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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SPARX Group Co., (SPARX) has announced the establishment of the Mirai Creation Fund IV (Fund IV), with initial capital from major Japanese financial institutions and Toyota Motor Corporation. The fund targets total commitments of JPY 100 billion by March 2027 and is scheduled to begin investment operations in June 2026.

The fund marks a strategic evolution from its predecessors by integrating the investment scope of the Space Frontier Fund into the Mirai Creation framework. Consequently, Fund IV will focus on four key technology categories: Intelligent Technologies (including AI), Robotics, Carbon Neutrality and Space.

Fund IV is backed by five core participating companies – Toyota Motor Corporation, Sumitomo Mitsui Banking Corporation (SMBC), MUFG Bank, Mizuho Bank and SPARX – with an initial combined investment of approximately JPY 15 billion. The fund will be managed by SPARX Asset Management Co, a subsidiary of SPARX.

The fund aims to accelerate innovation by investing in unlisted venture companies, both within Japan and internationally, that possess transformative technologies. The inclusion of Space as a core category reflects a broader strategic integration, following the 2024 launch of the Space Frontier Fund II, aimed at leveraging space-related technologies to drive terrestrial growth and sustainability.

This move continues a decade-long partnership between SPARX and Toyota, which began with the first Mirai Creation Fund in 2015. Since then, the funds have raised over JPY 177 billion and invested in more than 150 companies globally, focusing on technologies that address critical social issues and promote human well-being

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Maruti Suzuki India, the country’s largest passenger vehicle manufacturer, has announced the launch of DesignXathon 2026, the second edition of its flagship automotive design challenge.

The competition is open to students from Indian and global design institutes based in India, offering a platform to showcase futuristic mobility concepts.

The theme for this year's challenge is ‘Envision an iconic vehicle, Gen Z and Alpha aspire to own in 2036.’ Participants are tasked with designing a vehicle tailored for the 2035-2040 period, focusing on lifestyle relevance, sustainability and the integration of design philosophy with emerging technology.

DesignXathon 2026 will have cash rewards of up to INR 450,000, the winners have the opportunity to secure a 6-month internship with the Maruti Suzuki design team. The top 25 shortlisted teams will receive direct mentorship from experienced automotive design professionals. The last date for application submission is 13 July 2026.

The inaugural 2025 edition saw participation from over 400 students across 70 institutes, with winners emerging from the MIT Institute of Design, VIT Vellore and Strate School of Design. Currently, eight students from the first edition are undergoing internships with the company.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India, said, “Automotive design goes far beyond aesthetics; it is a blend of innovation, creativity, and fresh perspectives. I strongly believe that young minds play a pivotal role in challenging conventional design thinking and shaping the future of mobility. Through DesignXathon, we aim to nurture emerging talent and lay the foundation of a strong design ecosystem in India.”

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Prime Minister Narendra Modi outlined a transformative vision for India’s automotive and energy landscape, urging a strategic pivot toward alternative fuels and improved logistics to shield the economy from global volatility.

The Prime Minister was addressing a significant gathering in Telangana on Sunday, speaking against the backdrop of the ongoing West Asia energy crisis.

He emphasised that India’s automotive sector is central to navigating current geopolitical headwinds and highlighted the ‘unprecedented progress’ in ethanol blending, positioning it as a cornerstone of India’s sequential energy diversification strategy.

The Prime Minister detailed the government’s evolution in fuel management, noting that the initial push for universal LPG coverage has paved the way for a more sophisticated energy mix.  

The government is aggressively promoting CNG-based transport systems nationwide to provide a cleaner, cost-effective alternative to traditional liquid fuels.

"The need of the hour is to use petrol, gas, and diesel with great restraint," Modi asserted, framing energy conservation as a matter of national security. He noted that judicious consumption is essential to ‘save foreign currency and reduce the adverse effects of war crises.’

On the infrastructure front, the Prime Minister underscored the massive INR 1,750 billion allocation toward National Highway development. This 12-year investment trajectory has yielded significant results for the automotive and logistics sectors, particularly in southern India.

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German automotive luxury brand Porsche has announced the closure of three subsidiaries, as part of its strategic realignment to refocus on its core business.

The move comes following the sale of its stakes in Bugatti Rimac and the Rimac Group.

The strategic decision affects more than 500 employees across –

• Cellforce Group: Based in Kirchentellinsfurt, the battery cell specialist no longer fits the company's ‘technology-open’ powertrain strategy. An estimated 50 employees are set to be affected.
• Porsche eBike Performance: Operations at sites in Ottobrunn and Zagreb will be discontinued due to shifting market conditions for e-bike drive systems. This affects around 350 employees.
• Cetitec: The Pforzheim-based software developer, which specialised in data communication, will be closed. The move affects 60 employees in Germany and 30 in Croatia.

The management of these subsidiaries will now begin discussions with relevant works councils to manage the closures. The integration of software scopes from Cetitec is expected to align with Porsche’s broader restructuring of its Research and Development division.

Dr. Michael Leiters, Chairman of the Executive Board of Porsche, said, “Porsche must refocus on its core business. This is the indispensable foundation for a successful strategic realignment. This forces us to make painful cuts — including our subsidiaries.”

This restructuring follows yesterday's announcement regarding the suspension of the Car-IT division and its integration into the R&D department under Dr. Michael Steiner. The company continues to adapt its industrial footprint to navigate what it describes as a challenging phase of transformation in the automotive sector.

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