Hyundai's Manufacturing Excellence Eased Making All-new i20

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Ganesh Mani

Hyundai Motor India has showcased its Manufacturing Excellence through the origins of the all-new i20, a Masterpiece of Human Centric Engineering. With unassailable standards and processes, the company has created the all-new i20 that is perfected through a prudent use of Industry 4.0 and Automation.

Ganesh Mani S, Director – Production, Hyundai Motor India, said, “Our focus has remained on ensuring supreme levels of manufacturing excellence. This has perfectly culminated in the all-new i20, delivering robust and reliable performance. With our 24-year rich manufacturing heritage of ‘Make in India’, the all-new i20 is yet another benchmark brand from Hyundai that is an edge above the rest.”

THE ROBUST SUPERSTRUCTURE:   

  • Featuring an extensive application of 66 % Advanced & High-Strength Steel, Hyundai has created a Robust Superstructure to enhance crash worthiness and make the car lighter.
  • This super structure is created, using 5,400 Tons Stamping at the Press Shop
  • Incorporating an Online Condition Monitoring systems to monitor machine vibration, Hyundai offers enhanced process quality, changing shapes of metal in elegant curves & creases.  
  • The use of advanced Digital gauge to check the Panel thinning distribution - Crack, Neck Prediction methodology that helps in manufacturing ZERO Crack panels. 
  • Hyundai has used ‘High quality grade coils’ for sculpturing aesthetics and modern look of the all-new i20.
  • Use of 3D scanning of Parts – to analyse and strengthen the press panel parts accuracy and precision

THE IMPECCABLE APPEAL:

  • The all-new i20’s dynamic and futuristic appeal is created at the Body Shop on the Global Body Build Line.
  • Using technology enabled high-quality welding process that features over 450 4th Gen Robots offering 100 % Weld Automation with over 4,000 welding spots in each car, and more than 70 cars being processed every hour
  • Robots on the Line offer a glimpse of the flawless manufacturing process that gives a definitive shape to the origins of the all-new i20.
  • Body shop has three stage advance quality conformation where our quality system is enable with ‘Quality 4.0 techniques’
    • Intelligent weld monitoring
    • Real time weld quality confirmation system [Colour tip sensor]
    • Real time sealer quality confirmation system
  • In house Data scientists in shop floor apply Deep learning techniques for Quality confirmation of Mastic Sealer through Vision Inspection system

 

THE VIBRANT CHARISMA:

 

  • Vivid and striking colours of the all-new i20 are curated at the Paint Shop where High Throw Power 7th Generation Electro Deposition Paint is applied for long lasting Rust Warranty and corrosion resistance.
  • The vibrant charisma of the all-new i20 is processed in seamless automation line that features 72 Robots ensuring the conformity to supreme quality standards and long lasting stylish & glossy looks.  
  • Using an Anode Cell Current Monitoring system, Hyundai has enhanced the paint application quality through an Online Current monitoring method.

THE DYNAMIC PERFORMANCE:

  • Through immense research, hours of design, validation and testing of multiple iterations of operating condition, the all-new i20 has been prepared to offer rip-roaring performance.
  • To give these engines robust performance, Hyundai has employed technologically superior treatment that enhances its performance on road.
  • The in-house Endurance lab tests the performance with load condition for 849 Hours and without load condition for 5 lakhs cycles for transmission systems, and over 350 hours for the Engine system, to ensure enhanced durability
  • Hyundai also employs a Cold Test Bed that is an eco-friendly way of testing the engines over 15 parameters, without burning fuel. It is a fully automated system in which 100% of the produced engines are tested before assembling in vehicles.
  • At the Powertrain Shop, Hyundai manufactures both diesel & petrol engines using 700 CNC Machines with Integrated SPC (Statistical Process Control).
  • With High Speed Vision (60 frames/ minute) 58 Engine parts are verified, offering robust Quality for a Pleasurable Driving Experience.

