HMI has 2 plants, established in 1998 and 2007. In the last 5 years both the plants have been augmented for capacity enhancement. This was possible as the assembly lines were initially designed for flexibility in augmentation, expanding to the needs of the following 15-20 years. That has always been the philosophy of Hyundai which is really paying off now; it becomes easier to execute improvements in all their projects.

Consider the body shop where components are accumulated to be worked upon. It is built on global bodyline concepts. Not only volume escalation but also increase in the number of models can be managed effectively. Every day the plant processes 395 tonne of steel coils, globally monitored by ‘Die Management’ system, to make cars with each one having on an average 4,500 spot weldings done by 4^th gen robots. So far the company has manufactured more than 9 million cars using steel coils having a length that could cover the circumference of the earth 4 times. The intelligent weld management system generates about 30.6 million data points per day and the quality is controlled through real-time monitoring. Beginning with making one car every 4 minutes in 1998, the plant currently rolls out a car every 33 seconds.

Ganesh Mani S, Director, Manufacturing, HMI, told Motoring Trends that “we have 12 models now with 350 internal variants. The complexities in these are double challenges for us especially when we take to the next level. We were able to manoeuvre 3 or 4 models 3-4 years ago from a single line. Now it is 7 models. Volumes have also increased from 49 to 66 UPH (unit per hour). We have a two-pronged strategy; one is adding on volumes that can cater to the needs of consumers and, two, the capability for enhancement. Since we have our own Factory Automation companies in the automotive hub of South Korea, we have gone from Generation-1 to Generation-4 of robotics, which brings in a certain amount of flexibility and increase in the speed of execution. With CAFE and other norms, we need to make a model that is robust, which comes from the basic design and the way we build the product.”

Body shops are by and large 100 percent automated and therefore, the company was able to make them intelligent enough to understand, with the fourth generation robots. For every vehicle it is necessary to have resistant spot welding and for every spot there is a specification; this needs to be modified for each new model. The company has introduced intelligent timer controls, which is called MMDI - in the line before spot welding, it checks the number of components and their thickness and the level of current and voltage requirements.

Earlier they were pre-set, but now keep changing at every place. This gives twin advantages. The first is to have multiple components as technologies keep changing; aluminium may come in; high tensile steel welding has already come. At present the plant has about 400 robots with MMDI which have the capability to keep checking every time. Earlier it used to take 40 seconds to complete 30 spots; now within that TAKT time, it is able to make 50 spots increasing the speed of the line.

The second is having Intelligent Vision Control Systems. For instance, sealer has to be applied for vibration, harshness, noise, dust and rust prevention, strength, etc. The system monitors the route it has to follow and checks whether the job is being done properly or not. It ensures quality and traceability of the arrangement.

“Whenever we introduce a new model all we have to do is to make use of the carrier, a hardware that allows robots to move around and make the body parts. Only the carriers need to be replaced as the line operates depending on the types to be made. Earlier we had electric and pneumatic carriers to move across to lift the body and components while in the fourth generation robots at present the individual carrying capacity has been increased multiple times. The entire handling mechanism of conveyors, platforms, holding chains, etc has been replaced by just programming the robots which can handle them. All these save time and make the operation of the body shop more convenient,” he said.

A robot has shelf life of approximately 7 years; as and when replacements are due, new technologies are incorporated into the system. With so much innovation in robotics, the cost of robots is going down. Over the years the company has garnered expertise to the extent that a new robot can be commissioned in 48 hours, when it is needed to augment capacity. The industry average is 7 or 8 days. The supervisors and technicians can do the programming themselves, which also saves cost. Assembly shops have seven or eight major equipment and the company has been able to change or enhance the equipment that is augmented with VFD (variable frequency drive) as and when required. A fall back mechanism is in place to manage demand fluctuations. Robotic multi-skills and flexibility switchover help the line to go on smoothly. When not required some of the robots can be kept in sleep mode to save energy. Like managing absenteeism of people with multi-skills some of the robots can double up while the others can rest. 

On the scope for improvement in enhancing UPH, Ganesh Mani said, “We can manage with this arrangement till 2021. We change regularly our upgradation on various models and try to eliminate defects at the design stage itself. We have a team working on every model and the results are ploughed back at the design stage to remove deficiencies. Also, there is the influx of technology in terms of inspection and robustness of the process. ‘Before’ and ‘After’ is 100 percent mapped for the sealers so there is no question of missing and moving across to the next stage.”

