The project enables ZF to reduce conversion costs, improve inventory, performance and quality, and make their workforce more efficient. As all companies are a member of the Open Manufacturing Platform, other customers in the automotive industry will also benefit from ZF’s improvements gained in Diepholz

Transforming manufacturing requires a seamless integration of both information and operations technology. PwC Germany, part of one of the world’s leading professional service firm networks, Microsoft and ZF, as two of the world’s leading technology companies, combine their strengths and experience to translate complex technical information into valuable business insights. The ZF Diepholz plant in northern Germany was selected for a pilot project where ZF and PwC Germany will transform processes and workflows using Microsoft Azure to build the future Digital Manufacturing Platform (DMP) of ZF.

“The world is changing, and so is manufacturing,” says Gabriel González-Alonso, Head of ZF Corporate Production Management. “In these very turbulent times, it was especially important to us that we implement new digital solutions that enable our manufacturing to achieve higher flexibility and efficiency.” This is nothing less than a paradigm shift for ZF. In the past, the software was introduced into each plant one by one and installed on discrete servers. This has evolved into creating a platform in the cloud, connecting ZF’s plants to said platform and rolling out the functionalities to the plant via Microsoft Azure. This horizontal, cross-plant integration with easy scalability makes ZF independent of its local infrastructure.

“To further digitise the ZF Diepholz plant, we will implement a transformation programme with several additional use cases, all of which will be integrated into an end-to-end Smart Factory Transformation for ZF,” explains Michael Bruns, Partner Digital Operations at PwC Germany. Selected cases will aim at creating transparency of production performance from the plant as a whole all the way down to machine level. Others will focus on the traceability of production flows, analysis and prediction of production, and quality outcomes. The third set of used cases aims at enhancing maintenance operations through machine monitoring and fault prediction.

To master these tasks, ZF and PwC Germany will use Microsoft AI to improve planning efficiencies and effectiveness, improve maintenance, repair, and operations (MRO) inventory and present new insights to improve production performance.

Microsoft, which provides the software solutions for PwC Germany’s approach, sees this project as relevant for the digital strategy for all automotive suppliers like ZF. “Our aim is to make this initiative not only a best practice for success at ZF but also an industry-wide inspiration to other automotive customers endeavouring on their own digitalisation projects. We see strong interest across the manufacturing sector globally to leverage digital technologies to drive quality as well as process optimisation, and we’re excited for this project to serve as a true benchmark,” says Marianne Janik, Area Vice President, Microsoft Germany.

The partners will come together to bring fully-networked plants to the next level. Smart factories not only work quickly and reliably, but they also offer a high degree of adaptability for rapid design changes. This leads to more engaged employees, increased business velocity, and stronger growth margins.

Not only will other ZF plants benefit from the insights gained from digitising the Diepholz plant and the capabilities of the DMP, but other organisations may benefit as well. (MT)

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Asia’s largest integrated platform for traffic management, road construction and smart mobility solutions officially opened its doors today at the Bharat Mandapam, New Delhi. The combined Traffic Infratech Expo, Road Infratech Expo and Parking Infratech Expo are showcasing over 300 brands under the theme ‘Enabling Responsible Infrastructure and Mobility.’

The 2025 edition emphasises innovation, sustainability and collaboration, bringing together government officials, industry leaders and technology providers to address India’s rapidly evolving infrastructure needs.

Raj Manek, Executive Director & Board Member, Messe Frankfurt Asia Holdings, said, “At Messe Frankfurt India, our commitment to create platforms that don’t just showcase technologies but actively drive industry conversations and policy alignment. Traffic Infratech Expo has evolved into an ecosystem where government, industry leaders and innovators converge to shape the future of mobility. This year’s edition, with its scale and focus on responsible infrastructure, reflects India’s ambition to lead in safe, sustainable and technology-driven transport solutions.”

A key focus of the expo is ‘Transforming Transportation for the Future,’ with several high-level discussions planned on supporting home-grown technology solutions.

The event will host a significant Memorandum of Understanding (MoU) signing between the Centre for Development of Advanced Computing (CDAC) and the International Centre for Automotive Technology (ICAT) to accelerate indigenous technology development within the automotive sector.

Jayprakash Nair, Managing Director, Virtual Info System (VIS Group), said, “Over the years, Traffic Infratech Expo has become a catalyst for change in India’s transport and mobility landscape. Together with Messe Frankfurt India, we have built a platform that drives industry and government collaboration. Technology providers, product manufacturers, government associations, infrastructure, and policymakers are converging at the expo to discuss the real challenges and solutions needed. The 2025 edition is particularly significant as it not only introduces next-gen product categories but also brings multiple agencies and stakeholders to the table, reinforcing the show’s role as a driver of innovation and progress.”

The expo is supported by several key government bodies, including the Ministry of Road Transport and Highways (MoRTH) and the National Highways Authority of India (NHAI), and will feature the Smart Mobility Conference to enable in-depth policy discussions. The two-day event is set to host over 20 new product launches and facilitate B2B and B2G networking.

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Cognizant hosted Aston Martin Aramco Formula One Team driver Lance Stroll and driver ambassador Pedro de la Rosa at its GAR campus in Hyderabad. The visit was part of 'Celebrating Cognizant', a series of sporting and cultural activities for company associates.

Lance and Pedro met with Cognizant’s leadership team and hundreds of associates, discussing how Cognizant’s digital expertise supports the team, especially ahead of the 2026 regulations.

