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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Birla Carbon is set to showcase its innovative Nanocyl range of multi-walled carbon nanotube solutions at NanoTech 2026 in Tokyo, Japan, held from 28 to 30 January. The company’s presence at Booth 3W-A11 highlights a commitment to providing advanced materials that enhance performance and sustainability for industries including automotive, electronics, energy storage and transportation. Through the Nanocyl brand, a global leader in MWCNTs, Birla Carbon offers formulations that improve material efficiency, enable significant cost optimisation and support energy savings.

A key focus will be the NC7000 MWCNT, recognised for its high electrical conductivity, superior processability and strong mechanical property retention. Its UV resistance and exceptional cleanliness make it suitable for demanding industrial and advanced applications. Beyond the base material, Birla Carbon will showcase specialised engineered formulations that address specific industry challenges. These include thermoplastic concentrates for conductive polymers, elastomer masterbatches for durable static control and epoxy-based systems that improve conductivity with processing flexibility. The portfolio also features eco-friendly aqueous dispersions and specialised solvent dispersions tailored for energy storage applications, responding to the growing demand for sustainable and efficient conductive solutions.

This participation underscores Birla Carbon’s dedication to innovation-led growth and its commitment to developing advanced materials that meet evolving market demands. Visitors are invited to explore how these MWCNT technologies can enable new possibilities and support future growth in their own projects.

Laurent Kosbach, CEO, Nanocyl, said, “Nanotechnology is a powerful enabler of material innovation. Through the Nanocyl range of carbon nanotubes, we are advancing material properties such as electrostatic discharge (ESD), electrical conductivity, mechanical reinforcement and thermal dissipation across a wide range of materials. Nanotech 2026 provides an important platform to engage with global partners and demonstrate how our engineered formulations are already delivering value across demanding industries.”

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Union Minister for Road Transport and Highways Nitin Gadkari has announced the return of the Sadak Suraksha Abhiyan (SSA) 2026. This campaign brings together figures from the film industry to address road safety through a public awareness initiative. The ministry will host a telethon on 25 January in Mumbai to mark the fourth year of the programme.

Notable participants joining the movement include Amitabh Bachchan, Alia Bhatt, Vicky Kaushal, Kay Kay Menon, Shankar Mahadevan and Swanand Kirkire. Data from the ministry shows that India recorded 487,707 road crashes in 2024, leading to 177,175 deaths. Figures indicate that adults between 18 and 45 years old represent over two-thirds of these fatalities.

The theme for SSA 2026 is 'Kartavya' (Duty), which frames road safety as a shared responsibility. The tagline for the initiative is ‘Parvaah Se, Kartavya Tak’. The 2026 edition operates on four pillars: Kartavya (Duty), Kayda (Discipline), Kavach (Shield) and Kranti (Change). These are intended to influence road user behaviour across the country.

Factors contributing to fatalities include overspeeding, rash driving, overtaking, jaywalking and the non-use of helmets and seatbelts. The campaign also highlights the failure to provide assistance during the golden hour. The initiative aims to use conversations and performances to encourage the public to follow road regulations.

The event is designed to move from awareness to action within the road ecosystem. The telethon will be broadcast on CNN-News18 on 25th January from 11:00 am onwards.

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Sue Bai, Chief Engineer at American Honda Motor Co., Inc., has been elected to the SAE International Board of Directors.

She serves as the Director at Large for the 2026-2027 term, Bai is the second representative from Honda to join the governing body. Her appointment follows a career focused on the research and deployment of mobility technologies.

Bai manages the Sustainability & Business Development unit at American Honda. Her previous experience includes leading data business for the Digital Service Development Division, where she analysed transportation data to assist road infrastructure and traffic environments. Since joining Honda R&D Americas in 2004, she has held leadership positions at the Honda Research Institute USA and the Automobile Technology Division.

Within SAE International, Bai has chaired technical committees for Vehicle-to-Everything (V2X) standards. These protocols aim to coordinate safety for vehicles, pedestrians and cyclists. She has also acted as the technical lead for industry-government projects, including the Ohio Smart Mobility Corridor, a test bed for connected safety systems.

