Euler Motors has launched its first 4-wheeler in the small commercial vehicle (SCV) segment, aiming to meet the growing demand for cost-effective and high-performance inter- and intra-city transportation solutions.

Euler Motors, a leading commercial electric vehicle manufacturer, has disclosed its entry into the small commercial vehicle (SCV) segment with its first 4-wheeler that will offer a payload of a payload of 1000+ kg. Planned for launch in the upcoming festive season. Euler Motors’ new SCV will be designed to meet the growing demand for cost-effective and high-performance inter- and intra-city transportation solutions.

The HiLoad EV, a successful 3-wheeler, is set to launch a 4-wheeler with market-defining attributes. It will offer long driving range, high payload capacity, ergonomic design, and real-time fleet management, important in industries like logistics, FMCG, beverages, dairy, paint, and lubricants, enhancing the driving experience. 

Estimated to achieve a market value of INR 34,900 crore in India by FY2027, the SCV segment is currently dominated by ICE vehicles. While EVs may comprise a smaller share, they are poised to grow the fastest. With EVs, customers can expect significant cost savings and achieve price parity with traditional fuel vehicles, making them a compelling choice for businesses aiming to improve their operational efficiency and sustainability. Help customers achieve not only greater efficiencies and business ROI, but these vehicles will also align with the climate change commitments by the Government of India.

 Saurav Kumar, Founder & CEO of Euler Motors, said, “Commercial electric vehicles must cater to the needs of various industries, accommodating diverse volumes, payloads, and ranges. Our vision is to develop vehicles that seamlessly integrate into all industry verticals. Our study of retail and institutional customers in the SCV segment reveals that a significant number are eager to switch to or purchase EVs that deliver high performance, extended range, and advanced features to elevate the driving experience and optimise fleet management. This new 4W vehicle is a milestone, as it will meet all these criteria, making it the perfect, trustworthy companion for both long and short cargo transportation journeys.” 

Euler Motors’ expansion into the SCV segment, highlighted by several industry-first features, aligns with its mission to accelerate the adoption of electric vehicles, and to promote sustainable urban mobility – through innovation designed for and from India.

Kaustubh Deshpande, Founding Partner, Imoto

Passenger Vehicle sales dwindled slightly, but auto manufacturing showed resilience in July 2024, with strong growth in the Two-Wheeler and Three-Wheeler segments. The industry adapts and eyes the festive season for renewed momentum.

The automotive sector witnessed active production of Passenger Vehicles, Three-wheelers, Two-wheelers, and Quadricycles, reaching 2,437,138 units in July 2024. This production figure captures the capabilities of the automotive manufacturing sector to serve domestic and international demands despite challenges in certain segments.

In July 2024, passenger vehicle sales stood at 341,510 units, reflecting a slight decline of 2.5 percent compared to July 2023. 59,073 three-wheelers were sold, marking a 5.1 percent increase over the previous year. Sales reached 1,441,694 units, showing a healthy growth of 12.5 percent for two-wheelers.

The Passenger Vehicle segment decreased due to external economic factors and market saturation in certain areas. The financial crunch and the expectations of subsidy extension in budget announcement further.

Passenger Carrier subsegment saw an 8.7 percent increase in sales. This growth can be linked to the sector’s adaptive manufacturing processes and the rise in demand for efficient urban transport solutions.

The two-wheeler segment has been a stronghold of the Indian auto industry and saw a substantial 12.5 percent growth. This increase was driven by a 29.2 percent rise in scooter sales compared to last July.

The auto manufacturing sector has shown remarkable adaptability, especially in the Two-Wheeler and Three-Wheeler segments, where production adjustments have met rising consumer demand. The sector’s ability to scale production efficiently amidst fluctuations in certain segments reflects its robust infrastructure and strategic planning.

Commenting on sales data of July 2024, Vinod Aggarwal, President, SIAM said, “Though Three-Wheeler and Two-Wheeler segments are performing well, there has been some growth of Passenger Vehicles and Commercial Vehicles in July 2024, compared to July 2023. The above-average rainfall and the upcoming festive season will again propel growth in the short term. In addition, enabling budget announcements emphasised overall economic growth with fiscal support for infrastructure and the rural sector should augur well for the Auto sector in the medium term.”

July 2024 portrayed the resilience and adaptability of the Indian automotive manufacturing sector. Despite challenges, the overall growth in production and sales, particularly in the Two-Wheeler and Three-Wheeler segments shows the strength in derailment. With the festive season approaching and supportive economic policies in place, the industry is looking towards continued growth in the coming months.

Shan Qumer, Industry Leader – Environmental Mobility, Omron Automation Pvt Ltd

Euler Motors, a leading electric commercial vehicle manufacturer, offers the first look of its facility in Haryana, spanning 5 lakh sq. ft. The plant has a production capacity of 36,000 vehicles annually.

The commercial EV manufacturing and R&D facility of Euler Motors in the industrial hub of Palwal, Haryana is built with an investment of Rs 100 crore. The factory will serve as Euler Motors’ national manufacturing hub, catering to the rising demand for its 3W HiLoad EV from across the country. The company plans to expand its footprint from 26 to 40 cities by FY25.

The facility has an automated assembly line connected via a proprietary manufacturing execution system (MES), which drives production efficiencies by tracking the vehicle lifecycle from production to delivery. Additionally, the facility has the highest parameters for commercial vehicle testing, including dyno-testing, fully compliant shower testing, and a full-length testing track.

The plant houses a dedicated testing & validation team, advanced R&D labs, and collaborations with engineering experts, fostering a culture of continuous innovation.

“With such a strong supplier network in the vicinity, Palwal was naturally the ideal location for us. As we expand into new markets and aim to achieve 15% growth in FY25, this state-of-the-art facility will help us respond to the increased customer demand and adapt to changes in processes and products with agility and flexibility. It will also strengthen the company’s position as a trusted and leading player in the Indian commercial EV segment,” said Saurav Kumar, Founder & CEO, Euler Motors.

Gaurav Kumar, Head of Supply Chain & Manufacturing at Euler Motors, added, “Our new factory represents a significant leap in manufacturing commercial 3-wheeler EVs. We are setting new benchmarks for efficient and reliable production of vehicles by integrating cutting-edge technology and quality control that are at par with global standards. This facility will enhance our production capacity, and also reinforce our dedication to delivering powerful, locally manufactured vehicles that meet the evolving needs of our customers and the industry.”

The facility is an opportunity for value creation in the sector and will create job opportunities in the region. Currently employing over 500 people, including 20% women, the facility houses a dedicated learning and development centre, ‘Kamar-Taj’, to equip its workforce with the right skills, especially considering the skill gap that exists in EV manufacturing.

“I am incredibly proud to lead this commercial EV manufacturing facility. It has best-in-class automation and aligns with our commitment towards sustainable practices. The combination of our skilled workforce and the best of technology position us to deliver powerful electric vehicles across India, making a significant contribution to the country’s clean mobility future, said Anal Vijay Singh, Plant Head, Euler Motors.

Key highlights of the facility:

Industry-first Automation (among the cargo EV start-ups): Key automation initiatives include the EMS Hanger system for automated loading and unloading, the Trailing Arm Fitment Assist for better assembly ergonomics and takt time control, and a vacuum-based brake oil filling machine to minimise spillage and contamination. A portable CMM provides accurate body checks during and after production. Thorough in-house testing underscores Euler Motors’ commitment to vehicle performance and durability, setting industry benchmarks.

ESG at its Core: Demonstrating a deep commitment to environmental, social, and governance (ESG) standards, the facility incorporates advanced waste management systems, a sewage treatment plant, and a circular groundwater recharge system. These initiatives underscore Euler Motors’ holistic approach to operational efficiency and environmental sustainability.

Empowering Women in Manufacturing: Euler Motors prioritises a gender-neutral workplace. Key leadership positions, including safety and training officers, are reserved for women, promoting diversity and empowerment.

Economies of Scale and Quality Control: The facility marks a significant step towards achieving economies of scale through strategic investments in proprietary technology, modular vehicle design, and efficient production processes. This ensures high-quality EVs while meeting rising demand from both retail and institutional customers.

