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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UTAC, a prominent player in the automotive testing, inspection and certification sector, is significantly broadening its footprint in China. The company has unveiled plans for a cutting-edge proving ground in Huainan, situated in the central province of Anhui. This ambitious project is being developed through a collaboration with the Huainan City Government and is set to become the primary strategic hub for the UTAC Group’s operations within the country. By establishing this facility, UTAC aims to bolster the mobility industry with top-tier testing capabilities and specialised knowledge.

The new site will enable UTAC’s team of specialists to offer homologation and testing services that align with the most current international benchmarks and regulatory standards. This initiative is a direct continuation of the group’s overarching goal to foster a mobility landscape that is both safer and more environmentally friendly. The Huainan facility is designed to be comprehensive, featuring a variety of specialised tracks for vehicle testing, along with a technology park that includes rentable workshops and office spaces. It will also house a dedicated conference and exhibition centre and purpose-built laboratories outfitted with state-of-the-art equipment. These labs will be specifically geared towards testing the latest advancements in new energy vehicles.

Anhui province itself provides a rich environment for such an investment. Home to 70 million people, it hosts a dense and extensive mobility ecosystem. Major automotive manufacturers like BYD, Changan, Chery, JAC, NIO and Volkswagen, together with their extensive supply networks, are deeply embedded in the region. The province’s manufacturing prowess is underscored by its production of roughly 3.7 million vehicles in 2023, a figure that positions Anhui as China’s leader in overall vehicle manufacturing, new-energy vehicle production and vehicle exports. Consequently, the new proving ground in Huainan is poised to become a vital strategic component for UTAC, solidifying its presence in this central hub of the Chinese mobility industry.

Connor McCormack, CEO, UTAC, said, " We are extremely proud of our partnership with the city of Huainan, which is undergoing a significant transformation to support the future of the automotive industry. UTAC is delighted to contribute to this transformation and to bring our 100 years of specialist expertise, along with the European standards we have helped shape and validate, to China’s vital automotive sector.”

Mayor Zhang Zhiqiang of Huainan City said, “This represents a significant milestone in Huainan's efforts to accelerate the development of its intelligent connected vehicle industry. It is of great importance in bridging the critical gap in the regional automotive sector’s industrial chain of ‘testing-production-export' and establishing a specialised vehicle testing and certification platform with international recognition. The successful cooperation on this project will undoubtedly advance the high-end and intelligent transformation of the regional automotive industry, providing strong impetus for Anhui Province's efforts to foster a new energy vehicle industrial cluster with international competitiveness.”

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Gulf Oil Lubricants India, a Hinduja Group company, has announced a four-year extension of its partnership with the Chennai Super Kings (CSK). Gulf will serve as the Official Lubricants Partner for the franchise, continuing an association that has spanned 13 seasons.

The renewal maintains one of the longest-running brand partnerships in the Indian Premier League (IPL). The collaboration focuses on consumer engagement through marketing campaigns and fan-focused initiatives.

The 13-season history between Gulf and CSK has been a central part of Gulf’s brand strategy in India. The company uses the platform to reach cricket fans through digital activations and on-ground experiences.

This follows the recent announcement of fellow Hinduja Group company, Ashok Leyland, joining CSK as an official sponsor.

Ravi Chawla, Managing Director & CEO, Gulf Oil Lubricants India, said,“Gulf’s 13-season journey with CSK reflects a relationship built on trust, shared passion, and mutual success. This partnership has consistently delivered far beyond the commercial contract, forging a deep emotional connection with the loyal CSK fan base and cricket enthusiasts across the nation. Continuing this association is a proud moment for Gulf as it reflects our global heritage of supporting performance sports and iconic teams that inspire millions of fans.”

KS Viswanathan, Managing Director, Chennai Super Kings, stated, "We are pleased to continue our long-standing association with Gulf, a partner that has been with us through many memorable seasons. Over the years, Gulf has consistently brought creativity and energy to the partnership while engaging with our fans. We look forward to strengthening this relationship over the next four years. We are really pleased about how it has come together"

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Volvo Car UK is marking a major milestone in automotive safety this year, celebrating seven decades of pioneering seatbelt innovation with a groundbreaking new system in the EX60 model. This latest development represents the world’s first multi-adaptive safety belt.

