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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Horse Powertrain has introduced the HORSE W30, marking the company’s first production-ready V6 engine, ahead of its official display at the Beijing Auto Show 2026. Known for low-emission powertrain systems, the manufacturer has now applied its expertise in three- and four-cylinder engines to the V6 category for the first time.

The newly developed 3.0-litre engine is positioned as the lightest V6 on the market, weighing only 160 kilogrammes, which is approximately 10 kilogrammes less than its closest competitor. Designed with a hybrid-first approach, the HORSE W30 delivers outstanding fuel economy and efficiency. Its two cylinder rows are offset at a 90-degree angle to lower the centre of gravity, improving installation ease and catalyst layout. The engine can be configured either transversely or longitudinally, allowing broad vehicle compatibility.

Performance specifications include an output range of 350 to 400 kilowatts and torque between 600 and 700 Nm, with a maximum engine speed of 8,000 rpm. Integrated exhaust manifolds and turbochargers mounted directly on the cylinder heads help maximise efficiency. Intended for both mild- and full-hybrid vehicles, the first models featuring the HORSE W30 are expected on roads by 2028.

To showcase the engine’s hybrid-first mindset, Horse Powertrain will also present the new HORSE 4LDHT four-speed hybrid transmission at the Beijing show. Weighing 199 kilogrammes, the transmission is designed for a P1 plus P3 mounting configuration. The P1 motor, which supports the crankshaft and charges the battery, can output between 250 and 300 kilowatts, while the P3 motor for driving support can deliver between 350 and 450 kilowatts.

Horse Powertrain will display the systems at the Beijing Auto Show 2026 in Hall A1, Booth A111. A press conference on its strategic vision and hero products is scheduled for 24 April 2026 at 11:40 AM China Standard Time.

Matias Giannini, Chief Executive Officer, Horse Powertrain, said, “At Horse Powertrain, we believe we can offer automakers unprecedented economies of scale and innovation by consolidating the powertrain production and development pipeline that traditionally would have been replicated by many individual OEMs, allowing everyone in the industry to benefit from best-in-class technologies. The HORSE W30 is clear proof of this concept – bringing our mindset and expertise to a new category, we’ve developed the lightest V6 that was designed from the outset to support hybrid vehicles.”

Fortune Zhao, Chief Technology Officer, Horse Powertrain, said, “The HORSE W30 showcases Horse Powertrain’s technological versatility and represents our first venture into the V6 engine category. Leveraging expertise from our wide portfolio of hybrid-first engines, the HORSE W30 is lighter and more compact than any other V6 currently on the market, all while delivering superior performance. As well as embodying our engineering sophistication, it also highlights our flexibility in providing world-class hybrid solutions to every market.”

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Ferrari has revealed the livery of its 100-foot flying ocean monohull during Milan Design Week, marking a major step in offshore sailing where innovation, aerodynamics and design research converge. The project, named Ferrari Hypersail, emerges from a creative process that blends the Maranello manufacturer’s aesthetic language with cutting edge maritime technology, underscoring a deepening relationship between design, performance and engineering.

The initiative functions as an open innovation platform, merging diverse expertise into a collective effort to redefine nautical possibilities. Key contributors include the Ferrari Tech Team guided by Matteo Lanzavecchia and Marco Guglielmo Ribigini, the Ferrari Design Studio led by Flavio Manzoni and naval architect Guillaume Verdier. Their goal is to transfer into the yachting world the same design philosophy that distinguishes Ferrari’s road cars, balancing constant innovation with respect for form.

In Hypersail, design arises directly from function, with every volume shaped by the interaction of wind, water and speed. As an offshore vessel, aesthetic decisions developed under strict aerodynamic and engineering constraints from the outset. The Ferrari Design Studio worked closely with the engineering team and Verdier to turn hydrodynamic and structural limitations into aesthetic opportunities.

The monohull’s streamlined silhouette recalls the proportions seen in the Ferrari Monza SP1 and SP2. The deck’s coachroof exterior echoes the graphic architecture of the Le Mans winning Hypercar 499P. Surfaces on the deck and coachroof, developed directly by the Ferrari Design Studio, ensure maximum technical efficiency, mirroring the development process of any Ferrari car. Solar panels integrated into the deck and hull sides are walkable with a specific grip, positioned after advanced study of solar exposure during navigation.

For the livery, the studio chose Nuovo Giallo Fly, a yellow shade with deep narrative roots. Historically representing Ferrari’s second soul, Giallo Fly first appeared on the 275 GTB, inspired by Fiamma Breschi, friend of Enzo Ferrari and widow of driver Luigi Musso. The name Fly creates a linguistic link to the vessel’s foiling nature. The carbon fibre hull appears in a new grey variant, Grigio Hypersail, expressing the material’s lightness and performance. The interplay between Grigio Hypersail and Nuovo Giallo Fly evokes Ferrari’s stylistic codes, including the colour separation of the 512 BB, while the Ferrari logo on the sail continues the elongated F motif seen on recent Formula 1 cars and other models.

From 22 to 26 April, Hypersail will be exhibited at the Ferrari Flagship Store in Milan through a dedicated display. The project also includes a lighthouse installation, an exclusive sculpture by the Ferrari Design Studio on the HIGHLINE Milano terrace overlooking Piazza del Duomo, positioning Hypersail as a symbol of future technology and performance in offshore sailing.

