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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Mumbai-headquartered SUV major Mahindra & Mahindra has upgraded its popular offering, the Scorpio-N Z8L variant, with Level 2 Advanced Driver Assistance Systems (ADAS) tech.

This will see the Scorpio-N Z8L variant coming with Forward Collision Warning, Automatic Emergency Braking, Adaptive Cruise Control with Stop & Go, Smart Pilot Assist, Lane Departure Warning, Lane Keep Assist, Traffic Sign Recognition and High Beam Assist features.

The ADAS tech will further enhance safety quotient for the Scorpion-N with exclusive features such as Speed Limit Assist and Front Vehicle Start Alert, marking a first for Mahindra ICE SUVs.

Furthermore, the company has also expanded the Scorpio-N line-up with the introduction of the Z8T variant at INR 2.02 million. The new variant will sit between the Z8 and Z8L variants. It comes with a compelling mix of premium features, including R18 diamond-cut alloy wheels, a 12-speaker Sony-branded audio system, front camera, front parking sensors, 6-way powered driver seat, electronic parking brake (EPB), ventilated front seats and an auto-dimming IRVM.

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Maruti Suzuki India, the country’s largest passenger vehicle manufacturer, has achieved a new milestone in its aftersales service. The company recorded servicing (free and paid) over 2.45 million vehicles in May, the highest in a single month in its history.

The feat was achieved through the company’s vast network of over 5,400 service touchpoints.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India, said, “This is the first time in the company’s history that we have serviced over 24.5 lakh vehicles in a month, an achievement that reflects scale, depth, and efficiency of the service network. It is a result of the tireless efforts of our service teams and dealer partners across the country.”

“Good quality aftersales service is critical to maintain vehicle health, leading to a delightful car ownership experience and strengthen customer retention. Even before we started mass sales of vehicles in India, our focus was on building a robust service network, a foundation that continues to support us as we expand our business further. Going forward, we aim to expand our service touchpoints to 8,000 by FY 2030-31 and introduce innovative formats to cater to the requirements of diverse customer needs. This will help in our EV launch as well. We are preparing 1,500 EV enabled service workshops covering over 1,000 cities with specially trained manpower and special equipment to extend all EV related support to our customers,” he said.

Maruti Suzuki India has through its dealer partners introduced several innovative and industry-first service formats, to address the smallest query to full-car service needs ranging from traditional brick-and-mortar workshops to mobile workshops. Over the years, it has also created a dedicated Quick Response Team (QRT) to provide emergency on-road assistance across the country.

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Mercedes-Benz India, the German luxury car brand, has announced a significant organisational change, effective from 1 August 2025, with the appointment of Brendon Sissing as the new Vice-President of Sales and Marketing. He will take over from Lance Bennett, who has moved to Mercedes-Benz Middle East as their Chief Financial Officer.

Santosh Iyer, Managing Director & CEO, Mercedes-Benz India, said, "We are excited to welcome Brendon Sissing as the Head of Sales & Marketing for Mercedes-Benz India. Brendon takes over the responsibility from Lance Bennett, who has joined Mercedes-Benz Middle East as the CFO. Brendon brings rich experience from the world of financing and insurance, as he successfully steered Mercedes-Benz Financial Service India, doubling its portfolio, driving record profit and business transformation, while elevating the integrated customer journey. We are confident Brendon will continue the growth momentum of Mercedes-Benz in this highly diverse and dynamic Indian luxury car market. We thank Lance for his immense contribution and wish them both, the very best in their respective new roles."

Brendon Sissing previously served as the Head of Mercedes-Benz Financial Services India, where he was instrumental in doubling the company's portfolio and achieving record profits. He is recognised for his strong advocacy of digital transformation and risk management, leveraging his expertise in credit risk to drive operational excellence. He has extensive experience within the Mercedes-Benz group, having worked with Mercedes-Benz Malaysia and Mercedes-Benz South Africa, leading Credit Operations in both markets. He also held roles in Credit Underwriting and Key Accounts at Daimler Mobility, Stuttgart, before joining Mercedes-Benz Financial Services India in 2022.

The German brand stated that under Sissing's leadership, Mercedes-Benz Financial Services India significantly enhanced customer journeys through integrated online and offline platforms. He is also noted for his passion for coaching and mentoring, fostering high-performing team environments. Sissing holds a B. Tech degree in Cost & Management Accounting from Technikon Pretoria, South Africa and a Diploma in Credit Management from the Institute of Credit Management. He is also a founding member of Mercedes-Benz Services Malaysia, established in 2012.

A South African national, Sissing has worked in various international locations, including Malaysia, South Africa, Germany and India.

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Honda Cars India has launched a new variant of its popular mid-size sedan, the Honda City Sport, adding a dynamic and youthful edge to the City line-up. Priced at INR 1.48 million (ex-showroom, Delhi), the City Sport is positioned as a limited-edition offering designed to appeal to style-conscious, spirited drivers.

The new variant will be exclusively available with a CVT automatic transmission and is offered in three colour options — Radiant Red Metallic, Platinum White Pearl, and Meteoroid Gray Metallic.

Sporting a blacked-out exterior theme, the car features a Sporty Black Grille, Glossy Black Shark Fin Antenna, Trunk Lip Spoiler and multi-spoke grey alloy wheels. Inside, the cabin gets an all-black treatment with red stitching, leather seats and ambient lighting for a premium, performance-inspired feel.

Under the hood, it retains the 1.5L i-VTEC petrol engine, delivering 121 PS and 145 Nm of torque, with a claimed fuel efficiency of 18.4 kmpl. The model also comes equipped with Honda Sensing, the brand’s advanced driver assistance suite.

Kunal Behl, Vice-President, Marketing & Sales, Honda Cars India, said, “The new City Sport has been crafted to meet the aspirations of young buyers who value individuality and a spirited driving experience. It embodies a perfect blend of sporty exterior and interior style, fun to drive performance and the everyday usability that Honda City is known for, at a price that makes it even more compelling.”

The City Sport is being positioned as a limited-unit, exclusive edition for customers seeking distinction in both design and driving dynamics.

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