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)

Comments (0)

ADD COMMENT

Link Copied!

Hyundai Motor India (HMIL), one of the leading passenger vehicle manufacturers, has announced that bookings for the Hyundai Venue have exceeded 100,000 units. To mark this milestone, the company has introduced the HX8 Diesel Automatic (AT) variant, priced at INR 1.36 million.

The new variant is powered by a 1.5L CRDi diesel engine is paired with a 6-speed automatic transmission. This addition expands the Venue line-up, providing a diesel torque-on-demand option with an automatic gearbox for the compact SUV segment.

The HX8 variant includes several updates to the vehicle's interior, safety and mechanical systems. Notable mechanical additions include rear disc brakes and an electric parking brake with an auto-hold function.

The technical and convenience suite includes – paddle shifters, drive modes (Eco, Normal, Sport) and traction control modes (Sand, Mud, Snow). The cabin also gets front row ventilated seats, 4-way electric driver seat adjustment and ambient lighting. Over-the-Air (OTA) vehicle updates and Hyundai Bluelink connected car systems.

On the inside, it features a dual-tone leatherette seats featuring Venue branding.

The introduction of the diesel automatic transmission targets customers seeking fuel efficiency combined with the convenience of an automated gear shift. The Venue competes in the compact SUV category, supported by Hyundai’s existing sales and service network across India.

Tarun Garg, Managing Director & CEO, Hyundai Motor India, said, “We are delighted that the new Hyundai Venue has crossed 100,000 bookings, reaffirming the strong trust Indian customers place in our brand. This milestone reflects the growing aspiration for smart, connected and feature-rich mobility solutions that enhance everyday driving. The introduction of the new HX8 Diesel Automatic variant further strengthens the Venue lineup, offering customers the perfect blend of diesel efficiency, torque-rich performance and effortless convenience. It underscores our commitment to providing meaningful choices backed by advanced technology and superior value. At Hyundai, we remain focused on delivering future-ready products that resonate with evolving customer expectations and drive the next phase of mobility in India.”

Comments (0)

ADD COMMENT

Link Copied!

German luxury car brand Audi has commenced bookings for the new Audi SQ8 SUV, which is set to be launched on 17 March 2026 in India, for an initial amount of INR 500,000.

The SQ8 occupies a position within Audi’s Q range, featuring mechanical and performance upgrades over the standard Q8. It is powered by a 4.0-litre V8 TFSI engine, which produces 373 kW and 770 Nm of torque, enabling a claimed zero to 100 kmph in 4.1 seconds. The top speed is electronically limited to 250 kmph.

It features Quattro System – permanent all-wheel drive with a self-locking centre differential. Adaptive air suspension sport as standard and all-wheel steering to assist with low-speed manoeuvrability and high-speed stability.

Audi India has indicated that the SQ8 will be available in limited numbers. This launch follows the existing Q8 family line-up in the Indian market, targeting customers in the performance SUV segment.

Balbir Singh Dhillon, Brand Director, Audi India, said, “The Audi SQ8 represents the ideal meeting point between everyday luxury and uncompromising sporty performance. Its formidable engine and distinctive S character make it a remarkably complete SUV. The enthusiasm we have seen for our Audi Q8 family in India gives us great confidence that the new Audi SQ8 will resonate strongly with our customers who seek more than a conventional luxury SUV. We are delighted to open bookings and encourage performance enthusiasts to secure their Audi SQ8 early, as availability will be limited.”

Comments (0)

ADD COMMENT

Link Copied!

Skoda Auto India, one of the leading passenger vehicle manufacturers, has inaugurated its first dealership in Shillong, marking the brand's entry into the state of Meghalaya. The Sales, Service and Spares (3S) facility has been launched in partnership with SSB Automobiles (La i Jong Skoda) to expand the company's footprint in the North-East region.

The facility, located in Laitkor Rngi, includes a 3,000 sqft showroom with a four-car display and a 7,250 sqft service centre equipped with three bays. The site follows the ‘Modern Solid’ design philosophy used by the manufacturer globally.

The inauguration is part of a broader strategy that has seen Skoda’s network grow from 120 touchpoints in 2021 to more than 325 across 184 cities. The Shillong outlet will provide access to the manufacturer’s full portfolio, including the Kylaq, Kushaq, Slavia and Kodiaq models.

Ashish Gupta, Brand Director, Skoda Auto India, said, “With the inauguration of our first-ever Customer Touchpoint in Shillong, we are delighted to bring Skoda Auto closer to customers in Meghalaya. The North-East is an emerging and promising market for us, and expanding our network footprint here reflects our commitment to making the Skoda brand more accessible across India. Following our biggest-ever year in India in 2025, strengthening our network remains a key focus. This newly inaugurated facility will provide customers access to our full product portfolio, including the Kylaq, Kushaq, Slavia and Kodiaq, along with the premium ownership experience and service standards that define the brand.”

Rakesh Kumar Singh, Dealer Principal, SSB Automobiles, added, “We are proud to partner with Skoda Auto India and bring the brand’s product range and services to Meghalaya for the very first time, starting with our new facility in Shillong. This new 3S facility has been designed to deliver a premium and seamless customer experience, right from sales to service. We are confident that customers in the region will greatly value the combination of Skoda Auto’s product excellence and our customer-first approach.”

Comments (0)

ADD COMMENT

Link Copied!

German luxury carmaker Mercedes-Benz India has expanded the line-up for its upcoming CLA Battery Electric Vehicle (BEV) with the addition of the CLA 200 ‘Standard Range’ variant. The new model will sit alongside the previously announced CLA 250+ ‘Long Range’ in the Indian market.

The CLA 200 ‘Standard Range’ provides a claimed range of 542 km. It features ‘Progressive Line’ styling, which includes comfort seats, a multifunction sports leather steering wheel, and two interior trim options. Mercedes-Benz confirmed that equipment levels and technology will remain consistent across both the CLA 200 and CLA 250+ variants.

Bookings for both variants of the CLA BEV have opened today with a payment of INR 150,000. Customers who pre-book the vehicle will receive a complimentary wall box charger, including installation.

The company aims to begin deliveries of CLA 250+ by end-April and CLA 200 in June respectively.

While the technology suite is standard across the range, the variants cater to different customer preferences for range and design. The CLA 200 focuses on the 'Progressive Line' aesthetic, while the CLA 250+ serves as the higher-range option. The introduction of the 'Standard Range' follows customer feedback requesting a secondary battery option for the BEV model.

Comments (0)

ADD COMMENT

Link Copied!