The brand’s legacy began in 1956, when the Volvo Amazon prototype was fitted with a two-point diagonal chest belt, making it one of the first European vehicles to offer such a feature. Just three years later, Volvo made history by becoming the first manufacturer to fit three-point seatbelts as standard. This design, created by engineer Nils Bohlin, combined a lap belt with a diagonal strap anchored at a low point beside the seat, establishing the template for the safety belts found in every modern vehicle.

Volvo’s commitment to saving lives was further demonstrated when it made the three-point belt patent available to all competitors free of charge. This altruistic move accelerated the widespread adoption of seatbelts globally and helped fast-track legislation making them a legal requirement, ultimately saving millions of lives. The engineering principles established 70 years ago continue to inform modern Volvos, with the new EX60’s multi-adaptive belt representing the latest evolution.

This advanced system leverages real-time data from interior and exterior sensors to tailor protection for each individual occupant. It considers factors like height, weight and seating position, adjusting its response based on the specific crash scenario. For instance, a larger occupant in a severe collision would receive a higher belt load to mitigate head injury risks, while a smaller person in a minor incident would experience a lower load to protect against rib fractures. Crucially, the system is designed to learn. Through over-the-air updates, the vehicle can continuously refine its understanding of occupant dynamics and crash responses, ensuring the technology improves throughout the car's life. This landmark achievement arrives as Volvo prepares to celebrate its centenary in 2027.

Nicole Melillo Shaw, Managing Director, Volvo Car UK, said, “Volvo has always been at the forefront of safety evolution and innovation, and we’re pleased that we can continue to make new developments on such vital features like the seatbelt. The latest multi-adaptive seatbelt in the new EX60 is a testament to our pioneering technology and approach to safety that is continued today.”

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Toyota Kirloskar Motor (TKM) has taken a significant step in its ongoing collaboration with the Government of Maharashtra by completing the upgrade of the Government ITI Deogiri in Chhatrapati Sambhajinagar. This development is part of a broader Memorandum of Understanding aimed at enhancing the state’s network of Industrial Training Institutes. The company has already facilitated the modernisation of 16 ITIs across the Marathwada and Nagpur divisions. The core objective of this partnership is to uplift rural youth by providing them with advanced technical training, thereby preparing them to become skilled technicians ready to support India’s expanding industrial sector.

A structured three-pillar strategy has been established to drive this transformation. The first pillar concentrates on educator development through specialised training programmes and workshops, including sessions held at Toyota’s facility in Bidadi. The second involves equipping the institutes with modern tools and learning materials, such as fundamental skill training kits and visual aids, to create an industry-relevant learning environment. The third pillar is dedicated to instilling a strong work culture by integrating practices that promote discipline, safety and environmental awareness. This holistic approach aims to cultivate graduates who not only possess technical expertise but also demonstrate integrity and a sense of social responsibility.

The rollout is planned in three distinct phases. Following the completion of the first phase covering 17 ITIs in the Marathwada and Nagpur regions, the subsequent phases will extend the initiative to the Amravati and Nashik divisions and finally to the Mumbai and Pune divisions by 2030. With the upgrade of ITI Deogiri, the institution now serves as a blueprint for this scalable skilling framework. Starting this academic year, it will begin offering training in both manufacturing and service domains to align with current industry demands. This long-term project, which ultimately aims to uplift 45 ITIs across the state, reinforces the national Skill India Mission by leveraging global manufacturing insights to address local skill development needs.

Mangal Prabhat Lodha, Minister of Skill, Employment, Entrepreneurship & Innovation, Government of Maharashtra, said, “Our youth are the foundation of Maharashtra’s future, and by nurturing their skills and aspirations, we are building a self-reliant society. This collaboration with TKM reflects our commitment to providing young people with industry-relevant training that enhances their confidence, employability and contribution to nation-building. Such initiatives ensure that our students are ready for the future to drive the country's growth story."

Vikram Gulati, Executive Vice President – Corporate Affairs and Governance, Toyota Kirloskar Motor, said, “At Toyota Kirloskar Motor, we firmly believe that the youth in rural India deserve the same opportunities as those in urban centres. Our vision is to empower them with world‑class technical capabilities so they can excel in their careers and contribute meaningfully to the nation’s progress. Guided by our philosophy of ‘Grow India, Grow with India’ and our mission of ‘Producing Happiness for All’, this initiative underscores our commitment to strengthening skilling at the grassroots level. As India moves towards the vision of Viksit Bharat 2047, we are dedicated to enabling equitable access to industry‑relevant skills that uplift communities and build a more resilient future.”

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