HMI has 2 plants, established in 1998 and 2007. In the last 5 years both the plants have been augmented for capacity enhancement. This was possible as the assembly lines were initially designed for flexibility in augmentation, expanding to the needs of the following 15-20 years. That has always been the philosophy of Hyundai which is really paying off now; it becomes easier to execute improvements in all their projects.

Consider the body shop where components are accumulated to be worked upon. It is built on global bodyline concepts. Not only volume escalation but also increase in the number of models can be managed effectively. Every day the plant processes 395 tonne of steel coils, globally monitored by ‘Die Management’ system, to make cars with each one having on an average 4,500 spot weldings done by 4^th gen robots. So far the company has manufactured more than 9 million cars using steel coils having a length that could cover the circumference of the earth 4 times. The intelligent weld management system generates about 30.6 million data points per day and the quality is controlled through real-time monitoring. Beginning with making one car every 4 minutes in 1998, the plant currently rolls out a car every 33 seconds.

Ganesh Mani S, Director, Manufacturing, HMI, told Motoring Trends that “we have 12 models now with 350 internal variants. The complexities in these are double challenges for us especially when we take to the next level. We were able to manoeuvre 3 or 4 models 3-4 years ago from a single line. Now it is 7 models. Volumes have also increased from 49 to 66 UPH (unit per hour). We have a two-pronged strategy; one is adding on volumes that can cater to the needs of consumers and, two, the capability for enhancement. Since we have our own Factory Automation companies in the automotive hub of South Korea, we have gone from Generation-1 to Generation-4 of robotics, which brings in a certain amount of flexibility and increase in the speed of execution. With CAFE and other norms, we need to make a model that is robust, which comes from the basic design and the way we build the product.”

Body shops are by and large 100 percent automated and therefore, the company was able to make them intelligent enough to understand, with the fourth generation robots. For every vehicle it is necessary to have resistant spot welding and for every spot there is a specification; this needs to be modified for each new model. The company has introduced intelligent timer controls, which is called MMDI - in the line before spot welding, it checks the number of components and their thickness and the level of current and voltage requirements.

Earlier they were pre-set, but now keep changing at every place. This gives twin advantages. The first is to have multiple components as technologies keep changing; aluminium may come in; high tensile steel welding has already come. At present the plant has about 400 robots with MMDI which have the capability to keep checking every time. Earlier it used to take 40 seconds to complete 30 spots; now within that TAKT time, it is able to make 50 spots increasing the speed of the line.

The second is having Intelligent Vision Control Systems. For instance, sealer has to be applied for vibration, harshness, noise, dust and rust prevention, strength, etc. The system monitors the route it has to follow and checks whether the job is being done properly or not. It ensures quality and traceability of the arrangement.

“Whenever we introduce a new model all we have to do is to make use of the carrier, a hardware that allows robots to move around and make the body parts. Only the carriers need to be replaced as the line operates depending on the types to be made. Earlier we had electric and pneumatic carriers to move across to lift the body and components while in the fourth generation robots at present the individual carrying capacity has been increased multiple times. The entire handling mechanism of conveyors, platforms, holding chains, etc has been replaced by just programming the robots which can handle them. All these save time and make the operation of the body shop more convenient,” he said.

A robot has shelf life of approximately 7 years; as and when replacements are due, new technologies are incorporated into the system. With so much innovation in robotics, the cost of robots is going down. Over the years the company has garnered expertise to the extent that a new robot can be commissioned in 48 hours, when it is needed to augment capacity. The industry average is 7 or 8 days. The supervisors and technicians can do the programming themselves, which also saves cost. Assembly shops have seven or eight major equipment and the company has been able to change or enhance the equipment that is augmented with VFD (variable frequency drive) as and when required. A fall back mechanism is in place to manage demand fluctuations. Robotic multi-skills and flexibility switchover help the line to go on smoothly. When not required some of the robots can be kept in sleep mode to save energy. Like managing absenteeism of people with multi-skills some of the robots can double up while the others can rest. 

