Witnessing manufacturing modernisation since Maruti Udyog began producing cars in collaboration with Suzuki of Japan at Gurgaon in 1984, the Indian auto industry landscape has drastically changed. Opening up to automation with the installation of some of the best robots available at Kuka, ABB and others, the auto industry has left no stone unturned. Such has been the fervor that Tal, a Tata Motors company, launched a robot called Brabo in 2018 to make manufacturing processes involving the application of sealants, picking and placing of parts, welding and vision inspection reliable and easy to perform. Made with an eye on manufacturing process the world over, the Brabo was tested in over 50 work streams and has so far found use in sectors like lighting, aerospace, software, electronics, plastics, education and logistics sectors apart from the auto industry. Coming from an auto maker that installed 300 Kuka robots to automate the assembly of Sumo and Safari at its Pune plant in 2009, the Brabo has seen many rounds of development and application-preparedness since its launch.                

Smart manufacturing trend

Highlighting the smart manufacturing trend, the TAL Brabo robot with payloads of two and 10 kilos has also found favour with companies in Europe and other places. Highlighting the prowess of Artificial Intelligence (AI) and Internet of Things (IoT), the robot is an example of the fast-changing manufacturing canvas. Producing about 1,286 engines per day, the Igatpuri plant of Mahindra & Mahindra became India's first carbon-neutral manufacturing facility by adopting smart manufacturing practices under Industry 4.0 in 2019. It invested in energy efficient technologies among others. It invested in recycling of water and other waste. It invested in solar panels to power some of its processes in the plant. An industry source expressed that the rapidly changing business environment the world over is providing impetus to smart manufacturing. It is driving efficiency enhancements and collaborations, he added. Emphasising on efficiency enhancements and collaborative efforts as key smart manufacturing drivers, an industry expert stated that technologies like AI, Industrial Internet of Things (IIoT), automation, big data and 5G are the biggest triggers. They are touching every aspect of manufacturing, from sourcing of raw materials to final inspection, he quipped.  

Industry 4.0

As companies like Lincode (it has collaborated with Switzerland-based Global Automotive Alliance), specialising in AI-powered visual inspection with multiple patent-pending defect detection capabilities, find more and more takers in India, the smart manufacturing shift is continuing to take place despite disruptions. It has, in fact, gained speed in India with the race to successfully accomplish BS VI transition in the last few years. A source in the auto industry mentioned that BS VI transition led to manufacturers upping their global ambitions. Vinay Raghunath, Partner and Leader, Automotive Sector, EY India, averred in a report that automotive shop floors are evolving and adopting digital technologies. This, he added, is happening amid challenges like slowdown in demand, non-availability of labour, concerns on health and safety management on the shop floor. Witnessing disruptions relating to ROI among other factors, as Raghunath has informed, the Indian auto industry has been an early adopter of digital manufacturing techniques.  

Working to dial higher efficiency, expertise and superior productivity, the Indian auto industry has been overhauling existing assembly lines, erecting new ones and extensively re-evaluating its manufacturing processes and practices in view of smart manufacturing, especially from an automotive value chain point of view. Taking to Industry 4.0, it is leveraging AI and IoT-based manufacturing technologies to automate further – to engage in machine-to-machine communication (M2M) such that there is self-monitoring as well as self-diagnosing. Taking to Industry 4.0 to tackle unanticipated disruptions like the Covid-19 pandemic, which has put well-oiled supply chains and production lines to the test and made it painfully clear that they in their current form are not as agile or resilient as expected, the auto industry is shifting to smart manufacturing in a big way. It is exploring and experimenting; it is finding new ways. It is doing so as it absorbs a significant change in technologies and products like electrification and EVs.

Operator 4.0 and hyper-intelligence

Investing heavily in data analytics infrastructure and capabilities, the auto industry is leveraging opportunities to digitally transform itself. It is defining the boundaries of physics for data-driven model. It is focusing on digital skills development. It is supporting the rise of Operator 4.0. Taking to collaborative robots that coexist with humans in a workplace, it is transforming its ways of manufacturing significantly. Drawing attention to the semi-conductor shortage and how the auto industry was affected despite using only 10 percent of the production, Vipin Sondhi, Managing Director, Ashok Leyland, explained that the rapidly changing consumer psyche is dictating a move to a completely different technological aspect. Emphasising on material technology, he said smart manufacturing is about digitising and achieving cost competitiveness. It was some two to three years ago that the Chennai-based CV maker began implementing smart manufacturing technologies to mitigate challenges. It took to modernising and digitising existing workplaces to address quality issues that are difficult for human beings to detect and acquire made-to-order or mass customisation capabilities. It took to equipping itself with an ability to expand and contract in tandem with the market conditions even as it took to modularisation of product lines.  

