OEMs are facing new challenges to improve the existing technologies and develop next-generation ones for the new mobility in shorter times. Reducing market responding time along with new complexities are paving the way for virtual simulation, which displaces physical tests and prototypes by virtually replicating product development, testing and manufacturing with simulations. Emmanuel Leroy, Executive Vice-President Industry Solutions at ESI Group, explains, “We enable our customers to drastically reduce every additional physical prototype by using our solutions. In the end, only one physical prototype is required to validate the whole concept. We envision that one day we may be able to virtually certify a product from end to end.” Excerpts:

Q) How did the Covid impact the software and services businesses of ESI Group?

The Covid pandemic has accelerated the need for more digitalisation within the industrial market. It has also somehow accelerated the readiness level of our customers and made solutions such as virtual prototyping even more relevant. Indeed, we enabled the continuity of our clients’ business. The use of virtual prototyping allowed them to continue designing, testing and prototyping their products. Our human-centric approach – one of ESI Group’s four outcome solutions – was particularly used by our customers to ensure the continuity of their businesses: using virtual reality to experience the product from home.

During pandemic times, we also provided our CFD (computational fluid dynamic) solutions to help investigating different scenarios to demonstrate the effect of occupant proximity, ventilation systems and contamination avoidance unique to each office and plant environment. ESI Group developed different virtual scenario, based on its facilities in India, to optimise the return to offices and on plant – especially on a car assembly line.

How the growing complexity of part process is influencing the virtual testing?

We notice that the automotive industry is facing more and more draconian regulations, disruptive technologies, intensifying competitions and shortening response time. Coupled with these, customers are getting more demanding on quality, reliability, safety and production deadlines in the business. Indeed, end users are no longer looking for products but for results (flight hours instead of engines, number of possible kilometres instead of electric car, etc.) and they seek for committed and responsible automakers to motivate their buys. At ESI Group, we have understood these preoccupations and we have defined four primary solutions answering our customers’ expectations.

The first one is the Pre-certification and Validation, enabling gains in performance and productivity. The purpose is double: meeting certification and validation requirements like crash, safety and fatigue issues in the first attempt and then increasing productivity with predictive models and process automation.

The second outcome is Smart Manufacturing, which enables to establish the right manufacturing processes to meet the performance indicators for industrial products and processes.

The Human-Centric Product and Process Validation, our third outcome, focuses on humans by implementing an operator-centric approach to ensure the efficiency of assembly, maintenance operation and the safety of human interactions.

The last one, Pre-experience, is the most advanced solution of ESI Group. Here, our customers and the operators do not look at the product itself, but virtually experience a product, component, subsystem or system under numerous conditions and environments.

Using these approaches, we identify industry challenges from the customer’s perspective and support them in achieving their results.

Finally, as products are getting more complex, one of our strengths is our end-to-end multi-material assembly solution with modelling of different materials (steel, aluminum, composite) and manufacturing processes, covering all the product development cycle.

What will be the growth drivers for the internal combustion engine-driven vehicles business?

Safety is essential and will remain a key driver in the future. Today, the active safety is gaining traction owing to the regulations and overall trends. There is an increasing demand for smart integrated safety, which caters to both active and passive what?

Alongside there are regulations on Co2. In Europe, the Worldwide Harmonised Light Vehicle Test Procedure (WLTP) Norm is challenging and will eventually be implemented in other countries. Regarding Co2 reduction, we focus part of our research and innovation around engine efficiency, aerodynamics and light-weighting, as we did with Bentley for instance.

OEMs are also looking to reduce the manufacturing cost and development time which are leading demand for virtual prototyping, digital twin and shifting OEMs’ investment from hardware to software. The end-to-end value and the digital continuity from the early design to the production is essential to achieve these goals.

OEMs are exploring possibilities to manufacture ICE vehicles and EVs on the same line. Being a solution provider for the smart manufacturing process, how do you see this as a challenge?