Compliance and Certifications: Euler’s Palwal facility, governed by the Factories Act of 1948, is the only cargo EV start-up with both ISO 9001 (QMS) and ISO 14001 (EMS) certifications, as well as the ISO 45001 (OHSAS) and IATF 16949 (QMS-Automotive) certifications, thereby boasting elevated compliance standards matching those of established OEMs in the e-mobility space.

EMS hanger system: Enables auto loading and unloading of vehicles on manufacturing stations.

Trailing arm fitment assist: Ensuring assembly ergonomics benefit and takt time control.

Vacuum base brake oil filling machine: Restrict spillage and contamination.

Portable CMM: For body accuracy checks during and post the manufacturing processes.

Dyno and shower testing facilities: Ensure comprehensive in-house testing of vehicles for performance and durability.

Chandan Mundhra, Founder & C.E.O, Savy Electric Vehicles

Amara Raja Energy & Mobility has also initiated the construction of a Customer Qualification Plant (CQP) at the Gigacorridor in Divitipalli, Mahbubnagar district, Telangana.

Amara Raja Energy & Mobility crossed a milestone in India’s battery manufacturing sector with the inauguration of Phase 1 of its battery pack plant and the foundation stone laying for a Customer Qualification Plant (CQP) at the Gigacorridor in Divitipalli, Mahbubnagar district, Telangana. The Gigacorridor spans over 260 acres and is poised to become a major hub for battery pack and cell manufacturing, with an ambitious target capacity of 5 GWh for battery packs and 16 GWh for cell production by 2031.

The newly launched Phase 1 battery pack plant has an initial capacity of 1.5 GWh and is tailored to produce lithium-ion (Li-ion) battery packs designed specifically for Indian conditions. These packs will serve the growing needs of electric vehicle (EV) manufacturers and stationary energy storage solutions. The forthcoming CQP, anticipated to be operational by the first quarter of the next financial year, will focus on producing various cell types for customer testing and validation, further solidifying Amara Raja’s role in advancing battery technology in India.

Amara Raja’s recent strategic moves include signing a Memorandum of Understanding (MoU) with Piaggio Vehicles Private Limited to develop and supply Lithium Iron Phosphate (LFP) cells and chargers for Piaggio’s EV 3-Wheelers, along with cells and battery packs for their upcoming 2-Wheeler models. A similar collaboration was also established with Ather Energy.

The Gigacorridor project represents a substantial investment of ₹9,500 crore, with plans to develop an advanced cell manufacturing Gigafactory and a cutting-edge research and innovation centre in Hyderabad, dubbed ePositive Energy Labs. This initiative is a critical component of Amara Raja’s broader strategy to lead India’s energy transition and drive sustainable growth in the region, while also reinforcing its position as a key player in the global battery manufacturing landscape.

Gururaj Bengeri, Director – Presales and Digital Transformation Consulting, Siemens Digital Industry Software

Francisco José Hurtado Mayén, Electric Vehicles Expert, remarks that the electric car market in India is marked by rapid expansion and a dynamic landscape. It is driven by a confluence of factors, including environmental awareness, supportive government policies, and advancements in electric vehicle technology.

The electric car market in India is one of the fastest-growing segments in the automotive industry. According to recent reports, the market size was valued at approximately USD 1.4 billion in 2023 and is expected to grow at a compound annual growth rate (CAGR) of over 40% in the next five years. The number of electric cars sold in India is projected to increase significantly, driven by both demand and supply.

Key drivers of growth

Environmental concerns: Increasing awareness about the environmental impact of fossil fuels has led to a surge in demand for cleaner alternatives. Electric cars, with zero tailpipe emissions, are seen as a solution to reduce air pollution in urban areas.

Government initiatives: Various government policies and incentives, such as the Faster Adoption and Manufacturing of Electric Vehicles (FAME) scheme, offer subsidies and tax benefits to manufacturers and consumers, making electric cars more affordable.

Technological advancements: Continuous improvements in battery technology have enhanced the range, performance, and safety of electric cars. The development of fast-charging technology is also reducing the downtime required for recharging.

Cost reduction: Economies of scale and advancements in production processes are gradually reducing the costs of electric cars and their components, making them more competitive with conventional vehicles.  

Consumer trends

Electric cars are becoming more popular among consumers because they are cheaper, supported by government policies, and better for the environment. Electric vehicles appeal especially to younger consumers and city residents. Moreover, the growing variety of electric cars with enhanced performance and capabilities is encouraging more people to buy them.

Competitive landscape

The competitive landscape of the electric car market in India is evolving rapidly. Established automotive companies are expanding their electric vehicle portfolios, while new entrants are also making their mark. Competition fosters innovation and leads to better product offerings that benefit consumers.

Market segmentation

The Indian electric car market is diverse and segmented based on several criteria, including vehicle type, price range, usage, and geographic distribution. Each segment has unique characteristics and appeals to different consumer groups. Understanding these segments is crucial for identifying market trends and opportunities.

Vehicle type

The market is categorised into three main types of electric cars: compact cars, sedans, and SUVs. Each category caters to different consumer needs and preferences.

Compact cars: Compact electric cars are popular for their affordability and suitability for urban commuting. These vehicles are designed for short to medium distances, making them ideal for daily use. Key models in this segment include the Tata Tigor EV and Mahindra eKUV100. These cars balance cost, range, and performance, appealing to budget-conscious consumers and first-time EV buyers.

Sedans: Electric sedans provide comfort, performance, and range. They are preferred by consumers looking for a more premium experience without compromising efficiency. Models like the Hyundai Kona Electric and MG ZS EV fall into this category. These sedans offer advanced features, longer driving ranges, and better performance metrics than compact cars, making them suitable for longer commutes and highway driving.

SUVs: The SUV segment in the electric car market is gaining significant traction due to the increasing consumer preference for spacious and versatile vehicles. Electric SUVs like the Tata Nexon EV and the upcoming Mahindra XUV400 are known for their build, advanced features, and superior driving range. This segment appeals to consumers prioritising space, safety, and higher ground clearance, making these vehicles suitable for diverse driving conditions, including urban, rural, and off-road environments.

Price range

Electric cars in India are available across a wide range of price points, catering to different economic segments of the population. This segmentation allows manufacturers to target diverse consumer groups based on their purchasing power and preferences.

Budget segment: Electric cars priced below INR 10 lakh fall into this category. These vehicles are typically compact cars designed for urban use. Their affordability makes them accessible to a larger segment of the population. Examples include entry-level versions of the Tata Tigor EV and Mahindra eKUV100.

Mid-range segment: Priced between INR 10 lakh and INR 20 lakh, this segment includes higher-end compact cars, entry-level sedans, and SUVs. Vehicles in this range offer better performance, longer driving ranges, and more features per the budget segment. The Tata Nexon EV and MG ZS EV are notable models in this category.

Premium segment: Electric cars priced above INR 20 lakh are considered premium models. These vehicles include high-end sedans and SUVs offering superior performance, luxury features and extended driving ranges. The Hyundai Kona Electric and future premium models from brands like Audi and Mercedes Benz are examples of this segment. These cars cater to affluent consumers looking for luxury and advanced technology.

Usages

Electric cars in India are used for personal use, commercial applications, and government or institutional use. Most electric cars in India are purchased for personal use. Consumers in this segment prioritise factors such as cost-effectiveness, environmental impact, and the convenience of charging. The growing awareness of environmental benefits and the availability of subsidies have significantly contributed to electric cars for personal use.

There is an increasing interest in electric cars for commercial purposes, including fleet operations for ride-hailing services, corporate fleets, and delivery services. Electric cars’ lower operational costs compared to conventional vehicles make them an attractive option for businesses looking to reduce expenses and enhance sustainability. Companies like Ola and Uber are gradually incorporating electric cars into their fleets.

Government agencies and institutions are also adopting electric cars as part of their efforts to promote sustainability and reduce carbon footprints. Various state and central government bodies are incorporating electric vehicles into their official fleets, setting an example for the public and supporting market growth.Geographic Distribution

The adoption of electric cars in India varies across different geographic regions and is influenced by factors such as urbanisation, infrastructure availability, and regional policies. Major metropolitan cities like Delhi, Mumbai, Bangalore, and Chennai are leading in electric cars. The availability of better charging infrastructure, higher environmental awareness, and supportive local policies contribute to the higher penetration of electric cars in these areas. Urban consumers are more inclined to switch to electric cars due to the frequent use of personal vehicles for commuting and the increasing congestion and pollution levels in cities.