In the body shop the operator has all the available information in front of him. In the assembly shop everything is mapped digitally. The operator looks at a digital display to know which component he has to pick up; he also gets an audio message regarding assembly of parts for rare models. The company has created a Smart Innovation and Automation Team (SIAT) which is one step ahead in process monitoring to ensure that errors do not creep into the system; it makes certain that the operator does not commit a mistake. For instance the lid of containers holding the parts for the specific models will only open when required and at the right station.

Asked what happens if the operator has not taken the required number of parts like fasteners, he said, “We have more than 700 dynamic bolts and nuts that are fitted on the vehicle; any mistake in fitment would create havoc. We have HIVIS (Hyundai Integrated Vehicle Inspection System) which is a tool by itself. The torque values while tightening every nut are registered in the system. Any mistake made triggers an alarm and the vehicle will not be allowed to go to the next stage. The tightening process is monitored in real-time and is coupled with sign-off gate. When there is a process deviation, the system will not allow the car to roll out of the assembly line, thereby ensuring mistake-proof delivery. The system, developed at HMIL, is so intelligent that it is used all over the world. For example, when new trainees come, sometimes cross-threads happen; the torque goes very high and the value is reflected in the torque curve. This helps us take immediate corrective action. One of our engineers developed a ‘gyro metric gun’ that works on the straightness principle. It has a sensor inside, working on the principle of gravitational force; if there is any deviation of line it will not allow the operator to tighten the nut. This is a unique system, being used in all the 32 plants of Hyundai globally.”

How can variability happen? It can happen because of improper training; the company has taken care of this. The other variability is fatigue that could set in and result in the operator making a mistake. To prevent this there is REBA - Rapid Entire Body-movement Analysis - that can calculate the fatigue level in the individual. This information would help improve his comfort level. Meticulous planning has been done for all the stations, upgrading them from category A (with possibility of over 12 risk occurrences) to category D (less than 4), to bring down the risk level. On this platform there are many assist systems for the operator. The company is working on EXO skeleton which is a human-machine interface where a vest is provided to the operator giving him, among other things, elbow support. This makes the process easier and lighter; consistency always gets measured.

Ganesh Mani explained, “We also have vision camera system robotics that can capture 70 frames per minute. It compares the pictures with the original and if there is an error sends the message within a TAKT time of 40 seconds. This is our third layer of inspection. By and large our pass ratio is 100 percent; it is only a fall-back mechanism.”

Though the number of models assembled in one line has substantially increased, the company hopes that it can increase further. In assembly, there can be a high of as many as 240 different models, the maximum in a single line, he pointed out.

However, when the UPH in the body shop is increased it has to match the TAKT time of the assembly line as well. “In a lean production system we don’t want too much of a cushion in the other shops as that would prevent hidden problems from coming out. So we don’t go beyond one additional UPH in the previous shop; in between we have some amount of stock for body storage. Within that we manage our line. Every hour the body shop can create 1 more additional body in the same time required for assembly. In this way we can manage any breakdown or process delay up to 1 UPH. On a cumulative of 22 hours that we run, everyday a cushion of 22 bodies will be available to help us manage any kind of change,” he said.

Industry 4.0

About the possibilities of a smart factory Ganesh Mani said, “As part of our agile manufacturing process in our technologically advanced and digitalised factory we wanted to use Industry 4.0 in a big way. Our initiatives for this have started. We have found out that earlier in a body shop alone close to 1GB of data was generated; today it is 15GB a year from all the modules put together. The next stage is to integrate the data seamlessly and put them on display so that the operator who is multi-tasking can see them easily and monitor them thoroughly. This also helps in predictive maintenance which is the objective of big data. We use this in a 6-8 hour slot on Sundays when the assembly line does not work. Any change can be made then. This phase pre-empts impending failures; we use infrared mechanisms to do this. We also have vibration sensors fitted in the equipment that constantly monitor and give an alarm if something is likely to happen like heating up of the motors. We have a Data Analytics Team that looks into all these and takes preventive action. Today, more than 50 data scientists are working on the shop floor. By 2021 we want to integrate all the shops through this process so that we can predict what could happen. An example of how digitalisation in Industry 4.0 is helping us is in the breaking of equipment; whenever the vacuum levels start going up, the machine stops. To avoid this, by digitalisation we can constantly monitor the control limits to ensure that the equipment works in the programmed range. If it goes beyond the safe level, the system sends an SMS to the maintenance team. This helps the operator to plan and change the machine to a new area.”