THE PARADIGM OF QUALITY:

  • To drive enhanced convenience and confidence, Hyundai’s assembly lines are ready to convert robust shells into fully functioning cars in the Assembly Shop.
  • Here 80% of the car’s parts are fixed, preparing it through a 100% systemized 3 stage dynamic tightening confirmation that features:
    • Electric tool tightening 700+ dynamic joints per car (safety and critical parts)
    • Re-confirmation system across all the line (Trim, Chassis and Final line)
    • Tightening quality and Sign-off interlock to ensure zero defect vehicle rollout
  • Additionally, systemized part feeding method is used for maintaining quality in feeding and assembly operation using:
    • Global Part Traceability Information System
    • Advanced Part Management System
    • Mobility Sequence Feeding System
    • Trolley Scheduling System
  • Through a 324-point check in HIDIS (Hyundai Integrated Digital Inspection System), Hyundai is ensuring the highest levels of conformation to quality standards.   
  • Each and every vehicle that rolls of the assembly line - right from the stage of panel press to complete vehicle roll out is thoroughly inspected by over 500 quality in-charge experts.
  • Vehicle final inspection method is digitally enabled for assembled part specification/ type verification.
  • The all-new i20 then undergoes a dynamic road test on 18 drive tracks for various road driving conditions as well as a unique leak test that is equivalent to driving through rain/water pressure that exceeds the heaviest recorded monsoons, with a shower condition of 60mm per minute or 3,600mm per hour at a pressure of 3bar.

The all-new i20 has been developed to create a Masterpiece of Human Centric Engineering that encompasses Human, Machine and Emotions, offering Quality Time to its Valued Customers.

Disseqt AI Partners Tata Technologies And Infosys For Agentic AI Adoption

Disseqt AI

Agentic AI platform Disseqt AI has announced a partnership with Tata Technologies and Infosys. As per the agreement, Disseqt AI will assist both companies' IT and DevOps teams in developing and fast-tracking the production of tailored Agentic AI applications for automobile and FinTech companies globally.

The partnership aims to help auto and FinTech firms embrace customised Agentic AI faster and in a secure manner.

Disseqt AI, which has operations in Bengaluru, San Francisco and Dublin, provides an enterprise-grade platform for IT and DevOps teams. The company claims its platform cuts down Agentic AI testing and operations cost by 70 percent and improves productivity by up to 80 percent. The platform allows these teams to test, simulate and monitor their Agentic AI systems tailored across industries, ultimately enabling enterprises to operationalise tailored Agentic AI faster and at scale, without sacrificing ethics, governance and compliance.

Apoorva Kumar, Founder and CEO, Disseqt AI, said, “This is a landmark announcement for us as we further embed Disseqt into enterprise workflows for testing, simulation, monitoring and auditability purposes. We are already working closely with both Tata and Infosys on several projects and are proud to be part of their innovation initiatives”

Last month, Disseqt AI announced a strategic collaboration with HCLTech and Microsoft to guide financial services institutions with Agentic AI adoption.

Battery Passport Implementation Beyond EVs To Be Focus Of Barcelona Event

Battery and Energy Storage Europe

Battery and Energy Storage Europe has announced a programme focused on the EU Battery Passport, a regulatory milestone that becomes mandatory in February 2027. The Barcelona-based event will address the compliance gap for applications beyond the electric vehicle (EV) sector, which have dominated the conversation to date.

The event, taking place on 8th and 9th September 2026 at Fira de Barcelona's Gran Via venue, will focus on solutions and talks for applications that fall within the regulation's scope: stationary energy storage, industrial batteries, grid-scale systems, long-duration energy storage and emerging applications in aerospace, maritime and rail electrification.

With the February 2027 legal requirement date approaching, the programme will bring together industry leaders, technology providers, and policy experts to address the compliance challenges facing these diverse sectors.

The Battery Passport is a digital record documenting a battery's entire lifecycle, from raw material sourcing to production, performance and eventual recycling. From February 2027, it becomes mandatory for all rechargeable EV, industrial and LMT batteries over 2 kWh sold in the EU.

Linked via QR code, the passport will track each battery's complete lifecycle, including composition, carbon footprint and recycled content, fundamentally transforming supply chain transparency and sustainability practices across Europe.