While adopting electric cars is slower in semi-urban and rural areas, there is potential for growth as charging infrastructure expands and awareness increases. State government initiatives aimed at rural electrification and the development of charging networks are expected to boost the adoption rates in these regions. The affordability and suitability of compact electric cars for short-distance travel make them appealing to consumers in smaller towns and rural areas.

Future Prospects

The future of the electric car market in India is promising, driven by several factors expected to contribute to its growth and development. Technological innovation will play a leading role in this growth.

Continuous improvements in battery technology, including improvements in energy density, charging time, and cost reduction, are expected to enhance the performance and affordability of electric cars. Solid-state batteries promise higher energy densities and faster charging times, and once they become commercially viable, they are likely to revolutionise the market.

Advancements in vehicle design and materials will contribute to more efficient and lightweight electric cars. Innovations such as aerodynamic designs, lightweight composite materials, and energy-efficient systems will improve overall vehicle performance and range.

Autonomous driving technologies and advanced connectivity features will enhance the appeal of electric cars. Autonomous driving can improve safety and convenience, while connectivity features offer real-time updates, predictive maintenance, and enhanced user experiences.

Government support and policy framework

Ongoing and consistent government support will be crucial for the sustained growth of the electric car market. The continuation and expansion of financial incentives and subsidies for electric car buyers and manufacturers will help bridge the cost gap with conventional vehicles. Policies that support domestic manufacturing and research and development will also boost the industry.

Implementing stringent emission regulations and fuel economy standards will encourage the adoption of electric vehicles. Policies such as zero-emission vehicle (ZEV) mandates and carbon credits can further drive market growth.

Government initiatives to expand and enhance the charging infrastructure will address range anxiety and make electric cars more convenient for consumers. Support for public and private investment in charging networks will be essential.

Market expansion and new business models

The electric car market is expected to expand, with new business models emerging to support its growth. Electric cars in commercial fleets, including ride-hailing services, delivery vehicles, and corporate fleets, will drive significant market growth. Fleet operators are likely to benefit from lower operational costs and government incentives.

Innovative business models, such as battery leasing and swapping, can reduce the upfront cost of electric cars and address concerns about battery lifespan and degradation. Companies offering these services will play a crucial role in market expansion.

Subscription-based models, in which consumers can lease electric cars monthly with inclusive services such as maintenance and insurance, will provide users with flexible and cost-effective options.

Increased consumer awareness and acceptance

Consumers are expected to switch to electric mobility with the increasing awareness and acceptance of electric cars. Continued efforts to educate consumers about the benefits of electric cars, available incentives, and charging infrastructure will drive this adoption. Real-world testimonials and success stories can help build confidence in electric vehicles.

Providing consumers with opportunities to experience electric cars through test drives and demonstrations will also dispel misconceptions and highlight the advantages of electric mobility.

As more automakers enter the electric car market and offer a wider range of models, consumers will have more choices that meet their preferences and needs. Increased competition will also drive innovation and lower prices.

Environmental and economic impact

The environmental and economic benefits of electric cars will further strengthen their adoption. They will reduce greenhouse gas emissions and air pollution, contributing to improved public health and sustainability. Electric cars can reduce India’s dependence on imported fossil fuels, which will positively impact energy security. Renewable energy sources for EV charging can further reduce the carbon footprint and promote sustainable energy use.

The growth of the electric vehicle industry will create new opportunities for economic development and job creation. The EV ecosystem will generate employment across various sectors, from manufacturing and R&D to charging infrastructure and maintenance services.

Global trends and collaboration

The global shift towards electric mobility will impact the Indian market. Trends such as the declining cost of batteries, technological advancements, and increased investment in EVs by global automakers will benefit India. Collaborating with international companies and governments can facilitate technology transfer, investment, and knowledge sharing. Partnerships in areas such as battery manufacturing, charging infrastructure, and R&D will accelerate the growth of the Indian electric car market.

The electric car market in India stands at a crucial juncture with an outlook of substantial growth and transformation. This report has explored the multifaceted aspects of this burgeoning market, offering a comprehensive analysis of its current state, key players, government policies, infrastructure developments, challenges, and prospects.

The transition to electric mobility is more than just a technological shift. It is to create a fundamental change in how transportation is perceived and utilised in India. This transition’s benefits are manifold: reduced greenhouse gas emissions, improved air quality, and economic growth. As India aims to meet its sustainability goals and reduce its carbon footprint, electric cars are a pivotal step in this direction.

TruCut offers top-tier solid carbide and HSS-Co rotating tools backed by over two decades of expertise. Its commitment to quality serves both domestic and international markets, ensuring precision and performance.

TruCut has over two decades of experience in the cutting tool industry, with its primary mission to offer customers a one-stop shop for all their cutting tool needs.

One-stop shop for all cutting tool needs

TruCut is present in domestic and international markets, offering a diverse range of solid carbide and HSS-Co rotating tools. In a competitive industry, quality is the ultimate goal. This commitment to excellence is evident in every aspect of its production and service.

TruCut takes great pride and confidence in its ability to meet all requirements with its high-quality product line, ensuring that end users will appreciate using the products as much as it enjoys producing them. TruCut provides comprehensive application support and supplies to pan India. From its facility in Chennai and through its extensive dealer network, it offers top-notch carbide-cutting tools for various metalworking industries.

Manufacturing facilities

TruCut’s 15,000 sq. ft. production facility in Chennai has advanced CNC grinding and tool inspection machines. This facility ensures that every tool meets stringent quality standards, allowing customers to benefit from significant savings and increased productivity over time.

TruCut ensures consistent tool performance by installing advanced CNC 5-axis and  7-axis grinding Machines. Its Non-Contact 5-axis CMM Tool Inspection Machine guarantees precise geometry and dimensions, while laser marking provides permanent identification. Each tool is protected with high-quality single-piece packaging. TruCut maintains consistent quality and uses high-grade microfine and ultrafine carbide raw materials, along with HSS-Co imported from Europe. Additionally, our in-house forming section processes Unground carbide blanks.

Quality control measure

TruCut Tools ensures the machining world operates smoothly by providing quality, consistency, and timely delivery. With an extensive inventory of catalogue items ready to ship the same day and custom tools available with minimal lead times, it helps meet machining needs efficiently. The quality of products is evident through optimised carbide quality, superior grinding techniques, innovative tool geometries, and advanced tool coatings. Each tool produced undergoes rigorous inspection and quality control to ensure consistency and best performance. The tools meet the highest standards in industries where precision and reliability are critical.

TruCut invests in advanced tool production equipment, supported by state-of-the-art inspection machines and micro-level inspection procedures, to ensure that every tool meets the highest standards of accuracy.

Industries TruCut  serves

TruCut is the perfect partner for developing and producing primary and secondary Aircraft components. TruCut offers the most comprehensive range of solid carbide tools for metal and composite materials available for the aerospace industry, which sets new standards with the highest possible productivity and process reliability through technical support.

When machining automotive parts, achieving the highest production at the lowest possible cost is essential. TruCut fulfils this need and delivers on its promise to dramatically reduce long-term, prioritising quality and efficiency rather than selling cheap tools.

In the Die & Mold Industries, TruCut has been bundling decades of experience in Die and Mould tool making with a forward-looking product portfolio and designing individual manufacturing solutions with continuous process chains.

The General Engineering segment comprises job shops, contract manufacturers, electronic components producers, and others contributing to the manufacturing world. We provide innovative solutions that improve their regular processes and achieve an efficient output.

Industry-specific solutions

TruCut offers specialised solutions across various industries that are customised to meet the demands of each sector.

TruCut tools ensure the highest production rates at the lowest possible costs in the industry, promising to lower customers’ overall machining expenses. TruCut designs individual manufacturing solutions with continuous process chains to ensure efficiency and precision. Offering a broad range of solid carbide tools for super alloys and composite materials, TruCut provides flexible machining solutions that set new standards for productivity and process reliability.

TruCut adheres to its 5-TS (TruCut Standard) to ensure a high-quality and consistent product by: 

• Appropriate Carbide Grade 
• New Tool Geometry 
• Precision Smooth Grinding 
• Proven Inspection Procedure 
• Advanced tool coatings.