On the scope for improvement in enhancing UPH, Ganesh Mani said, “We can manage with this arrangement till 2021. We change regularly our upgradation on various models and try to eliminate defects at the design stage itself. We have a team working on every model and the results are ploughed back at the design stage to remove deficiencies. Also, there is the influx of technology in terms of inspection and robustness of the process. ‘Before’ and ‘After’ is 100 percent mapped for the sealers so there is no question of missing and moving across to the next stage.”

In the body shop the operator has all the available information in front of him. In the assembly shop everything is mapped digitally. The operator looks at a digital display to know which component he has to pick up; he also gets an audio message regarding assembly of parts for rare models. The company has created a Smart Innovation and Automation Team (SIAT) which is one step ahead in process monitoring to ensure that errors do not creep into the system; it makes certain that the operator does not commit a mistake. For instance the lid of containers holding the parts for the specific models will only open when required and at the right station.

Asked what happens if the operator has not taken the required number of parts like fasteners, he said, “We have more than 700 dynamic bolts and nuts that are fitted on the vehicle; any mistake in fitment would create havoc. We have HIVIS (Hyundai Integrated Vehicle Inspection System) which is a tool by itself. The torque values while tightening every nut are registered in the system. Any mistake made triggers an alarm and the vehicle will not be allowed to go to the next stage. The tightening process is monitored in real-time and is coupled with sign-off gate. When there is a process deviation, the system will not allow the car to roll out of the assembly line, thereby ensuring mistake-proof delivery. The system, developed at HMIL, is so intelligent that it is used all over the world. For example, when new trainees come, sometimes cross-threads happen; the torque goes very high and the value is reflected in the torque curve. This helps us take immediate corrective action. One of our engineers developed a ‘gyro metric gun’ that works on the straightness principle. It has a sensor inside, working on the principle of gravitational force; if there is any deviation of line it will not allow the operator to tighten the nut. This is a unique system, being used in all the 32 plants of Hyundai globally.”

How can variability happen? It can happen because of improper training; the company has taken care of this. The other variability is fatigue that could set in and result in the operator making a mistake. To prevent this there is REBA - Rapid Entire Body-movement Analysis - that can calculate the fatigue level in the individual. This information would help improve his comfort level. Meticulous planning has been done for all the stations, upgrading them from category A (with possibility of over 12 risk occurrences) to category D (less than 4), to bring down the risk level. On this platform there are many assist systems for the operator. The company is working on EXO skeleton which is a human-machine interface where a vest is provided to the operator giving him, among other things, elbow support. This makes the process easier and lighter; consistency always gets measured.

Ganesh Mani explained, “We also have vision camera system robotics that can capture 70 frames per minute. It compares the pictures with the original and if there is an error sends the message within a TAKT time of 40 seconds. This is our third layer of inspection. By and large our pass ratio is 100 percent; it is only a fall-back mechanism.”

Though the number of models assembled in one line has substantially increased, the company hopes that it can increase further. In assembly, there can be a high of as many as 240 different models, the maximum in a single line, he pointed out.

However, when the UPH in the body shop is increased it has to match the TAKT time of the assembly line as well. “In a lean production system we don’t want too much of a cushion in the other shops as that would prevent hidden problems from coming out. So we don’t go beyond one additional UPH in the previous shop; in between we have some amount of stock for body storage. Within that we manage our line. Every hour the body shop can create 1 more additional body in the same time required for assembly. In this way we can manage any breakdown or process delay up to 1 UPH. On a cumulative of 22 hours that we run, everyday a cushion of 22 bodies will be available to help us manage any kind of change,” he said.

Industry 4.0

About the possibilities of a smart factory Ganesh Mani said, “As part of our agile manufacturing process in our technologically advanced and digitalised factory we wanted to use Industry 4.0 in a big way. Our initiatives for this have started. We have found out that earlier in a body shop alone close to 1GB of data was generated; today it is 15GB a year from all the modules put together. The next stage is to integrate the data seamlessly and put them on display so that the operator who is multi-tasking can see them easily and monitor them thoroughly. This also helps in predictive maintenance which is the objective of big data. We use this in a 6-8 hour slot on Sundays when the assembly line does not work. Any change can be made then. This phase pre-empts impending failures; we use infrared mechanisms to do this. We also have vibration sensors fitted in the equipment that constantly monitor and give an alarm if something is likely to happen like heating up of the motors. We have a Data Analytics Team that looks into all these and takes preventive action. Today, more than 50 data scientists are working on the shop floor. By 2021 we want to integrate all the shops through this process so that we can predict what could happen. An example of how digitalisation in Industry 4.0 is helping us is in the breaking of equipment; whenever the vacuum levels start going up, the machine stops. To avoid this, by digitalisation we can constantly monitor the control limits to ensure that the equipment works in the programmed range. If it goes beyond the safe level, the system sends an SMS to the maintenance team. This helps the operator to plan and change the machine to a new area.”