Automating its cab panel pressing plant at Hosur in 2019, which increased the output by up to 66 percent, Ashok Leyland has been one of the many automotive OEMs globally that are investing in hyper-intelligent automation. A confluence of AI and Robotic Process Automation (RPA), hyper-intelligent automation is redefining not just Industry 4.0 but also Operator 4.0. It is facing challenges like the high initial acquisition cost in terms of tools, but that isn’t worrying players involved like Tata Consultancy Services, Wipro, Mitsubishi Electric Corporation, Catalytic Inc and Infosys Limited among others. Estimated to grow at a CAGR of 18.9 percent as manufacturers strive to reduce energy consumption, up quality and reliability, and control costs through predictability and data-driven unique insights, hyper-intelligent automation is turning out to be yet another finer aspect of smart manufacturing. It is proving to be a big enabler for automating repetitive tasks – to enhance efficiencies, to take to cloud computing to ensure significantly more flexibility and to achieve scalability and the ability to collaborate and reduce costs.

Increasing visibility, predictability and enhancing control on operations and inventory, hyper-intelligent automation is aiding effective decision-making. Supported by development of new technologies such as 5G, which according to a domain expert, promises the need for speed and flexibility along with the capability to eliminate network instability or downtime, hyper-intelligent automation is helping automotive suppliers like Rane Madras Limited to make efficiency, reliability and cost control gains. In 2018, the company adopted automated solutions of Mistubishi Electric Corporation for its new plant in Gujarat. It led to a significant decrease in energy consumption. Aiding smart manufacturing, technologies like hyper-intelligent automation and 5G are helping the auto industry to achieve resilience and immunity against future uncertainties. They are helping to integrate Information Technology (IT) systems used for data-centric computing with Operational Technology (OT) systems – for data readiness and cyber security, and for the development of digital talent. Technologies like hyper-intelligent automation and 5G are helping to develop cross-functional profiles like engineering-manufacturing, manufacturing-maintenance and safety-security.

Tackling disruptions and smart working environment

Looking at productivity gains, emerging competition and risk aversity in the globalised world as per the EY report, the auto industry is taking to smart manufacturing to achieve significant technology transformations like electromobility as well. Apart from the creation of a smart working environment, it is also looking at the use of new materials, new process guidelines and practices. With health also becoming a disruptive factor in recent times, the auto industry is looking at automation in processes like inbound logistics, production planning, sourcing, press shop, body shop, paint shop, quality control and outbound logistics through data visualisation. With sensors and analytics shaping up, the smart working environment in a factory is coming to include AI-based alerts and fully automated work floors. This is increasingly getting compounded by data collection, historical data and high-quality extensive data mining. Helping to guarantee ROI, smart manufacturing is helping to lower the ‘takt’ time. It is also ironically undermining the involvement of humans on the shop floor.   

Reducing the cost of computation, storage and connectivity, smart manufacturing is coming of age with plummeting prices of sensors, 3D printers and robots. Empowering cloud-based manufacturing techniques and a gradual increase in the understanding of emerging technologies, smart manufacturing is providing an advantage in terms of the ability to respond to market changes quickly. Taking to develop a new light-duty truck platform with export ambitions and flexibility in terms of left-hand drive and right-hand drive orientation, VE Commercial Vehicles Ltd took to automating its welding line with robots at its Pithampur plant. It also took to robotising its windshield pasting station among others. Experiencing quality, consistency, efficiency and cost gains, the CV maker is also known to have reduced the takt time and energy consumption. As global ambitions and modularity strike in view of the ability to explore new export markets with a cost competitive BS VI product, the auto industry in India is using embedded sensors, RFID and GPS etc. for smart tracking. It is using smart manufacturing technologies to monitor parameters like temperature, pressure, vibration, machine rpm and flow rate.

Smart flexibility

As part of a shift to smart manufacturing, automakers and suppliers are resorting to flexible manufacturing and AR-based solutions to upskill. They are, in view of the technologies like connected vehicles and EVs, stressing on re-aligning their traditional manufacturing setups with that of the future. Emphasising on quality, resource optimisation, streamlining of business processes and adoption of new emerging technologies, they are closely evaluating the advantages of solutions like digital twins and rapid prototyping using additive manufacturing offer. With ROI on their mind, they are embracing smart manufacturing to move up the value chain.