Some OEMs assemble EV and ICE vehicles on the same line and look for flexibility, while others use completely dissociated platforms. We, consequently, must find the right strategy regarding their requirements. The new upcoming challenges in CASE mobility manufacturing will bring even more complexities from components to manufacturing. We have to consider the complexity to train the operators: our virtual reality solutions are key here. We help our customers by providing training, on both ICE vehicles and EVs manufacturing processes to their team, even from different place around the world, gathered on the same interface. This solution gathers all stakeholders (from operators to QHSE officers and plant managers) around the same product. This immersive tool helps getting complementary feedbacks early on in the process.

Where do you find more competencies or comfortability — in the complete vehicle design or component design?

Clearly, we are positioning ourselves on the whole vehicle design as it gives the most significant benefit for the OEM and other customers. We are talking about an end-to-end value that we can demonstrate on full scale CAE demonstrators. When it comes to a standalone component, the complex interactions between components and environment are not well taken into account and can lead to reduced predictiveness. In this case, we come up with a holistic view of the problem itself. It is how we defined the four outcome solutions introduced earlier.

Do you think that virtual prototypes will, at a 100 percent, completely replace physical ones ?

Virtual prototypes are step by step replacing physical prototypes. Nevertheless, I think physical prototypes remain today essential to certify the product at the very end of the development phase. To give an example, in 2019 Renault succeeded a 5-star rating of its Clio 5 on the Euro NCAP safety certification test with a single physical prototype, the one needed for the consumer test. Virtual certification is a topic discussed within the automotive ecosystem, allowing to solely relying on the simulation from end to end. But we are not at that point right now.

Which is your largest market for automotive business?

The automotive industry is the most significant contributor to our total revenues. Today, Japan is the largest market for our automotive business. However, India has been an important market for ESI, and it has been growing quite well over the years.

Most of our engineering developments teams, for both our software and our platforms, are based in India.

What are the challenges in the business?

The increasing complexity I mentioned before is definitely a challenge, but it also brings opportunities to us. Our end-to-end multi-material, multiprocess solutions and chaining capabilities are key to overcome the challenges of the automobile market. Due to the ever growing content of electronics, system simulations and systems of systems techniques are improving as well. Our focus is to strengthen our collaboration with partners in the ecosystem to support the customers in solving their complex problems. (MT)

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German technology giant Freudenberg Group has announced the expansion of its Freudenberg Training Centre in Nagapattinam, Tamil Nadu, reinforcing its long-term commitment to community development in India.

Esther Maria Loidl, Chief Human Resources Officer and global board member of Freudenberg & Co., laid the foundation stone for a new extension and auditorium at the training campus. The upgrade will include converting the existing auditorium into a computer lab, with a focus on offering digital and computer-based vocational courses. The new facilities are expected to be completed by mid-2026.

The expansion aims to attract and support more women students, equipping them with skills for financial independence and sustainable employment. The centre, established in 2008 in the aftermath of the 2004 tsunami, offers training in welding, fitting, machining, motor mechanics and electrical work. It has trained over 1,400 students to date, many of whom are now employed at leading firms such as Hyundai Motor India, TVS Motor Co and Simpson Group, while some have launched their own ventures.

Freudenberg has invested over INR 400 million in the region over the past 16 years. The 28-acre training campus is staffed by 18 qualified educators and led by Principal Dr Chitrakala Mohan.

Esther Maria Loidl, said, “It’s a pleasure and privilege to lay the foundation for further expansion of our largest CSR initiative in India - the Freudenberg Training centre in Nagapattinam. The institute’s growth affirms the visionary decision in 2008 to support the region’s rebuilding by empowering its young people with the right vocational skills. We look forward to investing and supporting the institute to grow further in its noble mission to power the aspirations of the needy in this region.”