Artificial Intelligence (AI) is being integrated into electric vehicles (EVs) to improve safety features. Indian brands like Tresa Motors leverage in-house AI expertise to develop resilient BMS systems.

AI has become sophisticated with advanced integration and its use for electric vehicles is transforming the market. OEMs are using advanced technology to enhance vehicle safety and help safeguard lives on the road. AI extracts important data on factors that impact operators, including weather conditions, road topography, traffic patterns, and common performance issues. AI optimizes vehicle performance to address anticipated safety concerns by analyzing this data. Here are ways electric vehicle manufacturers are integrating artificial intelligence (AI) and advanced technologies to enhance safety features:

Advanced Driver Assistance Systems: These systems help drivers operate their vehicles safely by including features such as autonomous emergency braking, lane-keeping assistance, and adaptive cruise control. Using sensors and cameras, ADAS detects nearby obstacles or driver errors and responds accordingly. Indian brands like Tresa Motors leverage inhouse AI expertise. Tresa’s 3D mapping technology, powered by LIDAR sensor fusion, revolutionizes route optimization and energy conservation for drivers and fleet management. It predicts road conditions, hazards, and obstacles, ensuring driver safety and optimizing energy usage by continuously mapping and re-locating routes in real-time.

Battery Management Systems: A BMS is a critical component for the safety and reliability of the battery pack powering an electric vehicle. AI enhances BMS by monitoring cell health, temperature, and charging cycles to deliver optimal efficiency and prevent safety hazards. Tresa Motors is developing resilient BMS systems in-house, with a strong emphasis on safety, especially for high-capacity packs.Advanced Telematics Platforms: These platforms provide critical insights into driver behaviour and risks in real-time. Data on harsh braking, acceleration, and cornering helps identify unsafe manoeuvres or traffic violations. Location tracking verifies stoppage times and route deviations. This data improves individual driver safety and contributes to overall road safety by reducing the likelihood of accidents and enhancing responsiveness to incidents. Telematics systems of Tresa Motors stream over 500 monitoring points to the cloud for constant performance, safety, and efficiency analytics.

Vehicle-to-Everything Connectivity: This technology allows vehicles to share information with other vehicles on the road, enhancing driver safety. V2X enables drivers to take preventive actions by informing others of road accidents, potholes, and other hazards ahead.

As India expedites its connected vehicle infrastructure, such technologies will be pivotal in achieving the goal of zero road fatalities. EV manufacturers understand the paramount importance of driver safety and thus they are committing to craft cutting-edge electric vehicles.

The plant will serve Indian businesses, further localise the product portfolio, and thus, reduce dependence on imports. It will also help address the supply-demand gap of high-performance adhesive solutions for the manufacturing, maintenance, repair and overhaul (MRO), and automotive components sectors. 

Henkel Adhesives Technologies India Private Limited (Henkel India) completes Phase III of its manufacturing facility in Kurkumbh, near Pune, Maharashtra. The Kurkumbh site, launched in 2020, serves the growing demand of Indian industries for high-performance solutions in adhesives, sealants, and surface treatment products. The new Loctite plant, named after Henkel’s renowned brand Loctite, was inaugurated by Mark Dorn, Executive Vice President, Henkel Adhesive Technologies, along with other Senior Management members of the company. 

Henkel has been expanding its presence in the country through consistent strategic investments to meet the rapid growth. The company has a strong footprint in India and operates five manufacturing sites, two innovation centres, a customer experience centre, a packaging academy, and an application centre for the footwear industry. The new Loctite plant in the Kurkumbh manufacturing site reflects Henkel’s vision to drive growth in the Indian market.

Speaking on the launch, Mark Dorn, Executive Vice President at Henkel Adhesive Technologies, said, “India has emerged as a focus market for Henkel globally. The new Loctite plant highlights our vision to emerge as a self-reliant global market player with a strong local presence. With continued investments, efficient supply chains, and customer-focused solutions, Henkel is committed to driving growth in India and building ecosystems of innovative and sustainable solutions with our partners and customers.” The Kurkumbh site also showcases Henkel’s dedication to the local community as a responsible corporate citizen. It meets the highest sustainability standards and is LEED Gold certified, a rare feature among chemical plants. In addition, Henkel aims to achieve carbon neutrality in Kurkumbh for Scope 1 and 2 emissions by 2030. To support this ambition, the site has signed a green electrical energy Power Purchase Agreement and installed on-site solar panels. 

S. Sunil Kumar, Country President of Henkel India, commented, “The expansion of our manufacturing footprint reinforces Henkel’s sustained commitment to making India a manufacturing hub for advanced and high-performance adhesive, sealant, and functional coating solutions. A key highlight of the new Loctite plant is the Automated Storage and Retrieval System (ASRS), which enables fast execution of material storage and retrieval. The plant will leverage Industry 4.0, optimize production efficiency, and further drive profitable, organic growth for Henkel India while continuing to contribute to the ‘Make in India’ initiative of the Indian government.”

Divyesh Kolwadkar, Sales Area Manager – West Region, HMS Industrial Networks India Pvt. Ltd

Compressed air in automobile manufacturing is a conscious selection process that leads to operational efficiency, safety, and quality across various applications. Thus, careful consideration of factors like air requirements, working pressure, and power efficiency requires a factorial decision.

The automotive sector uses compressed air widely, from manufacturing and assembly to functions like body shops. In our daily lives, on our way to work, we regularly inflate the tyres of the vehicle we drive; this is indeed an application of compressed air. Compressed air is used to make tyres, seats, automotive assembly lines, robotic applications, etc. Its adaptability has made it a vital tool for operational safety and efficiency and for simplifying production with dependable and effective compressed air equipment.

Applications of compressed air in the automobile sector

Compressed air tools: Pneumatic Tools like power wrenches, air rachets, air rivets, air hammers, drills, sanders, and pneumatic nailing are all powered by compressed air systems. They are essential to the automotive assembly line due to their consistent performance, safety and compact design. They also generate sustained torque and speed without producing excessive heat or requiring complicated electrical systems.

Painting and body finish: A superior quality paint is expected to give a car a premium look. Compressed air is employed in spray painting applications to guarantee a flawless mirror surface and a consistent, dependable paint spray for door panels, side panels, roof pieces, and other auto body parts. Chicago Pneumatic Compressors offers a comprehensive solution for compressed air with add-on filters and refrigerated air dryers, which can reduce the compressed air temperature to a point where moisture condensation occurs. This can help remove moisture and minimise contaminants like dirt and oil within the air stream.

Laser, Plasma-Cutting and welding applications: Compressed air is used in laser and plasma-cutting processes for car manufacturing, where it acts as the primary or secondary gas to generate high-pressure and high-temperature plasma jets. Compressed air shields the weld in certain welding operations and improves weld seam quality.

Tyre inflation: Right from a petrol pump to a puncture shop, we all have seen a piston or a screw compressor used for inflating air in tyres to maintain sufficient pressure, ensuring a smooth drive.

Pneumatic Robotic assembly lines and material handling and holding: To boost the productivity of assembly lines, lean and flexible manufacturing and assembly systems are designed. These robotic assembly systems lift heavy auto parts and automobile body components via vertical lifts or conveyor systems. These automated systems are pneumatically operated and powered by compressed air systems.

Factors for selecting a compressor for automobile manufacturing

Compressors orbit almost every application in the world of automobile manufacturing. Selecting a compressed air solution requires some key considerations as it contributes to saving power, adding profits to business, leading to faster returns on investments, and reducing the carbon footprint for stepping towards a better, greener tomorrow.

Air Requirement: A compressed air installation should happen based on the required FAD(CFM), not compressor power. This is because, with every CFM, the power requirement increases, as does the capital and running cost. Load factor and simultaneous usage factor are important as all the machines are not loaded 100% and are not used simultaneously. Contact your nearest Chicago Pneumatic representative to learn your optimal air requirement.

Working Pressure: Energy expenses rise by approx. 7% for every bar increase in working pressure. Choosing an appropriate compressor working pressure is crucial to achieving an effective installation.

