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)

BYD India launched its much-anticipated BYD SEALION 7 Pure Performance eSUV at the Bharat Mobility Global Expo 2025. The fully electric SUV is now open for bookings under a special Promotional Booking Offer valid until 17 February 2025. Alongside the SEALION 7, BYD India showcased the BYD SEALION 6, BYD Super Plug-in Hybrid EV and the groundbreaking Yangwang U8 luxury electric SUV. 

Marking 17 years of successful operations in India, the SEALION 7 embodies ocean-inspired aesthetics and advanced innovation. This globally acclaimed vehicle is built on BYD’s cutting-edge technology, including Intelligence Torque Adaption Control (iTAC) and CTB (Cell to Body) technology. The SEALION 7 features an 82.56 kWh Blade Battery integrated into the chassis for enhanced safety, performance and interior space. 

Available in Premium and Performance variants, the eSUV delivers impressive acceleration, reaching 100 km/h in 4.5 seconds in the Performance trim and 6.7 seconds in the Premium variant. The Performance model offers 542 km range and generates 390 kW of power with 690 Nm of torque, while the Premium provides 567 km range, 230 kW power and 380 Nm torque. 

Designed by BYD’s Global Design Director, Wolfgang Egger, the SEALION 7 boasts aerodynamic styling with a distinctive ‘OCEAN X’ front design. Interior features include a 15.6-inch rotating touchscreen, quilted Nappa leather seats, 128-colour ambient lighting, a panoramic sunroof, and advanced noise insulation. It also offers 12 Dynaudio speakers, ventilated and heated seats, a 50 W wireless phone charger and a VTOL (Vehicle to Load) system, allowing the vehicle to function as a portable power station. 

Under the Promotional Booking Offer, customers can reserve the SEALION 7 for INR 70,000, matched by a INR 70,000 contribution from BYD India. Early bookings include benefits such as a complimentary 7 kW home charger with free installation, an additional 7-year/150,000 km warranty on the low-voltage battery, and early deliveries for the first 70 customers. 

The BYD SEALION 6, powered by BYD’s DM-i (Dual Mode Intelligence) hybrid platform, combines electric and petrol propulsion for seamless performance and outstanding fuel efficiency. The platform enhances driving dynamics and eco-friendliness, advancing BYD's vision of sustainable mobility. 

Also showcased was the Yangwang U8 luxury electric SUV, featuring BYD’s e4 platform for Independent Torque Control and real-time wheel torque regulation. The U8 boasts unique capabilities such as all-terrain tank turns and the ability to float and steer in water for up to 30 minutes, making it a one-of-a-kind passenger vehicle. 

BYD India also presented its existing portfolio, including the BYD ATTO 3 eSUV, eMAX7 eMPV and the award-winning BYD SEAL electric sedan, alongside models from BYD’s global portfolio. With plans to expand its dealership network to 40 locations by January 2025, BYD India is poised to lead the transition to sustainable mobility.

Commiting on the occassion, Head of Electric Passenger Vehicles (EPV) Business at BYD India Rajeev Chauhan said, "The Bharat Mobility Global Expo 2025 is a milestone event for BYD, as we proudly launch the SEALION 7, a model that epitomises our vision for innovative and sustainable luxury mobility at the congregation. We are also showcasing the BYD SEALION 6, BYD Super Plug-in Hybrid EV with DM-i technology and the luxurious Yangwang U8. Our lineup represents a breakthrough in automotive technology, setting new standards for what consumers can expect from electric vehicles. We are excited to lead the charge in transforming the industry with products that not only inspire but also contribute meaningfully to a greener future. In line with this, we are set to expand our dealership network to 40 within January and grow our network even further through 2025."

Vietnamese automaker VinFast has officially announced its entry into the Indian market with the launch of its first electric vehicles at the Bharat Mobility Global Expo 2025. The company unveiled two all-electric premium SUVs, the VF 7 and VF 6, underscoring its commitment to delivering high-quality, smart and modern products to Indian consumers.

