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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VinFast India, one of the youngest electric vehicle manufacturers in the country and part of the Vietnamese conglomerate VinFast Group, has appointed Amit Arora as its new Director – O2O (online-to-offline) Sales.

In his new role, he will be responsible for building VinFast India’s retail presence, focussing on converting digital leads into actual sales.

Arora has more than two decades of experience in the automotive industry across marketing and sales functions. Till recently, he was the Head of Marketing for V-Green, part of VinFast Group, focusing on building the company’s brand presence, customer acquisition and support business growth in the EV charging ecosystem.

He also oversaw brand positioning, campaigns, partnerships and demand generation across segments.

Prior to that Arora, spent close to 11-years at Maruti Suzuki India as Senior Manager for International Markets, focussing on the Latin America and Oceania region. He also spent around 6 years of his career at Hyundai Motor India and rose to the ranks of Head of Sales Marketing Strategy.

Arora is a Commerce Graduate from Shaheed Bhagat Singh College and also holds a Postgraduate Degree in International Business from Birla Institute of Management Technology (BIMTECH).

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Aprilia Racing and Monster Energy have announced a multi-year partnership during the Grand Prix of Italy. The agreement initiates a collaboration between the two brands starting from the 2026 season, with Monster Energy scheduled to elevate its involvement to become the team's title sponsor for the 2027 championship.

Under the agreement, Monster Energy’s three-claw logo will be displayed on the factory Aprilia RS-GP bikes, rider leathers and official team assets. The arrangement marks the first time Aprilia Racing has signed a title sponsor for its premier class campaign.

The partnership coincides with a period of competitive growth for the Noale-based manufacturer. In 2025, Aprilia established itself as the European manufacturer with the most wins in FIM Grand Prix history, securing third place in the riders’ championship with Marco Bezzecchi and second place in the manufacturers' standings. During the 2026 season, the factory team has recorded victories in the opening three rounds, podium finishes across the first five races, a podium lockout at the French Grand Prix, and currently leads the rider, manufacturer and team standings.

Massimo Rivola, CEO of Aprilia Racing, said, “We are extremely happy to announce this partnership with a global company like Monster Energy, who will be alongside us in 2026 as main sponsor and who will take on the role of title sponsor in 2027. This agreement represents a milestone for Aprilia Racing and the crowning moment of our path of success. For this reason, we are particularly proud of this collaboration which will contribute to further reinforcing the ambition of our project. I would like to thank Monster Energy for the trust they have placed in us, and we will do everything we can to ensure that it pays off as we begin this new chapter together.”

Mitch Covington, Senior Vice-President of Sports Marketing, Monster Energy, added, “Partnering with Aprilia Racing marks an exciting step forward for Monster Energy in MotoGP. The team has established itself as one of the most competitive and progressive forces in the championship, and we are looking forward to being part of that journey as it continues to evolve. MotoGP represents the pinnacle of two‑wheel racing, and it remains a key platform for Monster Energy to connect with fans globally. Together with Aprilia Racing, we are committed to elevating that connection and contributing to the continued growth and momentum of the sport.”

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Italian luxury carmaker Maserati hosted an official stamp cancellation ceremony at its historic Viale Ciro Menotti plant in Modena to celebrate the 100th anniversary of its iconic Trident logo and its first competitive motorsport victory at the 1926 Targa Florio.

The event follows an initial official unveiling of the commemorative philatelic asset held on 9 April 2026 at the Ministry of Enterprise and Made in Italy in Rome. The Modena ceremony brought together internal engineers, master artisans, and key regional stakeholders from Italy's ‘Motor Valley’ industrial ecosystem.

The Viale Ciro Menotti facility serves as the historical engineering hub where all Maserati production vehicle platforms have originated. Today, the specialised factory floor manages the high-end assembly lines for the brand's current performance and luxury lineup, including the GranTurismo, GranCabrio, MCPURA and the GT2 Stradale.

The centenary marks a defining milestone in Italian automotive history. On April 25, 1926, the Maserati Tipo 26 made its competitive track debut at the gruelling Targa Florio endurance race. Driven by co-founder Alfieri Maserati, the car secured a class victory while displaying the Trident logo on its front bonnet for the first time.

The emblem was originally sketched by Mario Maserati, an artist and the only brother not deeply involved in mechanical engineering, who drew inspiration from the Fountain of Neptune in Bologna, where the company was first founded in 1914.

The newly issued stamp is part of the Italian government's ‘Excellence of the production and economic system’ commemorative series.

The graphic profile was sketched by the Maserati Centro Stile design house and finalised by the Philately Centre of the Istituto Poligrafico e Zecca dello Stato. The foreground highlights the clean, contemporary geometry of the modern Trident. The background displays an interconnected pattern of the original 1926 logo layout cast over a classic blue canvas.

Printed by the Officina Carte Valori, the stamp is being distributed by the Italian Post Office (Poste Italiane) for regular postal use alongside a limited-edition collector's philatelic folder.

The cancellation ceremony was attended by prominent regional political and automotive figures, including Vincenzo Colla, Vice-President of the Emilia Romagna Region, Paolo Zanca, Councillor for Economic Activities at the Municipality of Modena, Andrea Pontremoli, President of the Motor Valley Association & CEO of Dallara Group, Sen. Stefano Corti, Board Member of the Istituto Poligrafico e Zecca dello Stato, Barbara Negroni, Head of Regional Branches, Italian Post Office, Santo Ficili, COO, Maserati and CEO, Alfa Romeo.

Santo Ficili, said, “Today, we welcome this special stamp to our home in Modena, to celebrate not only the Trident's centenary but also the beginning of an extraordinary all-Italian story. I would therefore like to thank the women and men of Maserati, our dealer network, our customers and all the stakeholders who contribute every day to the brand's growth in over 70 international markets."

"With its long-standing vocation for motorsport, this local area formed the roots of our extraordinary Brand, the longest-standing in the entire Italian Motor Valley, with the ability to bring to the world a unique vision of performance and driving pleasure. A strong, unbreakable bond that continues to guide our commitment to this community and to generate new opportunities for growth for the local area and its inhabitants,” he added.

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Hyundai Motor India, one of the leading passenger vehicle manufacturers, has appointed Gaurav Mathur as its new Vice-President and Head of Corporate Planning.

He joins the company after spending over two decades at Maruti Suzuki India, rising from the ranks of Assistant Manager in June 2004 to Vice-President EV Development in April 2024.

Mathur was instrumental in leading Maruti Suzuki India’s electrification plans, including the introduction of the e-Vitara.

In his new role, he will be responsible for driving strategic growth across corporate planning, business transformation, export expansion from India, future mobility business and innovation initiatives. He will also work closely on innovation and startup ecosystem partnerships, future mobility business initiatives, including AI and connected technologies.

“With India emerging as a key global hub for innovation and manufacturing, the focus will be on building future-ready capabilities that support sustainable growth and meaningful progress for humanity,” said Mathur.

Mathur is a Mechanical Engineer from Delhi College of Engineering and holds a Master's in Business Administration (MBA) – Marketing & Strategy from Management Development Institute, Gurgaon.

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