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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Tsuyo Manufacturing, an e-mobility component manufacturer, has appointed Prashant Ranjan as Director In-Charge – Sales & Service. The appointment is intended to strengthen the company’s leadership team and accelerate growth within India's electric mobility sector.

In his new role, Ranjan will lead domestic business operations, focusing on market expansion, business development, customer engagement and the creation of a service excellence network.

Ranjan brings experience from organisations including Saint-Gobain, Wipro and Godrej, where he led business transformation and revenue growth initiatives.

Prashant Ranjan, said, "India's electric mobility sector is entering a transformative phase, driven by innovation, policy support, and increasing consumer adoption. Tsuyo has established itself as a key player in the e-mobility component ecosystem through its strong manufacturing capabilities and technology-led approach. I am excited to join the organisation at this important stage of growth and look forward to working closely with the team to contribute to the company's long-term vision of accelerating India's transition towards sustainable mobility."

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Maruti Suzuki India Limited has formalised an agreement with Gujarat’s Directorate of Employment and Training to establish Advanced Manufacturing Labs within five Industrial Training Institutes located in Palanpur, Bhavnagar, Surendranagar, Godhra and Dahod. This partnership is structured under the company’s corporate social responsibility framework and directly supports the national Skill India mission.

These specialised labs are engineered to mirror actual shop-floor conditions, offering trainees practical exposure to critical automotive processes including assembly, welding, painting, machining, mechatronics and safety protocols. The overarching goal is to elevate the employability of ITI graduates and cultivate a workforce that is immediately adaptable to the demands of modern manufacturing.

This educational initiative coincides with a massive production scale-up in Gujarat. Maruti Suzuki is preparing to activate a fourth production line at its Hansalpur facility this year, which will boost annual capacity to one million units from the current 750,000. Concurrently, a new manufacturing plant with an additional one-million-unit capacity is under construction in Sanand, positioning the state to eventually host a total annual production volume of two million vehicles.

The company’s commitment to skill development is already extensive, supporting 31 ITIs nationwide in manufacturing trades. The addition of the five Gujarat labs will increase the total count of Advanced Manufacturing Labs to 23 across seven states and union territories. Furthermore, the automaker sustains four Japan-India Institutes for Manufacturing in Gujarat and Haryana, a bilateral initiative designed to generate a robust talent pipeline for the industry.

Rahul Bharti, Senior Executive Officer, Corporate Affairs, Maruti Suzuki India Limited, said, “Maruti Suzuki aligns with the Government of India’s flagship Skill India mission to impart the relevant skill training to create livelihood opportunities for the youth. Through Advanced Manufacturing Labs, we are equipping students with experiential learning and confidence in modern equipment, nurturing professionals who can seamlessly integrate into the evolving automotive ecosystem. We have a robust plan to expand manufacturing operations in the State. Each expansion brings with it a new industrial ecosystem, one that demands skilled and future-ready workforce. The Advanced Manufacturing Labs will play a pivotal role in meeting this latent need and ensuring that talent is ready to meet the industry demands.”

Stuti Charan, IAS, Director, DET, Government of Gujarat, said, “Maruti Suzuki, while being the market leader, has consistently demonstrated its commitment to skill development in India. By setting up Advanced Manufacturing Labs in Gujarat’s ITIs, Maruti Suzuki is bridging the gap between classroom learning and industry requirements. This initiative will empower our youth and strengthen Gujarat’s position as a hub for the automotive sector, in line with Hon’ble Prime Minister Shri Narendra Modi’s vision of Viksit Bharat and Hon’ble Chief Minister of Gujarat Shri Bhupendrabhai Patel’s guidance toward Viksit Gujarat 2047. The momentum and support from Hon’ble Cabinet Minister Shri Kunwarjibhai Mohanbhai Bavaliya, Labour, Skill Development & Employment, Hon’ble State Minister Shri Kantibhai Amrutiya Labour, Skill Development and Hon'ble Secretary Shri Lochan Sahera, Labour, Skill Development are paving the way for future-ready learning skills that match the pace of global development.”

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Spiro, an African electric vehicle (EV) and energy infrastructure platform, has closed its latest funding round at USD 270 million, following a USD 55 million investment from Chinese growth-stage fund NewTrails Capital.

The platform currently operates across seven African markets, with 100,000 electric vehicles deployed and 2,500 smart-swap stations in operation. This capital injection will support the expansion of Spiro's battery-swapping network, industrial footprint and EV infrastructure.

Gagan Gupta, Founder of Spiro and Chairman of Equitane, said, "I would like to thank NewTrails Capital for believing in Spiro’s model and supporting our unique tech, energy and innovation journey. Having deployed 100,000 electric vehicles and 2,500 smart-swap stations across seven active markets, Spiro has firmly moved past the proof-of-concept phase. Partnering with NewTrail Capital’s deeply experienced team marks a powerful new chapter for Spiro as we prepare for the next steps of our pan-African and international expansion."

Yufan Zhang, Founding Partner, NewTrails Capital, added, “We believe Spiro is driving a profound “energy revolution” across mobility use cases in Africa. This represents not only a vast and highly imaginative market opportunity, but also the potential to grow into an infrastructure-like business that creates meaningful commercial, social, and environmental value. In our view, Spiro’s core strengths lie in its deeply localized operating capabilities, vertically integrated supply chain, digitally enabled ecosystem, sound unit economics, and strong ability to scale rapidly. More importantly, Spiro has systematically integrated vehicles, batteries, energy replenishment, payments, and service networks into a solution that is truly tailored to the needs of African users, effectively addressing long-standing structural pain points in the local market.”

Spiro’s consortium of investors also includes FEDA, Impact Fund Denmark, Equitane, Nithio and the Africa Go Green Fund.

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US-headquartered vehicle cockpit and technology company Visteon Corporation has announced the appointment of Gary Hicok to its board of directors, effective 1 July 2026, who is also set to serve on the company’s Technology Committee.

Hicok has nearly 25 years of experience at Nvidia, where he served as Senior Vice President and led the company's automotive, mobile (Tegra) and PC core logic businesses and directed Xbox chip development. He was also involved in developing infrastructure for AI platforms, robotics and real-time computing.

Before his tenure at Nvidia, he held senior positions at Trident Microsystems, Cirrus Logic and VLSI Technology, focusing on PC audio, 3D graphics and system-on-chip (SoC) architectures. He holds a Bachelor of Science degree in Electrical Engineering from Arizona State University and holds 40 U.S. patents.

Francis Scricco, Chair of Visteon's Board, said, "We are delighted to welcome Gary Hicok to Visteon's board of directors. Gary brings a unique combination of automotive, semiconductor and systems leadership experience gained over decades at the forefront of technology innovation. His leadership in building NVIDIA's automotive business and advancing complex computing platforms will provide valuable perspective as Visteon continues to accelerate innovation for software-defined vehicles and next-generation cockpit solutions."

Hicok stated, "Visteon's leadership in digital cockpit technologies, software-defined architectures and AI-enhanced solutions provides a strong foundation for growth. Beyond automotive applications, the company's AI and software capabilities have the potential to address opportunities across a range of intelligent, connected systems markets. I am excited to join the board and contribute to Visteon's continued innovation, growth and value creation."

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