The VF 7 and VF 6 have been strategically chosen as the first models to debut in India, which will also be the first market to receive right-hand drive versions of these vehicles. The VF 7, a premium SUV, offers an exhilarating driving experience, embodying VinFast’s 'Asymmetric Aerospace' design philosophy. The vehicle features a bold and robust exterior coupled with a driver-focused interior that integrates intelligent technologies, creating a spacious, enjoyable and futuristic driving experience.

Meanwhile, the VF 6, another premium SUV, exemplifies exceptional performance inspired by the 'Duality in Nature' design philosophy. This concept balances contrasting elements, producing a vehicle that is both dynamic and sophisticated, seamlessly blending advanced technology with human-centric design.

VinFast also showcased an impressive portfolio of vehicles at the expo including the VF 3, VF e34, VF 8 and VF 9 SUVs, electric scooters such as the Evo 200, Klara, Feliz, Vento and Theon, the DrgnFly electric bike and the VF Wild pickup truck concept.

The unveiling of these India-focused models reaffirms VinFast’s dedication to the Indian market. Last year, the company began construction of an electric vehicle manufacturing plant in Thoothukudi, Tamil Nadu. This facility is aimed at bolstering global manufacturing capabilities, meeting growing demand, and accelerating the adoption of sustainable mobility solutions in India and beyond.

Commenting on the launch Vinfast Asia Chief Executive Officer Pham Sanh Chau said, "Our presence at the Bharat Mobility Show 2025 represents a significant milestone as we showcase our India- bound products here for the first time. We believe our premium SUVs VF 7 and VF 6 are the game changers that will accelerate of the adoption of EVs in India. We are thrilled to exhibit our broader portfolio of electric mobility solutions at the Expo. Our presence here not only underlines our commitment to the Indian market but also showcases our vision for sustainable mobility solutions and advanced technology."

Deputy Chief Executive Officer of Sales and Marketing at VinFast India Ashwin Ashok Patil shared, “Our India centric premium SUVs VF 7 and VF 6 are expected to go for sales from early second half of CY 2025. VinFast is appointing dealers across all major towns in India with omni channel presence.”

Skoda Auto India is making waves at the Bharat Mobility Global Expo 2025 in New Delhi, held from January 17 to 22. With an impressive showcase of eight models, Skoda’s pavilion in Hall 3-01 at Bharat Mandapam exemplifies its century-old global legacy of innovation, performance and its steadfast commitment to sustainable mobility.

The Skoda Kylaq, the brand’s first-ever sub-4-metre SUV designed specifically for India, is a highlight of the expo. The Kylaq in Olive Gold seamlessly combines contemporary design with cutting-edge engineering. Powered by a reliable 1.0 TSI engine with options for a six-speed manual or automatic transmission, it is available in four variants and seven colours. Its robust safety features, earning it a 5-star Bharat NCAP rating, underscore Skoda’s emphasis on passenger protection.

Skoda’s all-new Kodiaq stands as a testament to luxury and versatility. This seven-seater 4x4 SUV combines spacious interiors with refined driving dynamics and off-road capabilities, making it an ideal choice for those seeking comfort and adventure in one package. Equally impressive is the fourth-generation Skoda Superb, a sedan that redefines elegance and sophistication. With its premium features and spacious interiors, the Superb continues to set benchmarks in the executive sedan category.

The facelifted Skoda Octavia vRS, a performance icon, returns to the spotlight with its thrilling agility and dynamic driving experience. Renowned for its speed and precision, it remains a favourite among enthusiasts. Adding to Skoda’s innovative line-up is the Elroq, an entry-level global EV that balances sleek design, practicality and environmental consciousness, positioning itself as a promising addition to Europe’s EV market.

Skoda’s Vision 7S, a futuristic concept car, offers a glimpse into the future of mobility. This vehicle embodies Skoda’s Modern Solid design language and showcases sustainability and advanced technology. It represents the brand’s commitment to driving electric mobility forward with intuitive and eco-friendly innovations.

