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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Maruti Suzuki India Limited marked a significant operational achievement with its Manesar in-plant railway siding, which crossed the 100,000-dispatch mark in under nine months. Being India’s largest facility of its kind and the company’s second PM GatiShakti terminal, this siding has played a key role in reducing environmental impact by avoiding an estimated 16,800 metric tonnes of CO2 equivalent emissions.

The siding facilitates the movement of popular models from the Gurugram and Manesar plants, including Alto, Brezza and Dzire, through a robust hub-and-spoke network. With over 500 rakes since it commenced operations in June 2025, the company now efficiently serves 380 cities from 17 hubs. This logistical strength builds on Maruti Suzuki’s legacy as the first automaker to secure an AFTO (Automobile-Freight-Train-Operator) license back in 2013, having moved more than 2.95 million vehicles by rail since fiscal 2014-15.

By advancing rail-based dispatch, the company actively contributes to UN Sustainable Development Goal 13. This initiative underscores its ongoing commitment to integrating sustainability into core industrial operations.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India Limited, said, “In June 2025, Hon’ble Union Minister for Railways, Information and Broadcasting, Electronics & Information Technology, Shri Ashwini Vaishnaw and Hon’ble Chief Minister of Haryana, Shri Nayab Singh Saini inaugurated India’s largest automobile in-plant railway siding at our Manesar plant. I am happy to share that within a short span of nine months, we have dispatched 100,000 units, through this siding. This initiative reinforces our commitment to reduce carbon footprint in vehicle dispatches while easing overall road congestion. At full capacity, the Manesar siding has the capability to dispatch 450,000 units annually.

“In CY 2025, the company set a record by dispatching over 585,000 vehicles through railways. Interestingly, in the past decade, our share of rail mode in outbound logistics has grown exponentially, from 5 percent in 2016 to 26 percent in 2025. Going forward, we aim to scale up rail-based vehicle dispatches from the current 26 percent to 35 percent by FY 2030-31, in line with our commitment to build efficient and sustainable logistics and contribute to India’s net-zero ambition.”

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The Society of Indian Automobile Manufacturers (SIAM) has unveiled its ‘Smart Integrated Automotive Mobility Lab (SIAM Lab)’ at the Smart Mobility India Expo 2026. Held at Bharat Mandapam from 23–25 March 2026, the pavilion serves as a collaborative platform for original equipment manufacturers (OEMs), technology providers and research institutions.

The SIAM Lab, located in Hall-1, is organised into three functional areas designed to demonstrate the evolution of the Indian automotive sector:

• Sustainable Mobility: Focusing on decarbonisation and green transport.
• Research & Testing: Showcasing validation frameworks and safety standards.
• Technology: Highlighting software-defined vehicles and connectivity.

The exhibit features 14 electrified vehicles from manufacturers including Tata Motors, Kia India, JSW MG Motor India, Toyota Kirloskar Motor, BMW India and Hyundai Motor India. Two-wheeler and last-mile segments are represented by TVS Motor Company, Honda Motorcycle & Scooter India, Ather Energy, Hero MotoCorp, Montra Electric and EKA Mobility.

The initiative involves partnerships with technical and data entities such as ARAI, Qualcomm, HERE Technologies, Google, ITS India Forum and Onnyx. These collaborations aim to integrate hardware with digital infrastructure, reflecting the industry's shift towards smart mobility solutions. The exhibition aligns with national objectives for advanced and sustainable transportation.

Prashant K Banerjee, Executive Director, SIAM, said, “The SIAM Lab reflects the collective strength of India’s automotive ecosystem in advancing smart and sustainable mobility. Our participation at the Smart Mobility India Expo provides a platform to showcase innovation, foster collaboration, and highlight the industry’s readiness for future mobility solutions.”

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Recreatives Industries, the manufacturer behind the legendary MAX 6×6 Amphibious All-Terrain Vehicles, is broadening its sales network by welcoming two new authorised dealers. The company has added Cart Guys Inc., based in Gastonia, North Carolina, alongside Globalsoft Equipment in Rochester, New York, which operates as Global MAX ATV. With Cart Guys Inc. coming on board as the second new dealer added in 2026, the United States dealer network now encompasses nine locations.

This expansion marks a strategic step in rebuilding what was once a robust North American dealer network that historically included over 200 active sites. Management views this legacy as proof of the platform’s long-term scalability as efforts continue to reestablish and grow the company’s retail presence. The focus remains on cultivating a high-quality, geographically diverse network capable of supporting rising demand across recreational, hunting and commercial sectors.

Commercial adoption of MAX ATVs is already evident, with vehicles being utilised by aqua management firms and the U.S. Army Corps of Engineers, alongside a loyal customer base in hunting and recreation. Upcoming models, including the MAX 4 and Buffalo, are expected to further extend the brand’s footprint into utility, industrial and commercial markets. Production of the MAX 2 is currently active and additional models are scheduled to launch in the summer of 2026, with the dealer network being aligned to support both current sales and these new introductions.

Recent operational developments include a truckload delivery of vehicle bodies to sustain ongoing MAX 2 production following the completion of the initial manufacturing run. Concurrently, the company is converting the existing MAX 4 and Buffalo moulds into its 3D CAD system, preparing for the initial production of next-generation vehicle bodies. This overall momentum reflects Recreatives Industries’ broader strategy to strengthen market presence, enhance customer access and build a scalable distribution network positioned for future growth.

Andrew Lapp, CEO, Recreatives Industries said, “Expanding our dealer network is a core priority as we continue building momentum behind the MAX brand. Adding Cart Guys in North Carolina, along with Globalsoft Equipment in New York, strengthens our regional coverage and positions us to better serve customers across key markets.”

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Vedanta Aluminium has deployed its first cohort of 30 women crane pilots at the Bharat Aluminium Company  (BALCO) unit in Korba, Chhattisgarh. The group includes 20 Pot Tending Machine (PTM) pilots and 10 beam-raising operators, marking a shift toward women-led operations as the facility enters the ‘million tonne club’.

The pilots operate in a smelting environment, executing tasks for stable metal production. These responsibilities include: anode changing & covering, tapping of molten aluminium and beam raising activities across all potlines.

The deployment followed a training programme involving classroom instruction, simulator sessions and on-the-job exposure. Currently, beam-raising activities at the plant are led by women designated as Beam Raising In-Charge in each room.

The initiative is part of a broader strategy to automate core manufacturing roles and make them gender-agnostic. Vedanta Aluminium has previously implemented:

• Jharsuguda: India’s first fully women-operated potline.
• Lanjigarh: An all-women team managing the digital command centre at the alumina refinery.
• Logistics: An all-women locomotive crew for in-plant rail operations.

BALCO also integrates transgender professionals into functions such as forklift operations and security, supported by policies including financial assistance and paid leave for gender reaffirmation.

Rajiv Kumar, CEO, Vedanta Aluminium, said, “Automation and advanced technologies are reshaping how modern aluminium operations function across all our units. This transformation is creating space for a new generation of highly skilled professionals to lead critical, technology-enabled roles. At Vedanta Aluminium, we are proud to see women stepping confidently into these specialised positions across our operations. This milestone at BALCO reflects our commitment to building a future-ready workforce while fostering greater participation of women in core manufacturing.”

Naaz Fatima, a PTM pilot, commented, “Working as a PTM pilot is both challenging and deeply rewarding. What I value most is that the company trusts us with these critical operations and invests in our growth. It feels empowering to know that our work directly contributes to BALCO’s progress and that we are shaping a new future for women in industrial roles.”

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