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German luxury automotive brand BMW India is set to increase prices across its entire model range by up to 3 percent beginning 1 September. The company cites continued foreign exchange impacts and rising material and logistics costs as the primary reasons for the price adjustment.

Vikram Pawah, President and CEO, BMW Group India, said the company has seen significant sales growth in the first half of the year.

“BMW India’s growth and sales momentum in the first half of the year has been remarkable. However, factors like continued forex impact and global supply chain dynamics have been leading to increased material and logistics costs. Our commitment to offer best value and experience throughout customer journey is steadfast. In the festive season, we are geared to introduce several new power-packed profiles of our cars. As the strong demand for BMW’s luxurious, pioneering cars continues, we will deliver exceptional performance and innovation to our valued customers,” he said.

At present, BMW sells the locally produced the BMW 2 Series Gran Coupe, BMW 3 Series Long Wheelbase, BMW 5 Series Long Wheelbase, BMW 7 Series, BMW X1, BMW X3, BMW X5, BMW X7, BMW M340i and BMW iX1 Long Wheelbase.

in India. The company also offers a wide selection of imported models, including the BMW i4, BMW i5, BMW i7, BMW i7 M70, BMW iX, BMW Z4 M40i, BMW M2 Coupe, BMW M4 Competition, BMW M4 CS, BMW M5, BMW M8 Competition Coupe and BMW XM (Plug-in-Hybrid) as completely built-up units (CBU).

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In a joint effort to improve road safety, Skoda Auto Volkswagen India (SAVWIPL) and the SaveLIFE Foundation have successfully completed a two-year project on a high-risk section of National Highway 19 in Uttar Pradesh.

The initiative, named ‘Surakshit Sadkein, Surakshit Bharat’ (Safe Roads, Safe India), has resulted in a 7.5 percent reduction in road crash fatalities on the Agra–Etawah–Chakeri corridor since its launch in November 2022.

The program benefited over 720,000 commuters and focused on a comprehensive, evidence-based approach to road safety, addressing four key areas:

Engineering: Over 7,000 engineering hazards were fixed, with the addition of crash barriers, speed-calming measures and improved pedestrian facilities.

Enforcement: Electronic enforcement tools and new signage were deployed to improve traffic management.

Emergency Care: More than 300 first responders were trained in Basic Trauma Life Support.

Education: Awareness campaigns, including billboards and local outreach, reached a wide audience and commercial vehicle drivers received training in anticipatory driving.

This project was a collaboration with several government bodies, including the National Highways Authority of India (NHAI) and the Uttar Pradesh Police. The partners hope this successful model can be replicated in other high-risk areas across the country.

Piyush Arora, Managing Director & CEO, SAVWIPL, said, “For us, progress in the automotive sector is as much about building safer communities as it is about innovation. The Group takes safety seriously – our Made-in-India models have achieved full 5-star safety ratings, and we are committed to extending that safety beyond our cars to the roads we share. The NH 19 Zero Fatality Corridor with SaveLIFE Foundation shows that when engineering, enforcement, training, and awareness come together, lives are saved. This measurable impact strengthens our vision of a self-reliant India, where independence also means the freedom to travel without fear.”

This is the second Vision Zero Fatality Corridor project supported by SAVWIPL, following the Mumbai–Pune Highway initiative, which achieved a 61 percent reduction in fatalities.

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The Indian automotive industry has again shot back in the green with wholesales of 1.97 million vehicles sold in July 2025, which is 7 percent higher compared to 1.84 million units sold last year. This also marks a 2 percent growth over last month, when a total of 1.93 million vehicles were sold in the country.

Interestingly, the passenger vehicle segment has reported a slight decline with 340,772 units sold, as against 341,510 units sold last for the same period last year. On the other hand, compared to the previous month, the segment clocked a 9 percent growth. SUVs continue to power the segment with a total of 192,763 units sold last month.

The three-wheeler segment, with wholesale of 69,403 units, reported a healthy 17 percent growth YoY and 12 percent growth MoM.

The two-wheeler segment witnessed a total of 1.56 million units being sold last month, which was 9 percent higher compared to last year, but a flat growth over June 2025. While scooter and motorcycle sales grew at 16 percent and 5 percent on a year-on-year basis, respectively, the motorcycle segment witnessed a 10 percent decline over last month.

Going forward, the automotive industry is expecting the healthy monsoon, rural sentiment and the beginning of festival season to drive growth further.