Energy Conservation

HMI has completely switched over to LEDs, saving about 40 percent energy required for lighting. “Within 18 months we were able to get back the cost of the whole system. We always ensure that energy efficient motors are used. We are also very careful in using water, especially in places like Chennai where water is scarce. We are into hundred percent rain water harvesting. One mm of rain means a saving of 750 kl of water throughout the plant. We can manage 150 days of production without water from other sources; we are planning for complete independence,” he said. (MT)

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Maruti Suzuki India (MSIL), the country’s largest passenger vehicle manufacturer, has further expanded its product portfolio with the launch of the Victoris SUV.

The Victoris is being made available in multiple powertrain options, including petrol with strong hybrid, Allgrip Select (4x4) and factory-fitted S-CNG with an underbody tank design. Bookings are now open at INR 11,000.

The SUV can be had with a 1.5-litre hybrid powertrain with EV mode and e-CVT transmission, a multi-terrain 4x4 system with four drive modes and a CNG variant with dual ECUs.

The Victoris will join the Brezza, Ertiga, Fronx, Grand Vitara and Jimny to further expand its play in the SUV segment.

The new SUV features a 26.03 cm fully digital instrument cluster, 25.65 cm SmartPlay Pro X infotainment system with wireless Apple CarPlay and Android Auto, over-the-air updates and Alexa Auto integration. It also introduces a segment-first Infinity by Harman 8-speaker system with Dolby Atmos, 64-colour ambient lighting, ventilated seats, powered driver’s seat, wireless charging with cooling and a panoramic sunroof.

On safety, the Victoris comes with six airbags as standard, Level 2 ADAS with more than ten driver-assist features, all-wheel disc brakes, electronic parking brake, and a 360-degree camera. In fact, the Victoris has scored a 5-star Bharat NCAP safety rating for both adult and child occupants.

It comes with Maruti Suzuki India’s Arena Safety Shield, including ESP, ABS with EBD, hill hold control and a standard three-year/100,000 km warranty.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India, said, “The new-age Indian customer is well-travelled, hyper-connected, socially aware, technologically progressive and environmentally responsible. To meet the aspirations of such customers, our new SUV the Victoris has ‘Got It All’. Victoris is a Latin word that means ‘victory’. We are confident the Victoris with its high technology, sleek design, intelligent and connected features, 5-star level safety and multiple environment friendly powertrains will win hearts in India. With Victoris we are strengthening our SUV portfolio and our overall market share.”

Partho Banerjee, Senior Executive Officer, Marketing & Sales, Maruti Suzuki India, said, “At Maruti Suzuki, we are always listening to our customers. Today’s young, and dynamic audience consider an automobile as a reflection of who they are – energetic, composed, confident and always moving forward. We gave this brief to our design and engineering teams for the all-new ‘Victoris’. SUVs may be the most loved segment today, but the SUV buyer has evolved. This new generation of young customers are ambitious, hyperconnected and value experiential living. The all-new Victoris is our answer to that shift - a progressive blend of tech, design and versatility. It is engineered with true SUV DNA and sets a new benchmark for what today’s automobiles can feel like. With the Victoris, we’re not just launching another SUV, we’re celebrating a new dimension to driving - one that’s ‘Got It All’.” 

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In celebration of India's dreamers and their aspirations, Mercedes-Benz India has announced the launch of its comprehensive festive campaign, ‘Dream Days’. Scheduled to run from 2nd September to 31st October 2025, the initiative is designed to make the ambition of owning a Mercedes-Benz more accessible than ever through a suite of tailored ownership benefits and experiential engagements.

The 360-degree campaign focuses on creating signature luxury experiences at every customer interaction. A core component is a range of innovative financial solutions aimed at empowering new and existing customers. For its entry and core model portfolios, Mercedes-Benz is introducing financial plans featuring exceptionally low monthly instalments, attractive interest rates and minimal down payments. First-time buyers will receive additional ‘Welcome Benefits’ when trading in their current vehicle.

Further enhancing flexibility, a unique ‘Seasonal Payment Plan’ allows customers to structure their payment schedules around periods of higher cash flow, such as bonus months, alleviating the burden of uniform monthly payments. A standout ‘Key to Key’ programme for select models like the S-Class enables customers to upgrade to a new vehicle after 24 to 36 months with zero down payment, effectively allowing them to own two new Mercedes-Benz cars within a four-year period.

Complementing these ownership advantages, Mercedes-Benz is elevating its customer service with nationwide ‘Service Clinics’. During these events, trained brand engineers will travel to various locations to provide personalised vehicle diagnostics and address owner concerns directly.