Lance Stroll, said, "It was a pleasure to visit the Cognizant offices in Hyderabad and meet so many of the team. Hearing first-hand about Cognizant’s technology and services was valuable and we felt incredibly welcomed by everyone we met.”

Rajesh Varrier, President – Global Operations and Chairman & Managing Director, Cognizant India, said, “Today’s celebration with Lance is a proud moment for our associates and a powerful reminder of how far we have come in shaping the future of the Aston Martin Aramco Formula One Team through innovation. I am inspired by what we have achieved together and optimistic about the promise this partnership holds for the future.”

A fireside chat with Lance, Pedro, and Rajesh underscored the role of technology in F1 and the Cognizant partnership. The drivers engaged with associates in a Q&A session.

In addition to the visit, Cognizant hosted a virtual hackathon for nine teams from three organisations supported by its Outreach programme. Participants developed low-code or code-based solutions to make the team’s Ai.lonso avatar into an engaging digital companion for fans. The top two teams won cash prizes and met Lance and Pedro.

Cognizant began its partnership with the Aston Martin Aramco Formula One Team in 2021. The technology company acts as the team’s digital transformation partner, improving IT infrastructure and daily operations.

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Ola Electric, one of India’s largest electric vehicle manufacturers, has announced that it became the first two-wheeler EV maker to get government certification for its in-house developed rare-earth-free ferrite motor.

The company claims that the ferrite motor eliminates its need to import rare-earth motors with permanent magnets.

The certification has been granted by Global Automotive Research Centre, Tamil Nadu, after undergoing rigorous performance verification and mandatory motor power tests as per AIS 041 that is notified by the Ministry of Road Transport & Highways (MoRTH), Government of India.

As per the company, the in-house developed ferrite motor’s performance matched that of the motors with rare-earth permanent magnet motors in terms of net power for 7kW and 11 kW variants.

Ola Electric claimed that the ferrite motor delivers efficiency, performance and durability on par with rare-earth permanent magnet motors, while dramatically lowering costs and de-risking supply chain fluctuations. The company first introduced its ferrite motor at its annual ‘Sankalp 2025’ event in August this year.

With this, Ola Electric is set to integrate the ferrite motor across its product lineup, further enhancing performance, affordability and sustainability.

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BASF and its partners are set to present two technologies at K 2025 that allow for the recycling of polyamides from end-of-life vehicles. While metal recovery from decommissioned vehicles has been standard for decades, about 200 kilograms of plastic per vehicle are often incinerated. The new technologies aim to change this, especially with upcoming requirements from the End-of-Life Vehicle Regulation (ELVR). Pilot projects show how automotive waste can be used as material and returned to a closed cycle for the car industry.

BASF developed a chemical recycling process that recycles used and contaminated plastic parts – including used oil pans from ZF Group vehicles. The core of the process is depolymerisation, where the long polyamide chains break down into their original monomers. The caprolactam monomer obtained from PA6 is then purified. This removes impurities that would have remained with mechanical recycling and potentially reduced the material's quality and safety.

The material is then repolymerised into high-quality polyamide, which is processed into a compound suitable for demanding car industry components, closing the automotive-to-automotive loop.

"What used to be considered non-recyclable is now the starting point for high-quality new products," said Martin Scheuble, Team Leader Circularity Engineering Plastics at BASF.

ZF Group processed the recycled material into a chassis component for Mercedes-Benz. Tests show that depolymerisation allows for polyamide compounds that can be used without compromising performance or other chemical and physical properties.

"This project highlights the potential of recycled plastic - even for technically demanding applications - and underlines ZF's innovative strength in establishing sustainable material cycles," said Dr. Michael Lohrmann, Director Materials Technology at ZF.

Solvent-based recycling of shredder residue

A second pilot project focuses on recycling automotive shredder residue (ASR) – a mixture of materials left after the removal of mostly metals and glass. Close cooperation with a recycling company, using new sorting and processing technology, has allowed the polyamides to be extracted from this mixture in a largely pure form.

This polyamide fraction was the starting material for a solvent-based recycling process. In this process, the polymer chain is selectively dissolved with a solvent, purified and then reprocessed into PA6 compounds.

Poppelmann manufactured and tested a chain guide rail in series production at Mercedes-Benz using this technology.

"The project impressively demonstrates that solvent-based recycling is a practical alternative for plastics that are difficult to recycle mechanically. It makes an important contribution to the holistic circular economy - from the car back into the car," emphasised Steffen Meyer, Team Leader Production Technology at Poppelmann.

Life cycle analyses (LCA) confirm that both the solvent-based and depolymerisation technologies offer substantial CO2 emission savings compared to both conventional polyamide production and traditional plastic recycling methods like thermal recovery.

BASF offers a range of recycling solutions, stating that targets are achieved only if technologies are used in a complementary manner, depending on the type and availability of waste.

Jana Kragenbring-Noor, Head of Sustainability & Environmental Protection at Mercedes-Benz, explained, "Mercedes-Benz is committed to the use of secondary raw materials in its vehicles today and in the future as part of resource conservation and circularity. To continuously increase the availability of such sought-after secondary materials, the expansion of existing and new recycling technologies is essential."

"We are continuously improving the efficiency of physical methods such as mechanical and solvent-based recycling. In addition, we are convinced that complementary technologies such as chemical recycling, which includes depolymerization, pyrolysis and gasification, are necessary to further promote the circular economy and reduce the plastic waste that still ends up in landfills or is incinerated today, as well as the potential to obtain high-quality recycled plastics," explained, Dr. Martin Jung, President of BASF Performance Materials.

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