Rajesh Menon, Director General, SIAM said, “All vehicle segments posted stable performance in July 2025, though overall sentiments in the Passenger Vehicles segment has remained subdued so far. Three Wheelers posted their highest ever sales of July in 2025, with a growth of 17.5 percent as compared to July 2024. With the advent of the festive season beginning with Onam festivities in the latter part of August, the Indian auto industry remains cautiously optimistic for the demand momentum to pick up in the coming months.”

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Tata Motors (TML) has announced its financial results for the quarter ending June 30, 2025. The company's consolidated revenue was INR 10,440 billion, a 2.5 percent decrease from the previous year.

The company shared was a challenging quarter for the company, as it was impacted by a decline in volumes across all its businesses and a drop in profitability, particularly at Jaguar Land Rover (JLR).

The consolidated reported a net profit of INR 40.03 billion, which was supported by a sharp reduction in finance costs. The free cash flow for the automotive sector was a negative INR 1,230 billion, primarily due to adverse working capital from seasonality and tariffs.

JLR delivered its 11th consecutive profitable quarter, despite challenging global economic conditions. JLR's revenue was GBP 6.6 billion, a 9.2 percent decrease compared to Q1 FY2025. The company's profitability and cash flow were directly and materially impacted by the application of 27.5 percent US trade tariffs on UK- and EU-produced cars exported to the US. The decrease in profitability was also influenced by foreign exchange headwinds. However, a newly signed UK-US trade deal, effective from 30 June2025, is set to reduce tariffs on UK-produced vehicles exported to the US from 27.5 percent to 10 percent. The EU-US trade deal, announced on 27 July 2025, will also reduce tariffs on JLR’s EU-produced vehicles exported to the US from 27.5 percent to 15 percent. The company's PBT for the quarter was GBP 351 million.

Adrian Mardell, JLR Chief Executive Officer, said, “Thanks to our talented people and the robust foundations we have built at JLR, we delivered an 11th successive profitable quarter amid challenging global economic conditions. We are grateful to the UK and US Governments for delivering at speed the new UK-US trade deal, which will lessen the significant US tariff impact in subsequent quarters, as will, in due course, the EU-US trade deal announced on 27 July 2025. Looking ahead, we remain focused on delivering our transformational Reimagine Strategy, including investing GBP 3.8 billion this financial year to support the development of our next-generation vehicles, including our stunning new electric Range Rover and Jaguar models.”

The Tata Commercial Vehicles (Tata CV) business saw its revenue decrease by 4.7 percent to INR 170 billion. Despite lower volumes, the business maintained double-digit EBITDA margins of 12.2 percent, an improvement of 60 bps. This was a result of better realisations and cost savings. Domestic sales volumes were down by 9 percent YoY, while exports increased by 68 percent. The business reported a net profit of INR 16.17 billion.

Girish Wagh, Executive Director Tata Motors, said, “Q1 FY26 was a challenging quarter for the commercial vehicle industry, with subdued demand across key segments impacting overall performance. We also witnessed a decline in domestic sales volumes, reflecting broader market softness and delayed fleet replacement cycles, while segments like Buses and Vans showed resilience and our International Business delivered growth. Our commitment to product innovation and customer-centricity remained strong. The launch of the Ace Pro mini-truck in multiple powertrain options received encouraging initial market response, reaffirming our focus on delivering relevant and affordable mobility solutions. Despite adverse volumes, the business delivered 12.2 percent EBITDA and healthy ROCE of about 40 percent. The acquisition of IVECO Group is a strategic leap forward in our ambition to build a future-ready commercial vehicle ecosystem. By integrating the strengths of both organisations, we will be unlocking new avenues for operational excellence, product innovation and customer-centric solutions.”

Tata Passenger Vehicles (Tata PV) revenue declined by 8.2 percent to INR 1,090 billion, reflecting softness in industry demand and the transition to new models. As a result, the EBITDA was 4 percent, down by 180 bps. The net loss for the quarter was INR 870 million, with profitability impacted by adverse volumes, realisations and the effect of leverage. However, these negative impacts were partially offset by continuous efforts to save on variable costs.

Shailesh Chandra, Managing Director TMPV and TPEM, said, “Q1 FY26 was a subdued quarter for the passenger vehicle industry, with volume pressures persisting across most segments. Demand softness weighed on overall performance, although the Electric Vehicle category remained a bright spot, supported by new launches and growing customer interest. Our continued focus on customer engagement and portfolio renewal remained strong during the quarter. New launches – Altroz and Harrier.ev –received encouraging initial market response, with their full impact expected to unfold in the coming months. Looking ahead, while the overall industry growth is expected to remain muted, we are confident that our recent and forthcoming series of launches – across ICE and EVs – will enable us to outperform the market and strengthen our position across key segments.”

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