The Skoda pavilion at the expo is designed to engage visitors through four unique zones. The Safety Zone highlights Skoda’s dedication to passenger protection, a core pillar of its engineering philosophy. The Power Zone celebrates the brand’s racing heritage with simulators and soundscapes, while the Sustainability Zone underscores Skoda’s eco-friendly initiatives and evolving product line-up. Finally, the Luxury Zone showcases Skoda’s craftsmanship, offering a blend of style and superior comfort.

An accessorised version of the Kylaq is also on display, featuring over 30 bespoke additions. From UV-protect sun blinds to premium 7D spill-proof mats, this version sets a new standard for personalisation, catering to the unique preferences of Indian consumers.

As Skoda Auto celebrates 130 years globally and 25 years in India, the brand reinforces its dedication to combining European engineering excellence with the evolving needs of the Indian market. By integrating innovation and sustainability, Škoda continues to pave the way for a greener and more dynamic future in mobility.

Speaking on the company’s participation, Brand Director Petr Janeba said, “The Bharat Mobility Global Expo 2025 is a remarkable opportunity for us to demonstrate our evolving global and Indian portfolio of ICE and EV vehicles. India is the second leg we stand on globally outside Europe and is a key market for us. From the all-new Kylaq to our insight into the future with the Vision 7S, all our models showcased at Bharat Mobility Expo focus on delivering innovation along with European design and performance for the ever-important Indian market. The technology and design from these products are going to be the key to our further expansion in India and our endeavour to attract newer customers in the Škoda Auto India family.”

Mercedes-Benz unveiled its Concept CLA Class, a new electric iteration of the CLA, alongside the latest Gelandwagen and a Mercedes-Maybach ultra-luxury SUV at the Bharat Mobility Expo 2025. Positioned as the electric successor to the CLA, the Concept CLA Class is the first model to feature the Mercedes-Benz Modular Architecture (MMA). It debuts the brand’s latest operating system, alongside fresh design and technological updates.

The Concept CLA Class previews the latest electric-drive technology from Mercedes-Benz, drawn directly from the Vision EQXX concept. With a claimed range exceeding 750 km and an energy consumption of 12 kWh/100 km, it has been dubbed the "one-litre car for the electric age" in reference to hyper-efficient internal combustion vehicles. The 800V electric architecture supports 250 kW DC fast charging, enabling the vehicle to recharge up to 400 km in just 15 minutes. Two battery variants are available: silicon-oxide anode for higher-spec models and lithium-iron phosphate for entry-level variants. Powering the vehicle is a 235 bhp permanently excited synchronous motor coupled with a 2-speed transmission. Weighing only 110 kg, the powertrain delivers an impressive 93% energy efficiency during long-distance driving.

Built on the MMA platform, the Concept CLA Class is designed primarily for electric drivetrains but also accommodates combustion engines. The vehicle is rear-wheel-drive by default, though the modular platform can be configured for all-wheel-drive. The concept also includes bi-directional charging, enabling vehicle-to-home (V2H), vehicle-to-grid (V2G), and vehicle-to-appliance (V2A) functions, underscoring its potential for smart energy integration.

Inside, the MBUX Superscreen delivers a full-width digital dashboard powered by the new MB.OS operating system. It integrates Google Maps and other embedded apps for a seamless user experience. Notable interior features include digitally visualised AC vents with floating effects and physical control interfaces, dynamic ambient lighting in blue and violet, and sustainable nappa leather upholstery in silver and crystal white. The cabin is also designed with advanced Level 3 Lidar-based autonomous driving capabilities, with over-the-air updates enabling future upgrades to higher levels of autonomy.

A standout safety feature is the Child Presence Detection (CPD) system, which uses cameras and sensors to detect breathing patterns. If a child is left unattended, the system triggers air conditioning, sounds the horn, and issues alerts to mitigate risks in hot weather.

Mercedes-Benz plans to launch the Concept CLA Class in India in 2025. The production model will closely resemble the concept and will offer Indian buyers a preview of the future of luxury electric mobility. Pricing details are yet to be announced.