Power Efficiency: Compressors with a variable frequency drive whose speed is controlled electronically help to keep the compressed air constant within a very tight pressure range and offer outstanding opportunities for energy savings as the power consumption is adapted to the flow requirement. At Chicago Pneumatic Compressors, we have tools and software like iTrack & Architect to determine the right usage of existing installations and simulate the energy-saving reports with the help of live recorded data. These tools help to make your existing installation better and energy efficient while maintaining design, simulation, size, and configuring a new installation setup.

Likewise, many other factors, such as air quality, noise levels, cost – initial and lifetime, maintenance, etc. —must be considered while designing an optimal solution.

Yogesh Umbarkar, Vice President – Mobility, Valtech Mobility

Sameer Walgude, Lead – Supplier 360 / Vihaan, Mahindra & Mahindra Ltd.

Parasram Parihar, Head, Supply Chain Operation, Hero MotoCorp Ltd

Founded by A.K. Sen in 2000, Tasa Automotive specialises in component manufacturing and bespoke machinery. Now, Tanushree Sen from Tasa Automotive Components is empowering women in tech and manufacturing to join the force, and Tasa Automotive is a leading example

Could you share the story of how Tasa Automotive began its journey?

A.K. Sen founded Tasa Automotive in 2000. He began his career in 1975 as a tool designer for Escorts Ltd.’s motorcycle and scooter division. He established Tasa Micro Special Purpose Machines, his first business venture, where he designed and produced fixtures, jigs, special cutting tools, and special purpose machines for automotive companies in the Delhi-NCR region. Among Tasa Micro’s clients were Sona Koyo Steering Systems and Hitech Gears, who saw potential in expanding their collaboration. Dr. Surinder Kapur of Sona Koyo Steering Systems provided an opportunity to launch a soft job work machining unit for their new Sona Okegawa Precision Forgings plant. With the guidance of individuals such as T K Pal and V V Verma, Tasa Automotive Components was founded in 2000.

Supported by Tasa Micro Special Purpose Machines, which developed affordable broaching equipment and SPM solutions, Tasa Automotive has earned the trust of numerous clients, including JTEKT India and Continental Brakes India Ltd., with whom they have maintained long-term partnerships for over 15 years. Tasa Automotive Component is committed to exceeding customer expectations in this dynamic and ever-changing environment by adhering to a customer-first policy.

What is your perception of the growth of the MSME industry in India?

Micro-small and medium-sized businesses (MSMBs) drive economic development, job creation, poverty reduction, and promoting equality worldwide. The MSME sector promotes economic growth by ensuring fair distribution and inclusive growth, especially in the automotive industry. In India, the MSME sector has significant potential but requires a supportive environment for growth. India should focus on expanding and developing the MSME sector to become a manufacturing powerhouse. Policies should be created to support businesses in the Indian manufacturing sector and provide them with platforms, guidelines, and resources to explore foreign markets. Many MSMEs are unaware of government benefits, so authorities must engage with entrepreneurs in the MSME sector to help them and reduce unemployment. The government could also establish trade routes between global and Indian industrial markets. The main challenges for MSMEs include finding skilled labour, a shortage of trained engineers, and the need for more financial support through government incentives. Organisations like EEPC and ACMA are essential in supporting Indian MSME manufacturers towards success and development.

How does Tasa promote women’s empowerment in the manufacturing sector?

Women empowerment in the manufacturing sector is transformative. It requires the removal of barriers and equal opportunities in traditionally male-dominated fields like component manufacturing. This shift is happening through equal opportunities and new job profiles. Elevating women to senior positions, especially in traditional family businesses, is crucial. A supportive family and a strong drive are key to women’s success. My family has always supported me. Women should embrace learning, technology, and adaptability. Acquiring skills boosts workplace confidence. At Tasa, women have equal opportunities in all roles, from shop floor to management. Organisations must create secure and knowledge-rich environments. Tasa believes in everyone’s potential, regardless of gender, and has practised equal opportunities for 15 years.

Please provide a brief overview of the services and manufacturing facility you offer.

We offer a wide range of services, including component manufacturing and on-demand manufacturing. We also design and manufacture our jigs, fixtures and machines. Finding all solutions under one roof is rare for an MSME organisation. We develop parts according to customer drawings and offer a variety of services through our developed supply chain partners which includes forging, casting heat treatment, and plating. We are certified with IATF16949, ISO14001, and ISO9001:2015. Our facilities include CNC Turning Centers, VMC Machines, and advanced inspection tools like Zeiss CMM and Zeiss Contour. We also provide automation solutions for SPM to meet specific customer requirements.

How do you build and maintain trust with your clients?

We have worked with esteemed companies like Sona BLW Precision Forgings Ltd, JTEKT, Continental Brakes India Ltd, and Dantal Hydraulics. We invest in machinery and inspection technology to ensure our clients receive excellent value and enjoy working with us. Building and maintaining client trust motivates us to excel in this competitive industry. We aim to enhance our capabilities and continue serving our customers.

According to Ayush Lohia, CEO, Lohia, collaboration between industry players and government authorities is essential to address infrastructure challenges in the electric vehicle (EV) ecosystem, fostering supportive policies, standardised protocols, and strategic investments for widespread EV adoption.

How does increasing consumer awareness contribute to the growing demand for sustainable transportation options, particularly EVs?

Increasing consumer awareness is vital in driving the demand for environmentally friendly transportation options, particularly electric vehicles (EVs). Heightened awareness of climate change and air pollution motivates individuals to prioritise sustainable choices.

Consumers are becoming more informed about the benefits of EVs, including avoiding fluctuations in fuel prices. They also appreciate the low maintenance costs and convenience of home charging. These factors are driving a growing inclination among consumers to switch to EVs. They are also easy to drive, produce no noise, and often come with government incentives. Therefore, efforts to educate the public about the advantages of EVs foster a growing demand for sustainable transportation options.

How can the challenges in transitioning to electric mobility, especially regarding adoption rates, be addressed?

The electric vehicle (EV) industry in India faces several anticipated challenges. Infrastructure remains a key concern, encompassing the need for a robust charging network to alleviate range anxiety among consumers. Additionally, despite decreasing battery prices, the high upfront cost of EVs poses a challenge to widespread adoption. Regulatory uncertainties, including fluctuating incentives and policy frameworks, can impact investor confidence and hinder long-term planning for manufacturers. Technological advancements and R&D efforts are crucial to addressing battery performance, charging times, and overall vehicle efficiency concerns.

Furthermore, consumer awareness and education initiatives are vital to dispel myths and misconceptions surrounding EVs. Collaboration among industry stakeholders, government bodies, and financial institutions is essential to surmount these challenges for sustainable growth in India’s EV sector.

How are industry players working with government authorities to tackle infrastructure challenges in the electric vehicle ecosystem?

Industry players must prioritise open communication and proactive engagement with government authorities to address infrastructure challenges within the electric vehicle (EV) ecosystem. This involves active participation in regulatory discussions to advocate for supportive policies, such as EV charging infrastructure development incentives and streamlined permitting processes. EV manufacturers should offer insights into infrastructure needs based on market trends and consumer behaviours, sharing data and expertise to aid governments in planning and implementing strategic infrastructure investments. Collaborative efforts should focus on establishing standardised charging protocols, expanding charging networks, and investing in innovative solutions like smart grid technologies. With increasing cooperative relationships with government authorities, EV manufacturers can help accelerate the transition to sustainable transportation, ensuring the necessary infrastructure is in place to support widespread adoption.

How do IoT, AI, and robotics improve efficiency and quality in the EV industry?

Integrating IoT, AI, and robotics into automobile production processes revolutionises efficiency and quality in the electric vehicle (EV) industry. IoT enables real-time monitoring of equipment and production lines, optimising resource allocation and predictive maintenance. AI algorithms enhance decision-making, optimising assembly processes and minimising errors. Robotics automates repetitive tasks with precision, improving consistency and speed. This integration streamlines production, reducing costs and time-to-market, which is crucial in the competitive EV landscape. Furthermore, it ensures superior quality control, enhancing EVs’ reliability and safety, thus reinforcing consumer trust and satisfaction. IoT, AI, and robotics play pivotal roles in propelling the EV industry forward and driving innovation and sustainability.

How have the Make in India and AtmaNirbhar Bharat initiatives promoted self-reliance in automobile manufacturing?