The programme will explore implementation topics including digital infrastructure requirements, data management systems, supply chain integration, verification processes and recycling traceability.

Ken Davies, Conference Programme Director at Battery and Energy Storage Europe, said, "The Battery Passport represents one of the most significant regulatory shifts our industry has faced, yet many companies are still grappling with what implementation actually means for their operations. While the EV sector has dominated the conversation, there's a critical need to address how this regulation applies to stationary storage, industrial applications and the innovative battery technologies powering Europe's energy transition. With the clock ticking toward February 2027, Battery and Energy Storage Europe will shine a light on the practical implementation requirements for these often-overlooked sectors, connecting stakeholders with actionable solutions and bringing together the expertise, technology providers, and collaborative spirit needed to turn compliance into competitive advantage across the full spectrum of battery applications."

Scania Selects Horse Powertrain For Range-Extender Truck Pilot In Sweden

Scania - Horse - Pilot

Horse Powertrain has been selected by Scania to provide its range-extender system for a pilot vehicle, currently operating as a heavy-duty timber truck in Sweden. The collaboration is a step in testing hybrid powertrain solutions for demanding transport applications such as forestry logistics.

The pilot is part of the Scania Pilot Partner program and is currently operating in Sweden under SCA, one of Europe’s forestry companies.

The vehicle is built to handle Sweden’s timber routes, transporting heavy loads through remote terrain where access to charging infrastructure remains scarce. By combining a battery-electric drivetrain with the generator designed in Sweden by Horse Powertrain’s division Aurobay Technologies, the truck achieves both long-distance capability and reduced CO2 emissions.

The test route covers approximately 16 km, with an operational target of completing 7–8 rounds per day, comparable to a diesel truck.

The configuration supports the truck’s battery packs with a 120 kW range-extender unit based on Horse Powertrain’s 2.0 litre multi-fuel engine. Acting purely as an onboard charger, the unit supplies electric energy when required during long hauls, temperature extremes, or delays.

Matias Giannini, CEO, Horse Powertrain, said, "Forestry logistics represents one of the toughest challenges for electrification. The forest roads of northern Sweden demand strength, range and reliability. Charging stations are few, but the timber never waits. You can think of our range-extender as a powerbank for a heavy-duty truck: silent, efficient, and always there when you need it. By partnering with Scania and drawing on our engineering excellence, we’re proving how a compact, high-efficiency range-extender enables electric trucks to operate reliably in the most demanding environments. It’s a technology that cuts CO2 now.”

Tony Sandberg, Vice-President at Scania Pilot Partner, added, "What we’re doing in Sweden with Horse Powertrain and SCA builds directly on the 100-day trial we ran together with a logistics partner in Germany earlier this year. That vehicle logged almost 22,000 kilometres and drove more than 90 percent of the time on pure electric power, only using the range-extender when no charging was available. The result was a CO2 reduction of over 90 percent compared with a diesel truck. Those learnings give us a strong foundation as we tailor the system for demanding Nordic timber operations."

Ingo Scholten, Chief Technology Officer, Horse Powertrain and Managing Director Sweden, Aurobay Technologies division, said, “Electrifying heavy-duty routes means understanding what drivers and operators face hour by hour. Long stretches without charging, variable loads and rapidly changing weather. This pilot lets us study those realities directly in day-to-day timber operations. The range-extender’s role is simple. Provide a stable, efficient energy supply so drivers can complete their full shift without interruption and with far lower greenhouse-gas emissions than a traditional diesel truck. The data we gather here will guide how we refine the technology and scale it for wider use across demanding transport applications.”

Horse Powertrain’s modular range-extender architecture builds on the core technology used in its passenger-car and light-commercial hybrid systems, adapted for the higher power output and durability demands of heavy-duty applications. Unlike conventional fixed-speed generator sets, the engine can operate across its full power band, allowing the system to deliver the required output efficiently while keeping fuel consumption, noise and vibration low.

