-2 and Tier-3 cities, and continuous improvement in brand and customer experience becoming better with every passing day. So that I see as another very, very strong tailwind for us,” concluded Brar.

Despite broader manufacturing sector concerns around labour shortages, BMW reports no significant issues, thanks to proactive AI and automation initiatives.

Data source: Vahan

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