The Make in India and AtmaNirbhar Bharat initiatives have reinforced self-reliance in automobile manufacturing. These initiatives have incentivised domestic production, reducing import reliance and fostering indigenous capabilities. The AtmaNirbhar Bharat initiative, in particular, has made a profound impact by encouraging companies to become self-sufficient. As exemplified by our company, which does not import parts for our vehicles, these initiatives have propelled the automobile industry towards greater autonomy and resilience. Through localisation of manufacturing and fostering a conducive ecosystem for domestic production, Make in India and Atmanirbhar Bharat have played pivotal roles in promoting self-reliance in the Indian automotive sector.

H S Bhatia, Managing Director of Daewoo India, emphasizes that a successful transition to electric mobility in India necessitates inclusive strategies. Key factors include government policies, technological progress, and infrastructure development, all crucial for overcoming obstacles and extensive adoption of electric vehicles through collaborative efforts between industry and government.

How does consumer awareness drive the demand for sustainable transportation options?

Increasing consumer awareness drives the demand for sustainable transportation options, particularly EVs in India. As the public becomes increasingly aware of the adverse environmental effects of traditional internal combustion engine vehicles, there is a growing shift toward cleaner alternatives.

The transportation sector in India is a significant contributor to pollution, especially in cities like New Delhi, where two—and three-wheelers account for 50 percent of surface PM 2.5 levels. This shows the urgent need for change.

Moreover, with transportation comprising about one-fifth of India’s total energy use, the shift towards EVs is environmentally crucial. It also aligns with the country’s energy consumption goals. India’s young and upwardly mobile population is increasingly adopting new technologies, further propelled by their improving socioeconomic status, which positions them better to afford EVs.

How to address the challenges while transitioning to electric mobility, particularly the adoption rate?

Transitioning to electric mobility in India involves overcoming several challenges, particularly adoption rates. Supportive government policies, increasing consumer awareness, and advancements in EV technology are crucial in this regard. Expanding charging infrastructure and developing locally produced battery technologies are essential to accommodate the rising demand for EVs.

The automotive industry in India stands to play a significant role in the global EV shift and has the potential to become a leader in this space. Private companies are instrumental in offering smart digital solutions, contributing to infrastructure development, and acting as a bridge between government agencies and end-users. These initiatives support fleet operators in transitioning to EVs and help original equipment manufacturers (OEMs) provide seamless driving experiences.

Collaboration with local governments is also key for rapidly constructing charging stations and increasing public awareness, facilitating the EV industry’s swift growth. Continued cooperation between the public and private sectors, coupled with innovation and investment, can accelerate the adoption of electric vehicles in India.

How are industry players collaborating with government authorities to address infrastructure challenges in the electric vehicle ecosystem?

Collaboration between industry players and government authorities is essential to addressing infrastructure challenges in the electric vehicle ecosystem. The Ministry of Power is incentivizing the establishment of EV charging stations through financial and non-financial measures, including a revenue-sharing model for land use and affordable charging rates.Private entities are working with municipal, state, and central governments to install EV stations and develop a Charger Management System (CMS) to streamline operations. Given that much of India’s electricity is coal-generated, which undermines the environmental benefits of EVs, the government is exploring alternative energy sources like solar, wind, and nuclear power.

Additionally, research and development in biofuels to power EV manufacturing units are being actively pursued. These government measures provide opportunities for private players to leverage technology and innovation to produce EVs more efficiently and at lower costs, ultimately reducing upfront cost for consumers and increasing EV adoption.

Addressing the challenges of limited driving range and battery capacity, private players must innovate lightweight, high-energy-density batteries supported by government tax credits and initiatives like the National Mission for Transformative Mobility and Battery Storage, 2019, promoting battery manufacturing and technological advancements.

Please discuss the role of IoT, AI, and robotics being integrated into automobile production processes to enhance efficiency and quality.

Integrating IoT, AI, and robotics into automobile production processes significantly enhances efficiency and quality. Smart factories equipped with IoT devices can monitor production lines in real-time, ensuring precision and operational efficiency.  AI algorithms can predict maintenance needs, reducing downtime and operational costs. IoT devices provide data that AI can analyse to optimise production schedules, manage inventory, and ensure the quality of manufactured parts. Robotics automates repetitive tasks, increasing production speed and accuracy while minimising human error.

How do Smart factories aid in the shift towards electric mobility and enhance manufacturing competitiveness?

Smart factories play a pivotal role in the shift towards electric mobility by enhancing manufacturing competitiveness. Equipped with advanced technologies such as IoT, AI, and robotics, these factories streamline production processes, improve resource utilisation, and increase output quality. In the context of electric vehicles, smart factories can efficiently manage the production of EV components, including batteries and electric motors, ensuring consistency and high standards. This technological edge helps manufacturers reduce costs, accelerate production timelines, and respond swiftly to market demands. Furthermore, the data-driven insights provided by Smart factories enable continuous improvement in manufacturing practices, fostering innovation and maintaining a competitive edge in the rapidly evolving EV market.

How do you assess the impact of the Make in India and AtmaNirbharta initiatives in promoting self-reliance in automobile manufacturing?

The Make in India and AtmaNirbharta initiatives significantly promote self-reliance in automobile manufacturing, particularly in the EV sector. Historically, India has relied on imports for critical EV components like lithium-ion cells and electric motors due to the lack of a domestic ecosystem. However, these initiatives encourage the development of a circular economy model aimed at minimising environmental impact and maximising resource efficiency.

The Production Linked Incentive (PLI) Scheme for the automotive sector, launched with an outlay of $3.1 billion, aims to foster domestic manufacturing of advanced automotive technology (AAT) products and attract investments in the automotive value chain. This scheme attracted substantial investments, exceeding target estimates, indicating strong industry interest. Similarly, the PLI Scheme for the National Programme on Advanced Chemistry Cell (ACC) Battery Storage, with an outlay of $2.1 billion, aims to boost the capabilities of India in battery manufacturing.

The EV Industry has high expectations from the Union Budget to be presented in July’2024 after the resuming of the Modi Government’s third term. These initiatives, combined with state-level policies promoting EV purchase and local manufacturing, align with Indian commitment to the Paris Agreement and the goal of achieving significant EV adoption by 2030.

Digitising sourcing and manufacturing processes in the EV industry assists operations management while boosting production capabilities in response to evolving market demands. Sonam Motwani, CEO and the Founder of Karkhana.io, shares her expertise in digitising manufacturing while navigating challenges.

Innovation is propelling growth in the fast-paced world of electric vehicles (EVs), with digitised sourcing and manufacturing processes emerging as a game changer. This digital transformation is more than implementing new technology; it is about altering how EV components are obtained, developed, and manufactured to simplify processes, improve efficiency, and increase output. This digital revolution provides several benefits, such as streamlining operations and improving efficiency and manufacturing capacities across the EV sector.

Challenge: Complexity in a new landscape

Digitising EV sourcing and manufacturing processes presents unique complexities to traditional automotive manufacturing. The intricate nature of EV components, such as batteries and electric motors, requires specialised expertise and stringent quality control measures. EV manufacturers collaborate with a diverse network of suppliers for advanced technology components, adding layers of complexity to supply chain management. The rapid pace of innovation in EVs further amplifies the challenge, necessitating continuous adaptation to evolving technologies and market dynamics. Despite these complexities, digital transformation offers opportunities for efficiency gains, cost optimisation, and accelerated innovation in the dynamic EV industry.

Digital transformation across the chain

Supply chain management receives a considerable boost from digitisation. Digital platforms provide visibility into the entire supply chain, from raw material sourcing to final product delivery. This visibility enables manufacturers to optimise inventory levels, minimise stockouts, and ensure timely component deliveries, ultimately reducing production delays and improving overall efficiency.

Another area where digitisation shines is efficient component sourcing. With digital platforms, EV manufacturers gain access to a vast network of suppliers. These platforms centralise supplier information, allowing manufacturers to quickly identify sources for required components at competitive prices, reducing the time and costs associated with sourcing.

Through digitisation, data-driven decision-making becomes a reality. Manufacturers gain valuable insights into inefficiencies, bottlenecks, and areas for improvement by collecting and analysing data throughout the manufacturing process. This data-driven approach allows for continuous optimisation of production processes, driving efficiency and innovation.

