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, the country’s largest passenger vehicle manufacturer, has reported its financial results for Q3 FY2026.

The company reported revenue of INR 475.344 billion, as against INR 368.02 billion last year, net profit came at INR 37.94 billion, as against INR 36.59 billion last year. It is to be noted that the net profit was impacted for Q3 FY2026 was impacted due to a one-time provision of INR 5,939 million relating to new Labour Codes.

During the period, the company achieved its highest quarterly domestic sales of 564,669 units, an increase of 97,676 units over the previous year. Total sales reached 667,769 units, which included 103,100 units in exports. This performance was supported by a recovery in the car market following GST reform, with the small car segment in the 18 percent GST bracket contributing significantly to the volume increase.

For the nine-month period from April to December 2025, the company recorded its highest sales volume, net sales and net profit. Total sales volume reached 1,746,504 units, with domestic sales at 1,435,945 units and exports at 310,559 units. Net sales for this period increased to INR 1,242 billion, while net profit grew to INR 1,085 billion.

Financial statements for the period have been restated following the amalgamation of Suzuki Motor Gujarat (SMG) with MSIL. This process took effect from 1 April 2025. The company continues to monitor market conditions as it manages its manufacturing and sales operations.

The recovery in the car market was led by the small car segment. Sales growth in this category accounted for 68,328 units of the total domestic increase. The company remains focused on domestic and export markets to maintain its sales volumes.

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Volkswagen Passenger Cars India has showcased the Tayron R-Line, marking the first of five product interventions scheduled for 2026.

The company plans to introduce updates or new models in every quarter to maintain market presence. These interventions will include SUV, Sedan and Hatchback body styles, with each model intended for different segments of the premium market.

For 2026, the company stated it has established objectives focused on products, customer engagement and experiences. The strategy involves using product actions to address various customer sets throughout the year. The brand aims to sustain interest through these quarterly releases across its vehicle portfolio.

The roadmap for the year is designed to cover multiple segments, ensuring a consistent rollout of updates. By addressing three body styles, the manufacturer intends to reach a broad audience within the premium category. The initiative forms part of a wider plan to enhance the ownership experience and interaction with the brand in India.

Nitin Kohli, Brand Director, Volkswagen Passenger Cars India, said, “Today, we are glad to showcase the Tayron R-Line for the first time in India. I am also delighted to announce that we have planned four more product interventions throughout the year. This year, every quarter will witness a new product intervention that will cater to a different premium customer set. Our objective is to continue building excitement for customers through smart product actions and introducing models that will continue to build aspirations.”

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Renault India has revealed the new generation Duster in Chennai, marking the return of the nameplate to the Indian market. The vehicle is the first product launched under the Renault International Game Plan 2027, a strategy positioning India as a hub for the company's operations outside Europe.

The SUV is built on the Renault Group Modular Platform (RGMP), with 90 percent of its components designed specifically for the Indian market. The vehicle features a 2,657 mm wheelbase and 212 mm of ground clearance, with approach and departure angles of 26.9deg and 34.7deg respectively.

The Duster introduces three engine options, including a hybrid variant for the first time in India. The Strong Hybrid E-Tech 160 pairs a 1.8L engine with a 1.4 kWh battery, designed to operate in electric mode for a claimed up to 80 percent of city driving.

Two petrol options are also available: the Turbo TCe 160, producing 163 PS and 280 Nm of torque and the Turbo TCe 100. Transmission choices include a six-speed manual and a six-speed dual-clutch transmission (DCT) with a wet clutch.

The cabin features a driver-centric layout with a 10.1-inch OpenR Link multimedia system. This system incorporates Google built-in, providing native access to Google Maps, Assistant, and the Play Store. A second 10.25-inch TFT display serves as the instrument cluster, capable of replicating navigation data.

Additional interior features include:

• Ventilated and electric front seats.
• Dual-zone automatic air conditioning with a PM2.5 air quality filter.
• Panoramic sunroof and electric tailgate.
• 17 Advanced Driver Assistance Systems (ADAS) functions.

Fabrice Cambolive, CEO, Renault Brand, said, “As part of the Renault International Game Plan 2027, we are making India a key pillar of our growth outside Europe. We now have a strong ecosystem in Chennai, bringing together design, engineering, manufacturing, and local operations at the highest level - making India one of the most complete and powerful hubs in Renault’s global network. The new Renault Duster is the first step in Renault’s renewal in India.”

Stephane Deblaise, CEO, Renault Group India, added, “With the new Renault Group Modular Platform, Renault brings an advanced hybrid technology and top-tier safety engineering. With Renault Forever program, we also offer our customers a significantly improved ownership experience. New Renault Duster is the start of a renewed product cycle and for an exciting trajectory for Renault in India. Renault is back.”

The vehicle comes with an industry first 7-year or 150,000 km warranty under the Renault Forever programme. Pre-bookings are open via the 'R Pass', with official pricing expected in mid-March 2026. Deliveries for petrol variants will commence in April 2026, while the Strong Hybrid version is scheduled for release during Diwali 2026.

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Stellantis-owned electric vehicle brand Leapmotor recently showcased its new range of product offerings at the Brussels Motor Show.

The OEM utilised the platform to display its latest vehicle technologies and models as part of an expansion strategy within the European market. The lineup featured both battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs) equipped with range extenders.

The event saw the European debut of the B03X, a model designed to showcase the brand's approach to electric technology. Additionally, Leapmotor provided the first public viewing of the B05 interior, highlighting a design philosophy focused on digital integration and materials.

Leapmotor launched the B10 Hybrid EV, which employs a range extender system. Unlike conventional hybrids where the internal combustion engine frequently powers the wheels directly, this architecture uses the electric motor as the sole source of propulsion. The engine serves as a generator to produce electricity for the battery when required and is never mechanically connected to the drivetrain.

This configuration is intended to provide the torque and noise levels of a pure electric vehicle while addressing infrastructure limitations and range anxiety. The system manages energy automatically, allowing for long-distance travel without a reliance on fast-charging stations. Leapmotor positions this solution as a practical transition for regions with varying levels of electrification readiness.

In a standard HEV, the engine drives the wheels, with the electric motor acting in a supporting role. Conversely, Leapmotor's system maintains a consistent electric driving experience because the engine does not provide mechanical drive.

By removing the mechanical complexity of traditional hybrid drivetrains that switch between multiple modes, the company claims a more refined operation. The range extender is designed to operate only in ideal conditions to optimise efficiency and reduce noise.

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