G Sivasailam, Director & CEO, Freudenberg Regional Corporate Center India & Managing Director, Freudenberg Performance Materials India, said, "I am immensely proud to see the growth of the institute to where it is today. This reaffirms many of the core values of the Freudenberg group – long-term commitment, proactive and responsible action, among others. I would like to credit the Principal and her faculty who have been instrumental in ensuring the delivery of quality education to the local youth. They have been constantly innovating and adding to the courses and teaching pedagogy to what it provides is needed in the industry.”

Dr Chitrakala Mohan, Principal, Freudenberg Training Center, said, “It has been a great journey leading this visionary initiative for 7 years. The whole-hearted and passionate support we receive from the group executives in India and at the global HQ has been pivotal to whatever we’ve been able to accomplish so far. The foundation laying today and the other initiatives in the pipeline will help us expand sustainable community development through world-class vocational education, which sees local youth gainfully employed with leading companies in India.”

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Daimler Truck, Mitsubishi Fuso, Hino and Toyota Motor Corporation have concluded definitive agreements to integrate Mitsubishi Fuso and Hino Motors. The arrangement has Daimler Truck and Toyota Motor Corporation at the top. The motive behind the definitive agreements being to integrate Mitsubishi Fuso and Hino on equal footing, the change is expected to affect over 40,000 people. They will have to learn some as the two automotive giants – Daimler and Toyota – sat through, thought through and came to an agreement, creating yet another value intensive enterprise that will be headed by Karl Anton Deppen as the CEO.   
Bundling forces to establish a new strong Japanese truck powerhouse to the benefit of all stakeholders, the agreement to integrate the two Japanese commercial vehicle manufacturers aims at a new listed holding company that will begin operations in April 2026. It will have the scale, resources and technology leadership to shape the future of the commercial vehicle landscape in the Asia-Pacific region and beyond

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Automotive wholesales for May 2025 showcased a dynamic landscape for the Indian automotive industry, with OEMs experiencing distinct sales trajectories. From significant growth in the two-wheeler segment to some PV makers facing headwinds, the month provided an indicative picture of shifting consumer preferences and market conditions.

Hero MotoCorp, the world's largest manufacturer of motorcycles and scooters, dispatched 507,701 motorcycles and scooters in May 2025, showing both sequential and annual growth. The company maintained strong market momentum with 500,000 VAHAN registrations.

Hero MotoCorp's global retail performance also showed robust momentum, particularly in Bangladesh and Colombia, with exports maintaining a steady trajectory. The electric vehicle brand, VIDA, powered by Hero MotoCorp, delivered growth with dispatches of 8,361 units and 7,161 VAHAN registrations for the VIDA V2 electric scooter range, achieving a 7.2 percent VAHAN market share.

Honda Motorcycle & Scooter India (HMSI) recorded total sales of 465,115 units in May 2025. Domestic sales for HMSI stood at 417,256 units. The company's exports contributed 47,859 units to the total sales figure.

TVS Motor Company demonstrated impressive overall sales growth in May 2025, increasing by 17 percent to 431,275 units from 369,914 units in May 2024. Domestic two-wheeler sales registered growth of 14 percent, increasing from 271,140 units in May 2024 to 309,287 units in May 2025. Motorcycle sales saw a 22 percent increase to 211,505 units, scooter sales grew by 15 percent to 166,749 units and electric vehicle sales surged by 50 percent to 27,976 units. The company's international business (exports) also saw growth of 22 percent.

Royal Enfield experienced a significant surge in May 2025, posting monthly sales of 89,429 motorcycles, marking a robust 26 percent increase compared to the same month last year. The company's domestic sales contributed significantly to this performance. A key driver for this growth was the outstanding performance in exports, which soared by 82 percent to 13,609 motorcycles, up from 7,479 units in May 2024.

Maruti Suzuki India, the country’s largest passenger vehicle maker, reported total sales of 180,077 units in May 2025, demonstrating a 3.17 percent growth compared to 174,551 units sold in May 2024. Domestic sales, including Light Commercial Vehicles (LCV), stood at 138,690 units, experiencing a 5.46 percent decline from 146,694 units in May 2024. Sales to other OEMs also saw a marginal dip of 3.07 percent, reaching 10,168 units in May 2025. Conversely, exports surged by 79.76 percent YoY, totalling 31,219 units in May 2025 compared to 17,367 units in May 2024. Within passenger vehicles, while the Mini and Compact segment saw a decrease in sales, the Utility Vehicles segment demonstrated slight growth.