Digital manufacturing processes also enable greater customisation and personalisation of EVs. Manufacturers can easily modify product designs and configurations to meet specific customer requirements, catering to the growing demand for personalised vehicles.

Furthermore, digital manufacturing processes are inherently scalable and adaptable, allowing manufacturers to quickly respond to changing market demands. Whether ramping up production in response to increased demand or introducing new product variants, digital technologies enable manufacturers to adapt swiftly without significant retooling or reconfiguration.Quality control also benefits significantly from digitisation. Real-time monitoring of manufacturing processes and quality parameters enables manufacturers to track key performance indicators and identify defects or deviations early on. By taking corrective actions promptly, manufacturers can maintain high-quality standards throughout the production process.

Digital tools, such as Computer-Aided Design (CAD) software and virtual prototyping, enhance design and prototyping processes. These tools enable rapid iteration of EV components, reducing the time and resources required for physical prototyping and accelerating the product development cycle.

Predictive maintenance, made possible by IoT-enabled sensors and data analytics, minimises unplanned downtime by allowing manufacturers to monitor the health and performance of EV components in real-time. By analysing data on equipment usage, temperature, and other parameters, manufacturers can predict maintenance needs and schedule proactive maintenance. 

Energy efficiency and sustainability are central tenets of the EV industry, and digitisation is crucial in achieving these goals. By optimising energy consumption and resource utilisation in manufacturing processes, digital technologies help reduce the carbon footprint of manufacturing operations, aligning with environmental objectives.

One of the most significant advantages of digitisation in the EV space is streamlined communication and collaboration. Digital platforms facilitate seamless interaction among stakeholders, including suppliers, manufacturers, and designers. Real-time messaging, file sharing, and collaboration tools ensure everyone is synchronised, minimising misunderstandings and delays. This enhanced communication lays the foundation for efficient collaboration throughout the production process.

The road ahead

Digitisation is not a solo endeavour. Effective implementation requires collaboration between EV manufacturers, suppliers, and logistics providers. Companies like Karkhana.io exemplify the potential of digital platforms to transform the EV industry. By linking manufacturers with a broad array of trusted suppliers and offering live updates on the manufacturing journey, manufacturers can make informed decisions, streamline processes, and foster innovation within the EV sector. The EV industry can forge a fully digital ecosystem through collaboration and the adoption of unified data exchange standards.

Furthermore, digitisation paves the way for a sustainable EV production process. Manufacturers can reduce their environmental footprint with thoughtful resource allocation and minimising waste. Additionally, real-time data on supply chains can help identify ethically sourced materials, promoting responsible practices within the industry.

In conclusion, digitising sourcing and manufacturing processes drives efficiency and production capabilities in the electric vehicle industry. By embracing digital technologies, EV manufacturers can achieve greater operational efficiency, higher productivity, and increased competitiveness in a rapidly evolving market.

Shirish Kulkarni, Founder & MD, STROTA ConsulTech Pvt Ltd

Atul Jairaj, Partner, Deloitte India

Squadron Leader Vijay Kumar Jadhav (Retd.), Lead Analyst: Process Excellence (Facilities, IT, SCM Opex & Digitalisation), Eaton

Many technologies are lucrative to take the enterprise to the next level. Veer Singh, CEO of Lord’s Automotive Pvt. Ltd., discusses how we can leverage these novel technologies to elevate Indian automotive manufacturers.

How can novel technology enhance efficiency in the automotive sector?

A multifaceted approach to cutting-edge technologies can enhance efficiency and reduce costs in the automotive sector. Technologies such as IoT sensors through production lines enable real-time data collection on equipment performance and product quality. Concurrently, Artificial Intelligence (AI) and Machine Learning (ML) algorithms can streamline resource allocation, scheduling, inventory management, and supply chain operations’ precision and responsiveness. Robotics and automation improve throughput and precision on the assembly line.

While these technologies unlock significant value, there are virtual simulations for workflows and test process improvements, additive manufacturing (3D printing) for rapid prototyping, and technologies that help reduce material waste in the automotive sector. Integration and how one derives the benefit are equally crucial with the multiple facets of technology.

How can one leverage robotics to enhance precision, productivity, and efficiency in automotive assembly?

Businesses can unlock a vast set of features and benefits when it comes to leveraging robotics for precise assembly and improved productivity. Organisations can integrate collaborative robots (cobots) alongside human workers for assembly tasks. Such cobots work safely alongside humans, scale up productivity by handling repetitive tasks, reducing errors, and improving overall efficiency on the assembly line.

Robotic vision or computer vision systems enable robots to recognise and precisely manipulate parts, ensuring accurate assembly-line productivity and downtime during rework. Many enterprises use robotic movements and assembly processes that rely on real-time data feedback. Such strategies streamline our manufacturing operations and elevate the quality and consistency of automotive products.

Please discuss advancements that are taking place in your manufacturing operations.

Qualitative engineering and research enabled us to launch two models quickly in the EV space. The Lords Prime offers a load-bearing capacity of 275 kilos, whereas the Lords Stylon offers a weight-bearing capacity of 200 kilos. Much research and design time was spent creating features such as fast charging times, improving range efficiency, enabling GPS features, etc. Other crucial areas include the software for autonomous driving systems, battery technologies, charging infrastructure, and even reinvigorating our supply chain efficiencies.

Many of these technologies, such as sustainability, appear very simple at first glance. Everyone talks about sustainability, but at Lords, we have re-engineered some of the processes to ensure a reduction in environmental impact. This approach has been continual. We continue to explore alternative ideas such as fuel options, lightweight materials, and even eco-friendly production methods.

How do you assess the challenge of upskilling in the industry?

Among the biggest challenges of scaling up processes in the manufacturing industry is the angle of cultural disruption. Addressing workforce skill gaps through training and upskilling programs is crucial for scaling up manufacturing operations. We can cultivate a skilled workforce capable of adapting to evolving production demands by investing in employee development initiatives focused on emerging technologies and best practices.

Fostering a culture of innovation and continuous improvement encourages employees to identify inefficiencies and propose solutions, driving operational excellence and facilitating scale-up efforts. Employees can make decisions by soliciting their input and providing autonomy within their roles, and their contributions must be recognised. This fosters a sense of ownership and accountability. 

Encouraging open communication, constructive feedback, and opportunities for professional development makes employees take initiative and drive innovation within the organisation.

Collaborating with educational institutions and industry partners to develop training programs and apprenticeship opportunities can also help bridge skill gaps. Addressing the manufacturing challenges can help us scale up operations and maintain a competitive edge in the automotive industry.

How are you adapting to the change required to scale up operations?

Markets, technologies, and consumer preferences are evolving, requiring companies to remain agile and responsive to change. Failure to adapt can result in inefficiencies, missed opportunities, and stagnation or decline.

Indian brands such as Maruti, Bajaj, and Hero have had a dynamic approach. All of them changed their stance and approach periodically. We all know that at one time, Tata announced the most affordable car in India. But today, the market demand for it is non-existent. Consumers are now demanding electric vehicles, and tomorrow, that can alter the demand for Hydrogen-powered vehicles. Indian enterprises must innovate continually while keeping their hearts glued to the streets to exceed.

How will domestic industry foster the process of scaling up manufacturing?

Promoting domestic manufacturing and incentivising investment encourages the growth of local industries. It also creates jobs and drives economic development. Localisation of production reduces the dependence on imports, enhances self-sufficiency, and strengthens the position in global supply chains. Additionally, the initiative aims to improve the ease of doing business, streamline regulatory processes, and support small and medium enterprises (SMEs), fostering a conducive environment for sustainable growth and competitiveness in the manufacturing sector.

A comprehensive and strategic approach is required for scaling up manufacturing. Anand Kabra, Vice-Chairman & MD of Kabra ExtrusionTechnik Ltd shares strategies for scaling up manufacturing through advanced technologies, supply chain management, and the Make in India initiative.

What technologies would you suggest to increase the scalability in manufacturing?