The pilot truck is now undergoing testing in regular operations, carrying full timber loads to gather performance and efficiency data in real-world conditions. The results will guide future deployments of electrified powertrains in the forestry sector and other heavy-duty applications.

Maruti Suzuki Launches One India, One EV Charging Platform

Maruti Suzuki One EV Platform

Maruti Suzuki India, the country’s largest passenger vehicle maker, is gearing up to mark its entry into the electric vehicle segment with the soon-to-be-introduced e Vitara has announced an EV ecosystem with a comprehensive end-to-end digital platform for charging needs, including home and public charging, with an integrated payment journey.

The company has signed collaboration agreements with 13 Charge Point Operators (CPOs) and aggregators to provide seamless charging experiences on a single platform.

Maruti Suzuki has established a network of over 2,000 exclusive charging points across its nationwide dealer network, spanning more than 1,100 cities. Customers’ charging needs are further supported by the extensive partner-operated all-India charging network.

Aligned with its global vision, Maruti Suzuki will work with its partners to enable more than 100,000 Public Charging Points by 2030.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India, said, “At Maruti Suzuki, we strive to extend a delightful ownership experience to our customers to build lasting trust. Today, we are taking a historic step, as we enter the domain of electric mobility with full readiness to address the EV charging concerns and boost customer confidence. We have established a robust network of over 2,000 Maruti Suzuki exclusive charging points across our sales and service network, spanning more than 1,100 cities. Further, we have collaborated with 13 Charge Point Operators to offer access to a vast charging infrastructure across the country. Aligned with Suzuki’s global vision, we plan to introduce multiple EVs and to support this, our aim is to enable a network of over 1 lakh charging points across India by 2030, along with our Dealer and CPO partners.”

'E for Me' Digital Platform

The Maruti Suzuki ‘e for me’ EV charging mobile app enables end-to-end usage of EV charging points from partner-operated charging points and Maruti Suzuki’s own network on a single platform.

The app offers a uniform customer journey for EV charging and payment through UPI or exclusive ‘Maruti Suzuki Money’, powered by Razorpay.

The platform's functions include:

  • Locate, Pay & Use EV charging points available on the app.
  • Use Public and Smart Home Charger from the same app.
  • One card for ‘Tap N Charge’ functionality at Maruti Suzuki dealer outlets and home charger.
  • Mirror e for me app on the infotainment system for seamless in-car EV charging experience.
  • Remotely start/stop and manage the power output of the smart home charger.

Partho Banerjee, Senior Executive Officer, Marketing & Sales, Maruti Suzuki India, said, “Today is the dawn of a new era for electric mobility in India. It gives me immense pleasure to say that Maruti Suzuki is EV ready and will be ‘By Your Side’ with our comprehensive new platform that addresses key concerns around EV charging infrastructure. Leveraging India’s largest dealer network and our charging partners’ network, we are ensuring there are EV charging points at an average distance of 5-10 kilometres at key locations in the top 100 cities of India. DC fast chargers are also located at regular intervals along key highways to enable nationwide driving freedom for our prospective EV customers. To further enhance peace of mind, we have deployed a 1.5 lakh-strong specially-trained EV workforce to cater to every need of our customers. We have also activated 1500+ EV-ready service workshops across 1100 cities for meeting after-sales requirements to support EV ownership in every part of the country.”

To showcase the network readiness, four e VITARAs were flagged off from Gurugram in all four directions – Srinagar (North), Kanyakumari (South), Bhuj (West) and Dibrugarh (East) – as a part of the ‘e drive’.

The e Vitara Born EV, which is ‘Made-in-India and exported around the world,’ has been rigorously tested over 10 million test kilometres. Tested from ‘Sand to Snow’ over a temperature spectrum of 60deg Celsius to -30deg Celsius, the e Vitara has delivered a driving range of 543 km.

Banerjee added: “Words aside, we are showcasing the prowess of this platform by flagging off a radical ‘e drive’ that will demonstrate the real-world efficacy of Maruti Suzuki’s comprehensive EV charging network. With the ‘e drive’, we aim to boost user confidence and execute faster EV adoption, working alongside the nation’s sustainability goals for net zero.”