Tata Motors presented a contrasting picture, with total sales in the domestic and international markets for May 2025 standing at 70,187 units, a decline from 76,766 units in May 2024. Domestic sales for Tata Motors were 67,429 units, with Commercial Vehicle (CV) domestic sales at 25,872 units (a 9 percent year-on-year decrease) and Passenger Vehicle (PV) sales at 42,040 units (an 11 percent decline). In terms of international business for commercial vehicles (CV IB), Tata Motors saw a significant increase of 87 percent to 2,275 units.

Hyundai Motor India (HMIL) reported total monthly sales of 58,701 units in May 2025. Domestic sales for HMIL were 43,861 units. The company noted that the availability of some critical models was impacted due to a scheduled biannual plant maintenance shutdown during the month. Export sales for HMIL reached 14,840 units.

Mahindra & Mahindra, the SUV specialist, reported robust sales performance in May 2025, with overall auto sales reaching 84,110 vehicles, marking a significant 17 percent YoY growth. This was largely driven by the Utility Vehicles (UV) segment, which saw domestic sales rise by 21 percent to 52,431 units, contributing to a total of 54,819 UVs sold including exports. The commercial vehicles segment also performed well domestically, recording 21,392 units. Exports saw exceptional growth, surging by 37 percent to 3,652 units in May 2025.

Toyota Kirloskar Motor (TKM) continued its positive sales momentum in May 2025, reporting a total of 30,864 units sold, a 22 percent growth over May 2024. Domestic sales played a crucial role, reaching 29,280 units. The company also contributed to exports with 1,584 units.

Kia India maintained its strong growth trajectory for the fifth consecutive month in May 2025, dispatching 22,315 vehicles in the domestic market. This performance reflects a healthy 14.43 percent year-on-year growth when compared to the 19,500 units sold in May 2024.

Ashok Leyland saw a 5 percent increase in its total domestic vehicle sales in May 2025, reaching 14,534 units, up from 13,852 units in May 2024. This growth was primarily driven by its Medium and Heavy Commercial Vehicle (M&HCV) segment, with M&HCV Trucks increasing by 12 percent to 7,466 units and M&HCV Buses growing by 1 percent to 1,920 units. Light Commercial Vehicle (LCV) domestic sales experienced a slight decrease of 3 percent to 5,148 units.

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Reporting a revenue of over INR 500 billion for the first time, up 12 percent year-on-year, on the basis of automobiles are spares in FY25, Bajaj Auto Ltd has revealed that volumes rose seven percent YoY during the respective period with a strong performance in the first half and a relatively soft performance in the second half.

Observing a solid rebound (double digit volume and revenue growth) in exports, the Pune-based company earned an all-time high EBITDA of INR 101 billion, up 14 percent YoY. PAT also hit a new record at over INR 80 billion. With a revenue of around INR 55 billion from electric vehicles (20 percent of its domestic), the company, with a full PLI certified portfolio, underlined its organisation agility and adaptability with significantly improved unit economics in a journey spanning over the last three years.

With the refreshed Duke 200/250 and the new Adventure 390, the KTM portfolio of Bajaj Auto experienced strong momentum in FY25. Also the Triumph motorcycle portfolio with sales up 60 percent YoY. The KTM and Triumph motorcycles sold one lakh units domestically

The commercial vehicles portfolio of the company comprising mainly of three-wheelers saw a revenue increase of over INR 100 billion. It combined the tradition ICE vehicle business and the newly developed electric vehicle business. The launch of GoGo electric three-wheeler and a wide network of over 850 dealerships helped to increase the momentum.

Image for representative purpose only. 

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