The campaign will culminate in the ‘Dream Days Festival’, a first-of-its-kind event touring six key cities: Chandigarh, Ahmedabad, Pune, Bengaluru, Chennai and Kochi. This two-day festival will offer participants hands-on driving experiences across specially designed tracks that demonstrate the capabilities of the brand’s sedans, SUVs, electric vehicles and high-performance AMG models. Attendees can also enjoy immersive brand experiences, such as the Burmester Sound Experience, fostering a deeper connection with the Mercedes-Benz brand.

Santosh Iyer, Managing Director & CEO, Mercedes-Benz India, said, "India is a nation built on dreams – from startup founders, entrepreneurs to seasoned executives, every dreamer deserves the luxury that they aspire for. This festive campaign, hence, underlines our commitment to fulfil the aspirations of our customers, offering flexible and curated financial solutions, supporting them with their purchase decision. We are confident these financial solutions will find immense value among customers, creating excitement and positive momentum in the market this festive season.”

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Hyundai Motor India (HMIL), one of the leading passenger vehicle manufacturers, has introduced the Creta King and Creta King Limited Edition to mark a decade of its popular Creta SUV in the domestic market. The company has also added new features to other Creta variants.

The Creta King includes features such as R18 diamond cut alloys, a driver power seat with memory function and a passenger seat with electric adjustments. It also comes with a dashcam, wireless Android Auto/Apple CarPlay and dual-zone automatic temperature control. The vehicle is available with a 1.5L petrol, 1.5L diesel and 1.5L turbo petrol engine. A new Black Matte colour is also being introduced.

The Creta King Limited Edition adds exclusive ‘King’ branding on elements like the seat belt cover, headrest cushion and key cover. This limited edition is available in Abyss Black, Atlas White and the new Black Matte colours.

The Creta King Knight, with its black design, also receives upgraded features including R18 matte black alloys, electric seat adjustments for the driver and passenger, a dashcam and dual-zone automatic temperature control.

Tarun Garg, Whole-Time Director and Chief Operating Officer, Hyundai Motor India, said, “At HMIL, we have always believed in delighting our customers with fresh choices and enhanced experiences. Ahead of this festive season, we are excited to introduce the Creta King and Creta King Limited Edition in our SUV, the Hyundai Creta. These additions, coupled with enriched feature offerings in the Creta line up will reinforce our commitment to offering products that blend style, performance, technology and safety. We are confident that these new introductions will add to the festive excitement and further strengthen the appeal of Hyundai’s most loved SUV among Indian customers.”

Additionally, new features have been added across other Creta variants, including a dashcam, dual-zone automatic temperature control and wireless Android Auto/Apple CarPlay. The Creta N Line also gets these new features.

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Honda Cars India has introduced a series of updates to its popular SUV, the Honda Elevate in time for the festive season. The enhancements include new interior colour options and exterior styling upgrades, aiming to give the vehicle a more premium and stylish feel.

The top-of-the-range Honda Elevate ZX grade now features a new Ivory interior theme, complete with ivory leatherette seats and soft-touch inserts on the doors and instrument panel. As an optional extra, customers can choose a new ‘Alpha-Bold plus Grille’ for a more commanding front profile, along with a 360-degree surround vision camera and 7-colour ambient lighting. With these additions, the Elevate ZX offers a choice of three distinct interior themes: Tan, Ivory and Black.

For the V and VX grades, Honda is introducing new black fabric upholstery, which replaces the previous shadow beige option. These variants also feature dual-tone interiors with ivory soft-touch inserts. The new Alpha-Bold plus Grille is available as an accessory for these models and the Crystal Black Pearl colour option is now offered across the V, VX and ZX grades.

Kunal Behl, Vice-President Marketing & Sales, Honda Cars India, said, “The Honda Elevate is a very successful model and has been greatly appreciated by customers for its versatility in both the domestic and export markets. With the introduction of the new ZX grade with ivory interiors and new enhancements across all grades, it is our endeavour to offer more choices to customers during the festive period and warmly welcome them into the Honda family.”

The Honda Elevate is powered by a 1.5L i-VTEC petrol engine and is available with a choice of a 6-speed manual or 7-speed CVT automatic transmission. The SUV continues to offer a range of safety features, including the Honda Sensing advanced driver-assist system in the ZX grade, which includes Collision Mitigation Braking and Adaptive Cruise Control.

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