Flavio Manzoni, Ferrari Chief Design Officer, said, “Hypersail represented an unexpected opportunity for the Ferrari Design Studio; a challenging objective due to its complexity, which allowed us to extend our creative research into a context different from our usual one. In reality, the Design Studio is not new to this kind of endeavour. In the past, the experience gained in racing car projects, one of the most technologically advanced sectors, has encouraged exploration into more complex fields, allowing us to test ourselves and expand our expertise.”

Matteo Lanzavecchia, Head of Vehicle Engineering at Ferrari and Chief Technology Officer of Hypersail, said, “Hypersail is a vessel unique in scale and technology, engineered to deliver peak performance within an environment as singular and unpredictable as the ocean. This is achieved through its core concept: foiling, made possible by a sophisticated control system, leveraging the expertise gained from our automotive developments, and powered by energy recovered from renewable sources such as wind, solar, and motion. The strategic choice of a monohull arises from the synergy between maximum hydrodynamic and aerodynamic efficiency. Throughout every design phase, the collaboration with the Design Studio allowed us to accentuate and refine Hypersail’s forms and features, establishing it as a definitive benchmark of design and innovation.”

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Amaron, the automotive battery brand under Amara Raja Energy & Mobility, has successfully engaged more than 5,000 mechanics nationwide through its Amaron Boss Mechanic programme, underscoring its dedication to India’s automotive service sector. The company now aims to dramatically expand the initiative, targeting 25,000 mechanics in future seasons.

The four-week on-ground initiative was structured around practical workshop tasks, allowing participants to showcase technical skill, speed, consistency and problem-solving abilities. A grand finale featured the Battery Boost & Endurance Challenge, a rigorous test of accuracy, pace and stamina. Winners were declared in Patna, Indore, Lucknow, Kolkata and Pune, with each receiving a new motorcycle. All finalists earned certificates and branded mementos.

By celebrating mechanics as trusted experts rather than just service providers, Amaron strengthens its grassroots connections across key markets. With plans to scale the programme into one of India’s largest mechanic engagement platforms, the initiative reflects the brand’s enduring promise of reliability and long-lasting performance.

Chandrasekar Radhakrishnan, Chief Business Officer – Automotive and Home Energy Business (India & SAARC), Amara Raja Energy & Mobility, said, “Amaron has built its brand not just through products but through strong relationships at the grassroots level, especially with the mechanic community. Every day, vehicles across India run reliably because of countless acts of quiet dedication by mechanics, and we believe great work happens in the quiet. Through Amaron Boss Mechanic, we celebrate the skill and trust that power the automotive ecosystem. The overwhelming response inspires us to take this initiative to more cities.”

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Horse Powertrain, a global leader in innovative and low-emission powertrain systems, is all set to unveil a new ‘all-in-one’ powertrain, the X‑Range C15 Direct Drive, at the Beijing Auto Show 2026. The unit consolidates a four-cylinder engine, transmission, power electronics and an electric motor into a single shared housing. Designed for rear subframe mounting, double isolated installation significantly improves noise, vibration and harshness.

This system replaces the rear electric drive unit on existing battery electric vehicle platforms. A manufacturer can maintain one common architecture across battery electric, hybrid, plug in hybrid and range extended electric model lines without substantial design or production changes. The X‑Range C15 Direct Drive joins the Horse F15 for front drive units and the Horse C15 range extender.

The 1.5-litre four-cylinder engine comes in two states. A naturally aspirated version produces 70 kilowatts for B and C segment cars. A turbocharged variant delivers 120 kilowatts for larger D segment vehicles and light commercial vans. Both integrate with a dedicated hybrid transmission and two electric motors.

The two motors follow a P1 plus P3 configuration. The P1 motor acts as a generator, outputting 70 kilowatts in the naturally aspirated variant or 110 kilowatts when turbocharged. The P3 motor provides electric traction independently in serial mode or together with the engine in parallel mode, where direct connection boosts efficiency beyond pure serial hybrids.

Depending on automaker needs, the unit can power rear wheels alone or enable all-wheel drive when paired with another electric drive on the front axle. Rear axle placement allows compact exhaust integration, freeing floor space for batteries or passengers. The unit contains a full set of power electronics ready to integrate with a DC‑DC converter, onboard charger and 800-volt booster.

Horse Powertrain will display the X‑Range C15 Direct Drive at the Beijing Auto Show 2026 in Hall A1, Booth A111. A press conference on its strategic vision and hero products is scheduled for 24 April 2026 at 11:40 AM China Standard Time.

Matias Giannini, Chief Executive Officer, Horse Powertrain, said, “The X-Range family of powertrains is about reflecting today’s market realities, allowing automakers to pivot from BEVs to hybrids and range extenders on a single platform, quickly and at scale. The X-Range C15 Direct Drive is an ‘all-in-one’ powertrain, allowing BEV platforms to be converted to HEVs, PHEVs and REEVs with little redesign or tooling changes required, dramatically reducing time-to-market, amortising BEV investments and catering to the diverse array of mobility needs in today’s global market.”

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