Energy Conservation

HMI has completely switched over to LEDs, saving about 40 percent energy required for lighting. “Within 18 months we were able to get back the cost of the whole system. We always ensure that energy efficient motors are used. We are also very careful in using water, especially in places like Chennai where water is scarce. We are into hundred percent rain water harvesting. One mm of rain means a saving of 750 kl of water throughout the plant. We can manage 150 days of production without water from other sources; we are planning for complete independence,” he said. (MT)

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Honda Cars India, one of the leading passenger vehicle manufacturers, has unveiled the updated Elevate SUV, featuring styling updates, interior additions and expanded safety technology.

Interestingly, India is the first market to launch the updated vehicle globally, representing the third of six product launches planned by the manufacturer for the current financial year.

The Elevate SUV gets a redesigned mesh grille with gloss black upper moulding, revised position light elements, gloss black trim on the lower bumper and side garnishes and a full-width connected tail lamp setup.

It features 17-inch dual-tone alloy wheels and retains its vehicle dimensions, measuring 4,312 mm in length, 1,790 mm in width and 1,650 mm in height, with 220 mm of ground clearance and a 2,650 mm wheelbase. A new exterior paint finish, Nordic Forest Pearl, has been added to the palette.

The Elevate continues to be powered by a 1.5-litre i-VTEC petrol engine generating 89 kW (121 PS) and 145 Nm of torque, paired with either a six-speed manual transmission or a continuous variable transmission. Fuel economy is rated at 15.31 kmpl for the manual version and 16.61 kmpl for the automatic. The model is offered across five trim levels – SV, V, VX, ZX and ZX+ – with ex-showroom Delhi prices ranging from INR 1.18 million for the base manual variant to INR 1.84 million for the top-spec automatic.

On the inside, the SUV features a dual-tone ivory and black cabin layout, orange ambient lighting, ventilated front and rear seats, power-adjustable front seats and an electric sunroof.

Technology updates include a 360-degree camera system, front parking sensors, a 10.25-inch touchscreen infotainment display, a 7-inch digital instrument cluster, an air quality indicator and wireless smartphone integration. The safety suite adds low-speed follow functionality to its camera-based advanced driver-assistance system (ADAS) on automatic variants, alongside standard features such as six airbags, vehicle stability assist and electric parking brake.

Toshiyuki Yanagisawa, President & CEO, Honda Cars India, said, "The Honda Elevate has established a strong connection with customers through its confident design, versatility and enjoyable driving experience. With the New Elevate, we are taking this character forward with a much bolder expression and significant enhancements across design, comfort, technology and convenience. Being the lead market for its sales, India is the first country to launch the New Elevate globally. Its bolder, more rugged styling and enhanced premium features are designed to meet the evolving aspirations of today’s SUV buyers. This is the third of our six key launches planned for this financial year. We expect the New Elevate to play a key role in driving our momentum during the ongoing festive season and strengthening our product portfolio offering customers more exciting choices."

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Czech automaker Skoda Auto India has announced pricing for the updated Slavia sedan, starting at INR 999,900 (ex-showroom) for the base Classic manual variant to INR 1.88 million for the top-spec Monte Carlo 1.5 TSI automatic model.

The Slavia is built on the MQB-A0-IN platform and is available across six trim levels: Classic, Classic+, Signature, Sportline, Prestige and Monte Carlo. The deliveries are set to commence next week, with an additional Cappuccino Beige colour variant scheduled for release in December 2026.

