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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Ashok Leyland Foundation is expanding its education-focused corporate social responsibility (CSR) initiatives with an ambition to reach a million learners across India, betting that community-led implementation and teacher capacity building can help bridge persistent learning gaps in government schools.

The foundation, which has impacted more than 626,000 students in FY2025-26 and over 910,000 lives overall, is scaling its flagship Road-to-School and Road-to-Livelihood programmes across multiple states.

The initiatives focus on foundational literacy and numeracy, digital literacy, career guidance, sports, wellness and life skills primarily for students from underserved communities.

While India has made significant investments in school education, the biggest challenge lies not in curriculum design but in execution, according to T Sasikumar, Chief Operating Officer, Ashok Leyland Foundation.

“The government curriculum and the programme content are top class. Most governments have excellent curriculum. It is only the implementation part where the failure actually happens,” Sasikumar told Motoring Trends.

According to him, two structural issues continue to affect learning outcomes in many parts of the country viz-a-viz teacher availability and teacher commitment.

“The two gaps that we see today are the availability of qualified, competent teachers and the commitment levels in schools. Otherwise, the curriculum in the country for school children is excellent,” he said.

The challenge becomes more acute in remote districts, where sanctioned teaching positions often remain vacant in practice.

“When you move to Jharkhand or interior Uttar Pradesh, you'll find teachers are on the rolls but never come to the school," Sasikumar said.

The foundation has adopted a community-based model, recruiting resource persons from villages where the programmes operate instead of relying on external educators to address the problem.

The organisation hires local graduates, teacher-training candidates and in some cases Class XII pass-outs providing them with training before deploying them in government schools.

“After we exit the programme, these young people continue to live in the community and continue to serve it. That has been one of the major successes of our model,” Sasikumar said.

The strategy complements the foundation's Road-to-School programme, which has benefited nearly 492,339 students across 4,234 schools in nine states since 2015. The programme reports a 25-30 percent improvement in literacy and numeracy, a 98 percent transition rate from middle to high school and Grade 10 completion rates of 95 percent exceeding the national average of 85 percent.

Its Road-to-Livelihood initiative is operating across five states and has reached more than 133,700 students by providing career guidance, digital literacy, financial literacy and soft-skills training.

The programme reports that 85 percent of participating students enrolled in higher education of their choice, while more than half of female participants opted for STEM courses.

Beyond deploying community educators, the foundation is also exploring teacher capacity-building partnerships with state governments.

Sasikumar said discussions are underway with the Uttar Pradesh government to train government school teachers using the foundation's pedagogical model.

“The Principal Secretary asked us why we don't train government teachers using our model so that the sustainability part can be taken care of. We are working on teacher capacity-building programmes in states where regulations permit,” he said.

Apart from education, the foundation has expanded its CSR interventions into healthcare and environmental sustainability, supporting children with Type-I diabetes, operating 13 mobile medical units, planting more than one lakh trees and implementing water conservation projects in water-scarce regions.

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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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