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 4^th 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 7^th 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.

Japanese mobility company Suzuki Motor Corporation and Tata Elxsi, a leading design and technology services company have inaugurated the ‘Suzuki-Tata Elxsi Offshore Development Center’ in Pune, India.

The facility will focus on driving innovations in advanced engineering for Suzuki Motor Corporation’s future offerings. Tata Elxsi says it will support Suzuki in its green mobility vision by aligning with the OEM’s global focus on sustainable innovation in lightweight design, safety, styling and engineering, eco-friendly materials, and advanced simulations to improve time-to-market.

Furthermore, the partners will also focus on developing next-generation powertrains (across electric, hybrid and alternate fuels) and software-defined vehicles (SDV).

Katsuhiro Kato, Chief Technology Officer, Suzuki Motor Corporation, said, “As the industry progresses in Connected, Autonomous, Shared, and Electric technologies, Suzuki must accelerate electronic and virtual development to meet evolving demands. Tata Elxsi’s expertise in advanced computing, simulation, and design digital makes them an ideal partner in bringing forward-thinking solutions to market. This strategic and long-term partnership incorporates Suzuki’s endeavor of minimising energy and enables India’s talent to actively contribute to our development efforts globally.” 

Manoj Raghavan, MD & CEO, Tata Elxsi, said, “The inauguration of Suzuki-Tata Elxsi Offshore Development Center marks a significant milestone in our partnership with Suzuki and our shared vision for the future of mobility. Tata Elxsi’s design-led, digital-first approach is uniquely positioned to support Suzuki’s energy minimisation and sustainability goals, advancing the future of automotive engineering with precision and responsibility. We are delighted to support Suzuki in this journey towards transformative automotive engineering.”

MathWorks, a leading developer of mathematical computing software, and NXP Semiconductors, a leading provider of automotive processing technology have joined forces to introduce Model-Based Design Toolbox (MBDT) for Battery Management Systems (BMS).

With this, engineers will be able to not only develop models but also validate BMS applications on MATLAB and Simulink. They will also be bale to automate C code generation from MATLAB for NXP Battery Cell controllers, and also support NXP’s software solution, the BMS SDK components. 

For the unversed, BMS is one of the crucial technology for electric vehicles that ensures optimal performance, durability and safety for the battery packs. The BMS design process the partners state increasingly relies on modelling and simulation to fine-tune algorithms tailored to EVs' specific battery cell types and battery pack configuration. 

The Model-Based Design provides efficient design of the BMS algorithms, which allows it to be tested in simulation for different scenarios, such as driving habits, environmental conditions, and fault occurrences. 

Lars Reger, CTO, NXP Semiconductors, said, "We’re excited to collaborate with MathWorks to support automotive engineers in developing the next generation of BMS solutions. Simplifying direct testing with MBDT on NXP processors offers a broad range of benefits, including faster design iterations that allow engineers to identify and fix issues upfront in the design process and reduce time to market.” 

The MDBT acts as a bridge between theoretical design and practical application.

Jim Tung, MathWorks Fellow, said, "By enabling engineers to go directly from creating BMS algorithms in Simulink to running them on an NXP processor, we're simplifying and accelerating the development process. The growth of the EV market demands more efficient, reliable, and safer battery systems, and tools like MBDT that streamline and enhance the engineering process will be critical. Reducing development times, facilitating easier testing, and accelerating market entry will be differentiators in this competitive market.”

Mushin Innovation Labs, a Software-as-a-Service (SaaS) start-up providing digital solution for the automotive manufacturing industry, has raised USD 250,000 in Seed Series Round led by Inflection Point Ventures. The startup through its Mushin Aqua platform supports Tier 1 and Tier 2 manufacturers to optimise their compliance and improve quality management. This it claims helps to reduce upto 85 percent cost reduction.

The new funds it intends to deploy towards improving sales and marketing operations, accelerate its R&D efforts, and further innovate its product suite. It also aims to expand its market presence, enhance product offerings, and develop new solutions to meet the ever-evolving needs of the automotive manufacturing sector.

Interestingly, Mushin Innovation Labs claims it already secured partnership with 15 leading automotive brands and has onboarded 70 factories within two years. It has successfully passed the Maruti Vendor System Audit (VSA) and obtained Letters of Intent (LOIs) from 15 factories. It currently has 14 active deployments and a pipeline of 52 factories. The start-up claims it has received interest from global OEMs such as Volkswagen, Skoda, Volvo, JCB, and Aston Martin. The start-up was founded by Rachit Srivastava (CEO) and Amman Batra (COO).

The company estimates that the total addressable market (TAM) for Mushin Aqua, is estimated at INR 7,000 billion annually. The serviceable available market (SAM), specifically targeting Tier 1 and Tier 2 manufacturers in India, is valued at INR 450 billion. Based on the company's current capabilities and market focus, the serviceable obtainable market (SOM) stands at INR 45 billion annually.

Vikram Ramasubramaniam, Partner and CIO, Inflection Point Ventures, said, “The automotive manufacturing industry has stringent compliance standards to follow while minimising costs and maintaining top-notch quality. Many Tier 1 and Tier 2 manufacturers struggle to meet these demands efficiently due to fragmented processes and outdated systems. Mushin Innovation Labs addresses this challenge and streamlines compliance and enhances quality management in an accessible price range, making lives easier for tier 1 and 2 manufacturers. IPV believes Mushin is well-positioned for sustainable growth, making it a right investment choice.”

Schaeffler India, a leading motion technology company, in partnership with Buddy4Study Foundation, has announced the winners of its 2024 edition of the Schaeffler India Social Innovator Fellowship Program.

The initiative under Schaeffler India’s CSR initiative HOPE (Healthcare, Occupational skill development, Preservation of Heritage & Environment and Empowerment of Society) in its third edition recognises and rewards social entrepreneurs for their unique sustainable solutions that has positive impact to the society.

The programme is open to applicants between the ages of 18 – 35 across different institutions including IITs, IIMs, NITs, non-profit organisations, and early-stage startups, to pitch their ideas and prototype solution across six key categories. These include environmental sustainability, renewable energy, carbon neutrality, circular economy, natural resource management, and application of technology in the social sector.

The participants undergo rigorous screening, of which 10 projects are shortlisted and receive a grant of INR 150,000 each. The winners were awarded 24-week hybrid mentorship at IIMA Ventures formerly (IIMA-CIIE), a startup incubator founded by the Indian Institute of Management, Ahmedabad. They also get an opportunity to connect with Schaeffler India's network of industry partners, and fellow innovators in the program.

The initiative which started in July 2024, has received over 276 registrations from over 25 states, including the Northeast, West Bengal, Jammu & Kashmir, and more, with 78 shortlisted applicants for assessment.

Harsha Kadam, MD and CEO, Schaeffler India, said, “At Schaeffler India, we are dedicated to advancing motion to foster a sustainable, efficient, and resilient world. The remarkable response to this year’s Social Innovator Fellowship Program highlights the potential of India’s youth to be agents of transformative change. Sustainability and innovation are inherently linked, and through this initiative, we are committed to nurturing young innovators who will help shape the future of India, where both people and the planet can thrive.”

The award ceremony saw attended by Munish Bhatia, Co-Founder, India Accelerator & CEO, Bharat Ventures, and Praveen Bhadada, CXO Advisor and Mentor, along with the Leadership Team of Schaeffler India.