The sedan retains its existing petrol powertrain options, offering a 1.0-litre TSI engine paired with either a six-speed manual gearbox or an eight-speed torque converter automatic transmission. On the other hand, the 1.5-litre TSI engine variant is mated to a seven-speed dual-clutch automatic transmission and includes rear disc brakes.

Exterior updates include redesigned light units, revised front and rear sections, sequential rear indicators, and new alloy wheel options.

On the inside, the Slavia gets a rear-seat massage function on higher trim levels, alongside a 360-degree camera system, front and rear parking sensors and a digital instrument cluster measuring up to 26.03 centimetres.

The 25.6-centimetre infotainment system incorporates a voice assistant powered by Google Cloud's Automotive AI Agent, supporting wireless smartphone integration. Safety equipment includes six airbags and standard electronic assistance systems across the range, maintaining its 5-star rating from Global NCAP testing.

Ashish Gupta, Brand Director, Skoda Auto India, said, “The Slavia has become an important part of Skoda Auto India’s sedan legacy, bringing together the design, driving experience, safety and engineering that customers associate with our brand. The new Slavia builds on that strong foundation with a more striking presence, greater comfort, smarter technology and an all-new eight-speed automatic. That is the essence of Says it All: a sedan that does not ask customers to choose between aspiration and practicality, performance and comfort, or technology and peace of mind. It brings these strengths together in one confident, complete package, making the sedan experience even more relevant and desirable for a new generation of customers.”

The vehicle comes with a four-year or 100,000-kilometre warranty, four years of roadside assistance and four routine labour-free services. Warranty coverage can be extended up to six years.

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German luxury car brand Mercedes-Benz India has launched the Mercedes-Maybach S 580e 4MATIC, introducing a plug-in hybrid powertrain to its Maybach range in India at INR 33.5 million. The company has introduced the Maybach S 580e with an initial allocation limited to 30 units. 

It combines a 3.0-litre petrol engine delivering 443 hp and 560 Nm of torque with an electric motor producing 160 hp and 480 Nm. Together, the system generates a total output of 585 hp and 750 Nm of torque via a nine-speed transmission and all-wheel drive.

Powered by a 22 kWh usable battery, the saloon provides a WLTP-certified electric range of up to 98 km and reaches 100 kmph in 4.8 seconds, with a top speed limited to 250 kmph. Charging options include up to 11 kW AC and up to 60 kW DC fast charging.  

The interior features a four-seat layout with individual rear seats and a central console. Equipment includes air suspension using navigation data, rear-axle steering up to 10 degrees, 15 airbags, and a 31-speaker sound system. Digital interfaces operate on the Mercedes-Benz Operating System, incorporating a front-passenger display screen and driving assistance functions.

Santosh Iyer, MD & CEO, Mercedes-Benz India, said, "The Mercedes-Maybach S 580e perfectly reflects our strategy of offering the most desirable luxury portfolio, while offering customers the freedom to choose the technology that best suits their lifestyle. We are seeing rising demand for Plug-In-Hybrid among our top-end customers, and the Maybach S 580e combines the timeless exclusivity, handcrafted luxury and iconic luxury of a Maybach with the convenience of a plug-in hybrid technology. With ICE, BEV and PHEV models in our portfolio, Mercedes-Benz is uniquely positioned to offer diverse luxury mobility solution, ensuring performance, sustainability and luxury."

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Swedish luxury carmaker Volvo Auto India has appointed Karan Arora as Director of Marketing and PR. He joins the luxury automaker with over 15 years of leadership experience across the luxury automotive and luxury real estate sectors.

Arora previously worked in the luxury automotive industry, spending over six years at Audi India as Head of Marketing Communications and Experiential, where he managed product launches, events and customer engagement initiatives. He also held the role of Regional Business Manager for North India at Jaguar Land Rover.

In addition to his automotive background, Arora has led marketing teams in the real estate and home solutions sectors. His previous roles include managing premium and luxury residential marketing portfolios at Godrej Properties, Central Park and Smartworld Developers, as well as overseeing marketing for GROHE and American Standard at LIXIL India. Most recently, he served as Vice-President of Marketing at Krisumi Corporation.

Arora holds a Master of Business Administration from the International Management Institute, New Delhi and a Bachelor of Technology from Panjab University.

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