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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The automotive industry world over faces significant sustainability challenges, including high carbon and other particulate emissions, depleting resources, supply chain complexities and slower pace of transition to cleaner and greener mobility. Indian automotive industry over and above has additional challenges, where gaps in recycling infrastructure, hazardous waste disposal and end-of-life vehicles (ELVs) management further obstructs sustainability in the sector. The balance between cost and greener technologies is much trickier to handle.

To bring national attention to this burning topic, a Sustainable Mobility Conclave 2025, is planned at NATRAX, Indore, which isn’t just another conference but a movement to reimagine, redesign and reinvent how Indian automotive carve out its sustainable future path.

The mission: A circular, sustainable and low-emission future

With its core theme, ‘Recycling, Circularity and Sustainability in Mobility’, the conclave seeks to align the Indian automotive ecosystem with global best practices on environmental responsibility. The event aims to be a catalyst for change – putting focus on how vehicles and its associated components are designed, manufactured, consumed and, ultimately, responsibly retired.

In view of the End-of-Life Vehicle (ELV) Management Rules and a rising need for compliance under Extended Producer Responsibility (EPR), the conclave arrives at a critical juncture.

Why this conclave?

India is poised to witness 80 million EVs on the road by 2030. But without parallel efforts in circular economy practices, recycling infrastructure and emission reduction, green mobility may not be truly green. The European Union already recovers 95 percent of vehicle materials from scrapped vehicles, a benchmark India must realistically chase.

Switching to recycled materials, embracing bio-based alternatives and integrating green energy into manufacturing are not just environmental mandates anymore – they are strategic business moves. Reduction in import dependency and a stable supply chain is the need of the hour.

What to expect?

This two-day summit is designed to bring together a powerful mix of automotive manufacturers, recyclers, government leaders, startups and academic minds. And the agenda? Packed with purpose.

Day 1 highlights:

• Session 1: Circular economy lessons – Tapping into waste as a resource, with a strong focus on e-waste, industrial scrap and auto components.
• Session 2: Nature’s waste into products – How bamboo, fruit pulp, seaweed and more are being transformed into auto-grade materials.
• Session 3: From policy to practice – Bridging gaps between regulation and action; featuring deep dives into ESG, green data centres and the Right to Repair.
• Session 4: Industry success stories – Real-world case studies from top OEMs on implementing sustainable systems.

Day 2 focus areas:

• Session 5: Beyond metals – Innovation in plastic, rubber and fibre reuse.
• Session 6: Sustainability education – Building a green-ready workforce.
• Session 7: Organisational sustainability – How automotive companies are embedding sustainability into their DNA.
• Session 8: Leadership reflections – A unique dialogue on the societal impact of green mobility transitions.

Join the movement

The Sustainable Mobility Conclave 2025 isn’t just about talks. It’s about transformation. Whether you’re an OEM, policymaker, recycling expert, student or sustainability advocate, this is where the narrative of Indian future mobility is getting actively debated and jointly co-created.

Because sustainability isn’t a choice anymore. It’s the only road ahead!

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Japanese auto major Honda Motor Co recently established a new retail finance company in India, christened ‘Honda Finance India’. The new company will provide customers with retail sales financing services, including loans and lease sales options for Honda products in India.

The automaker states that with demand for two-wheelers and four-wheelers set to grow in India, there will be a significant growth opportunity for retail finance too. Till now, retail sales financing services has been primarily done by local financial institutions in India.

However, Honda aims to further strengthen its business in India by offering its own sales financing services through a local subsidiary in India. For this, Honda Finance India is applying for a Non-Banking Financial Company (NBFC) license to conduct financial services business in India.

The Japanese company states that for it financial services business has been one of the main business areas and it has established local subsidiaries specialising in retail sales financing services in Japan and various countries in key regions such as North America and Europe. With the establishment of the new company, India became the ninth country where Honda has a local subsidiary to offer financial services.

Going forward, in anticipation of the global expansion of software-defined vehicle (SDV) sales in the future, Honda is looking into opportunities to offer new financial services designed to increase customer satisfaction and the value of the customer experience using various data from Honda SDVs.

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Rakesh Srivastava, the former Managing Director of Nissan Motor India, has been appointed as a Partner at Helyxa Consulting Group, a newly launched firm of senior professionals. Srivastava joins a team with over 150 years of collective experience from top-tier companies across various industries.

Helyxa Consulting Group, which was established on India's Independence Day, is focused on enabling India's growth journey and building a ‘Viksit Bharat’ in line with the vision of a USD 30 trillion economy by 2047. The firm aims to accelerate the growth of Indian companies by providing services in key areas including – AI Transformation, Board Advisory, Deals & Partnerships, Innovation in Entrepreneurship, Leadership & Culture Transformation and Planning & Process Transformation.

Srivastava will work alongside other key partners, including Managing Partner Bhanu Sharma, former President and Global Head of HR and IT at Tega Industries, and Partner Raman Madhok, a board member at Johnson Controls Hitachi and former Joint Managing Director and CEO of JSW Steel. The leadership team also includes Bindu Bhatia and Harish Bhatia.

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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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