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 has announced that cumulative exports of its Fronx model have passed 200,000 units in under 38 months following the commencement of overseas shipments in June 2023.

Manufactured at the company's Hansalpur plant in Gujarat, the SUV is exported to nearly 90 markets, including Japan. The Fronx reached its initial 100,000 export milestone within 25 months, with the subsequent 100,000 units shipped over the following 13 months.

Hisashi Takeuchi, Managing Director and Chief Executive Officer, Maruti Suzuki India, said, “Every vehicle exported by Maruti Suzuki carries the hard work and pride of our people. Together, these vehicles take a piece of Indian manufacturing to nearly 120 countries. Fronx has been a key contributor to Maruti Suzuki’s success in exports. Since FY 24-25, it has been India's No. 1 exported passenger vehicle* and is now shipped to nearly 90 countries. After crossing the milestone of 100,000 exports in record time, Fronx reached its second lakh significantly faster, underlining its growing demand in the international markets.”

“Aligned with ‘Make in India, Make for the World’, Maruti Suzuki continues to showcase the prowess of India’s manufacturing ecosystem. Sustained focus on exports has earned the Company the number one position in passenger vehicle exports from India*. Illustrating this leadership, all three of India’s top exported passenger vehicles in Q1 FY 26-27^ were from Maruti Suzuki. The growing export volumes year-on-year are a strong endorsement of the reliability and appeal of the Company’s products across global markets,” added Takeuchi.

The Fronx remains the company's primary export model within its passenger vehicle lineup, supporting its total export volume across international regions.

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Stellantis-owned Jeep India has launched the Jeep Compass 85th Anniversary Edition, limited to 85 units at prices starting at INR 2.67 million (ex-showroom).

The anniversary edition incorporates visual updates to the exterior and interior of the vehicle platform. External changes include 18-inch alloy wheels finished in gloss black alongside anniversary badging. The interior cabin features a black colour scheme paired with gold accents and contrast trim detailing.

Kumar Priyesh, Business Head and Director of Automotive Brands, Stellantis India, said, "The Jeep Compass has always been central to the Jeep story in India, bringing the brand's legendary capability, design and authenticity to customers who expect more from their SUV. As Jeep celebrates 85 years globally, the Compass 85th Anniversary Edition gives this iconic nameplate a distinctive new expression. With exclusive anniversary-inspired styling, curated accessories and safety technologies, this special edition has been crafted for customers who seek a Compass that feels even more personal, intelligent and exclusive."

The vehicle is offered with optional accessory packages under the brand's personalisation options. These packages add functional and cabin features, including sunroof illumination, ambient lighting, a digital inner rear-view mirror and integrated front and rear dashcams. Bookings for the limited-run vehicle have opened across the company's dealership network and online sales platform.

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German luxury car brand Mercedes-Benz India has opened its new sales facility in Lucknow in partnership with dealership operator T&T Motors. The outlet expands the company's network in Uttar Pradesh to 10 touchpoints across cities including Lucknow, Noida, Ghaziabad, Agra, Kanpur and Varanasi, contributing to a national presence of over 150 locations across more than 60 cities.

The new facility occupies 9,000 square feet, including over 5,000 square feet of carpet area and was completed in five months. The showroom accommodates four vehicle display bays, private and semi-private consultation zones, a lounge section for vehicle lines and a dedicated delivery bay. To support battery electric vehicles, the location incorporates a 180 kW DC fast charger with two charging bays, backed by a staff of 88 employees.

Brendon Sissing, Vice-President of Sales and Marketing, Mercedes-Benz India, said, “Mercedes-Benz continues to strengthen its luxury retail footprint across India, reflecting our ‘Go to Customer’ strategy. The inauguration of T&T Motors’ new facility in Lucknow marks yet another important milestone in bringing world-class luxury products, services and experiences closer to our customers. Uttar Pradesh remains an important emerging market for Mercedes-Benz, and the growing aspiration for luxury mobility in Lucknow presents strong growth potential for Mercedes-Benz. Through modern luxury infrastructure, personalised consultations, digital capabilities and EV readiness, we are elevating luxury retail experience for our discerning customers in the city.”

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Mumbai-headquartered automotive major Mahindra & Mahindra has unveiled its first global pick up christened Lifestyler, which will be launched in India as the Mahindra Scorpio Lifestyler. The vehicle will go on sale by April 2027 with prices starting below INR 1.97 million ex-showroom. 

First shown as a concept in Cape Town, South Africa, in August 2023, the pickup was designed at the Mahindra India Design Studio in Mumbai and developed at Mahindra Research Valley in Chennai. It is built on Mahindra’s next-generation body-on-frame architecture and is intended for both payload and lifestyle use. The company claims to have around 267 patents in terms of innovation for the Lifestyler.

Dr Velusamy R, President, Automotive Business, Mahindra & Mahindra, said, “From the outset, our vision was to create a world-class global pickup that raises the bar for the segment while remaining true to Mahindra's strengths in authentic capability and value. The Scorpio Lifestyler is a testament to the strong product development capabilities at Mahindra Research Valley (MRV). Built on our advanced next-generation body-on-frame architecture, it has been engineered to deliver the capability, durability, safety and refinement demanded by customers around the world.”

Pratap Bose, Chief Design and Creative Officer, Mahindra & Mahindra, said, “The Scorpio Lifestyler is inspired by how our customers work, play and explore. Combining bold exterior design, plush interiors and SUV-like comfort with unmistakable Mahindra toughness, it brings style and refinement to every journey. This philosophy is reflected in the three editions showcased today: Valley celebrates purposeful refinement, Reef embodies freedom and exploration, and Trail captures the spirit of boundless adventure. Together, they express our vision of a pickup that celebrates individuality while remaining rooted in capability, authenticity and the freedom to explore without limits.”

Nalinikanth Gollagunta, CEO, Automotive Division, Mahindra & Mahindra, said, “The Scorpio Lifestyler represents the convergence of global engineering and evolving customer aspirations. As we prepare for its India launch, we see a growing appetite among customers for a vehicle that delivers authentic capability without compromising on technology, safety, comfort or everyday usability. We are investing in building awareness, strengthening our network and creating the right ownership experience for this category. We believe the Scorpio Lifestyler has the potential to redefine expectations and shape the future of the pickup segment in India.”

While the technical details are still under the wraps, the company showcased three editions - the Valley Edition finished in Artemis Grey, the Reef Edition uses an Aquareef finish and the Trail Edition finished in Sahara Beige.

The Mahindra Lifestyler is aimed at the midsize lifestyle pickup segment in Australia and New Zealand, South Africa, Africa, the Middle East and Latin America. It has been developed to meet requirements for capability, durability, safety, technology and everyday use across those markets.

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