SAE International is a global network that develops consensus standards and provides career development for engineers. Bai has been a member for nearly 20 years and has received honours including the SAE Top Contributor of the Year in 2021 and 2022, as well as the James M. Crawford Executive Standards Committee Outstanding Achievement Award.

Bai holds a Ph.D. in Industrial Engineering and a Master of Science in Electrical and Electronics Engineering from the University of Michigan. Her work has spanned Intelligent Transportation Systems (ITS) and automated vehicle research.

Sue Bai, said, “I’m honoured to be elected to the SAE International Board of Directors. SAE plays a vital role in bringing engineers together to solve complex mobility challenges, and I look forward to further contributing to work that advances knowledge and solutions for the benefit of society.”

The SAE Board of Directors oversees the organisation’s mission to connect members through standards and learning opportunities. Bai’s term will focus on the application of engineering knowledge to address mobility issues.

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GreenCell Mobility (GCM), the electric bus platform backed by Eversource Capital, has completed a USD 89 million mezzanine funding round. The investment was provided by the International Finance Corporation (IFC), British International Investment (BII) and Tata Capital. The capital is designated to support the expansion of GCM’s electric vehicle operations across India.

The company currently operates a fleet of more than 1,200 electric buses and 270 charging stations. This funding will facilitate the growth of the fleet to 3,700 units. The expansion includes buses secured through the National E-Bus Programme and the PM Seva E-Mobility initiative. These vehicles will serve routes in Delhi, Madhya Pradesh, Andhra Pradesh, Bihar and Puducherry.

The mezzanine financing structure is intended to catalyse private and institutional capital for the transport sector. By increasing the number of electric buses on intra-city and intercity corridors, GCM aims to address air quality and carbon emission targets. The project also focuses on establishing payment-security models and financing structures that can be replicated in urban transport markets.

GCM functions as an OEM-agnostic platform, allowing it to integrate various bus models into its network. The investment will also fund the development of charging infrastructure required to support the larger fleet, specifically targeting connectivity in tier-2 and tier-3 cities.

Dhanpal Jhaveri, Vice-Chairman of Everstone Group and CEO of Eversource Capital, said, "Through this funding round for GreenCell Mobility, we are deepening our partnership with IFC, BII and Tata Capital (leaders in sustainable investments). The transaction exemplifies the catalytic role that private, development and institutional capital can play in accelerating India’s clean transport revolution. GCM’s expanded operations will drive transformation efficient transportation to cities and commuters while delivering returns."

Devndra Chawla, Managing Director & CEO, GreenCell Mobility, said, "This fundraise marks a significant milestone in GreenCell Mobility’s journey to build electric mobility as a mainstream, scalable public transport solution for India. The participation of IFC, BII and Tata Capital reflects strong conviction in our platform, our operating model, and our ability to execute at scale. As we expand our fleet and charging infrastructure across states under programmes such as PM Seva E-Mobility, our focus remains on delivering reliable, cost-efficient and zero-emission transport for cities and intercity corridors."

Katherine Koh, Regional Industry Manager, IFC, added, “Electrifying buses is central to India’s urban transformation agenda, and our mezzanine investment in GreenCell will accelerate the rollout of sustainable public transport for thousands of people across India’s tier-2 and tier-3 cities. It will create jobs while catalyzing private capital through innovative financing and payment-security models.”

Shilpa Kumar, Managing Director and Head of India, BII, said, “Climate action is a key priority for BII in India, with electric mobility as a key pillar of our climate investment strategy. Electric buses are a critical lever for decarbonising public transport at scale. Our investment in GreenCell Mobility reflects our commitment to supporting proven platforms that accelerate clean mobility.”

Manish Chourasia, Chief Operating Officer, Tata Capital, noted, "Tata Capital is pleased to participate in this strategic investment that accelerates India’s transition to cleaner, more efficient transport. GCM’s innovative approach aligns with our vision for sustainable urban development and inclusive growth.”

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