Securing efficient and productive manufacturing that is scalable requires a multimodal strategy that incorporates technologies. Industry 4.0, which includes advanced robotics, machine learning, artificial intelligence, and the Internet of Things (IoT), is at the forefront. When these technologies are cleverly combined, they transform conventional manufacturing methods. For instance, massive manufacturing data is analysed by AI and ML algorithms to find trends and improve operations instantly. Automating repetitive operations increases throughput and decreases error rates thanks to advanced robotics. IoT devices reduce downtime by offering insights into machinery performance for predictive maintenance. Reducing material waste, enabling quick prototyping, and supporting on-demand production are all made possible by additive manufacturing, especially 3D printing, improving flexibility and cost-effectiveness.

How can advanced robotics improve precision and productivity in manufacturing processes?

Advanced robotics offers precise assembly and heightened productivity when involved in manufacturing processes. Collaborative robotics, or cobots, work alongside human operators to excel in precision tasks and automate repetitive processes while ensuring safety. Automated Guided Vehicles (AGVs) are used in material handling and logistics to promote workflow efficiency. Vision-guided robotics use cameras and image processing to detect and align components accurately. This enhances product quality. Continuous training and maintenance programs empower employees to operate and maintain robotic systems effectively.

How does supply chain management contribute to seamless material flow and long-term sustainability in manufacturing?

Supply chain management provides seamless material flow and mitigates bottlenecks by streamlining processes and enhancing supplier collaboration. Investing in technology and innovation drives process improvements and product quality, fostering a culture of innovation and allocating resources to R&D initiatives. Workforce development equips employees with skills to handle advanced technologies effectively through training and upskilling. Adopting sustainability practices reduces environmental impact, enhances brand reputation, and resonates with environmentally conscious consumers to develop long-term sustainability and competitiveness.

Why is scaling up without changing the operational approach unsustainable?

Scaling up manufacturing assists in maintaining the status quo while making the company utilise the resources properly. Scaling up looks far-fetched without embracing innovative technologies and lean practices. The scope of scalability becomes limited and hinders the ability to meet market demands and achieve cost competitiveness. A rigid operational approach lacks adaptability, making responding to dynamic market conditions and technological advancements challenging. Flexibility, agility, and continuous improvement are the tools for sustaining growth and remaining competitive. As a business, we have to consider the needs of stakeholders to maintain our reputation and market share. Manufacturers embracing innovation, adaptability, and responsible practices align with economic, environmental, and social objectives, ensuring long-term sustainability and success.

How does the Make in India contribute to economic growth, job creation, and global competitiveness?

The Make in India initiative contributes to economic growth, job creation, and global competitiveness. It focuses on skill development and enhancing the capabilities of workers in handling advanced technologies. India has a cost advantage in terms of lower labour costs, attracting manufacturers to cut their production costs.

India has witnessed investments in the manufacturing sector stimulating growth and innovation. Promoting domestic manufacturing reduces dependence on imports and gives any country a stage for global competitiveness. Job creation helps with socio-economic development and contributes to poverty alleviation, inclusive growth and development objectives. The Make in India initiative is essential for growth by improving productivity and contributing significantly to economic development.

Emobi leverages AI for agile micro-factories while addressing scaling challenges with proprietary software. Bharath Rao, CEO of Emobi, focuses on IoT-integrated distributed manufacturing and advanced robotics for efficiency.

What approaches can redefine production efficiency to scale up manufacturing?

Integrating IOT systems and distributed manufacturing facilities managed through centralised procurement, supply chain management, and design teams would be the ideal way to minimise costs and optimise production efficiency despite the complexities of managing distributed manufacturing facilities.

The other approach would be to build mega factories with large-scale integration of advanced robotics and automation processes. This process ensures production in large volumes at optimal costs, with most of the capex involved built into the vehicle cost and recovered from the sale of the products.

How can you leverage advanced robotics to improve productivity?

An automated facility with extensive robotics needs the product design to be frozen for mass manufacturing. If the products are proven and require minimal changes, advanced robotics and automation would significantly reduce the assembly-related risks and maximise productivity.

How is Emobi using AI to enhance its distributed manufacturing model and benefit local markets?

Emobi is looking to innovate building software and core competencies by applying generative AI into a distributed manufacturing model consisting of micro-factories closer to the point of consumption. Our approach is built to be agile, allowing us the flexibility to change models and SOPs. This agile approach towards manufacturing, while working with multiple micro-factory partners, sustainably creates employment and upskilling in local markets closer to the point of consumption.

How do you tackle challenges to scale up manufacturing processes?

The key challenge is the supply chain while manufacturing through distributed decentralised micro-factories. The demand for the same level of quality and conformance with our SOPs across micro-factories are the key challenges we are looking to address through our proprietary software platforms. 

How do you create a culture of learning and upskilling workers?

We believe that our micro-factories act as training centres for upskilling workers and empower them with the software tools to act as ready reckoners. The learning route guides to assist them in their professional and career growth.

What are the advantages of the Make in India initiative?

The Make in India scheme has elements that incentivise localised manufacturing and state-level subsidies. It is coupled with central subsidies, making our model more attractive to promote micro-factories, skill development and employment generation across the parts of the country.

Plastics in automotive manufacturing offer weight reduction, as they are lighter than metals, enhancing fuel efficiency and reducing emissions, especially in the context of stringent environmental regulations and the increasing demand for electric vehicles (EVs).

The automotive plastic market is crucial in the modern automotive industry, offering lightweight, durable, and cost-effective solutions for vehicle performance and fuel efficiency. Its applications include interior and exterior components, under-the-hood parts, and electrical systems, driving innovation and sustainability in vehicle design and manufacturing.

Persistence Market Research predicts a 7.5 percent CAGR in the global automotive plastic market from 2024 to 2031, with a market size of $43.9 billion by 2031. Factors driving growth include increased vehicle production, stringent emission regulations, and demand for lightweight materials. The automotive industry is constantly evolving, driven by fuel efficiency, emissions reduction, and enhanced performance. Innovative use of plastics in vehicle design is a significant contributor to these advancements. The automotive plastic market has grown exponentially over the past few decades, with new materials and technologies pushing the boundaries of vehicle design and manufacturing.

Metals such as steel and aluminium have traditionally been the preferred materials in vehicle manufacture due to their strength and durability. However, plastics have evolved as a viable alternative, providing a number of advantages that metals cannot match. The usage of plastics in automobile applications began in the mid-twentieth century and has since grown dramatically. Today, the average automobile comprises roughly 20 percent plastic by weight, and this figure is anticipated to climb as manufacturers look for ways to cut vehicle weight and increase efficiency.

Key benefits of automotive plastics

Plastics in automotive manufacturing offer weight reduction, as they are lighter than metals, enhancing fuel efficiency and reducing emissions, especially in the context of stringent environmental regulations and the increasing demand for electric vehicles (EVs).

Plastics provide exceptional design flexibility, enabling manufacturers to create complex shapes and structures that are difficult or impossible with metals, thereby enhancing fuel efficiency and performance.

Cost Efficiency in plastics are generally less expensive to produce and process than metals. This cost efficiency extends to the manufacturing process, where plastic components can often be molded in a single step, reducing assembly time and labor costs.

Modern automotive plastics are durable and corrosion-resistant, ensuring their longevity and lower maintenance costs, resulting in longer vehicle lifespans.

Enhanced plastics safety can absorb and dissipate energy more effectively than metals, which is crucial in the event of a collision. This energy absorption capability helps improve crash safety and protect occupants.

Innovations driving the market

The automotive plastic market is experiencing significant advancements, particularly in the use of composite materials. These materials, which combine plastics with materials like carbon fiber or glass, are becoming more popular in automotive manufacturing due to their superior strength-to-weight ratios, making them ideal for applications requiring durability and lightweight properties.

Carbon Fiber Reinforced Plastics (CFRP) and Glass Fiber Reinforced Plastics (GFRP) are two promising automotive composite materials. CFRP is lightweight, strong, and rigid, used in high-performance sports cars due to its high cost. GFRP is used in body panels, bumpers, and structural components, balancing cost and performance. Research and development are making CFRP more affordable for mass-market vehicles.

Bioplastics and sustainable materials

As the automotive industry strives for greater sustainability, bioplastics and other eco-friendly materials are gaining traction. These materials are derived from renewable sources such as plants and algae, reducing the environmental impact of vehicle manufacturing.

Polylactic Acid (PLA): PLA is a biodegradable plastic derived from renewable resources like corn starch or sugarcane. It is being explored for use in interior components and other non-structural applications.

Polyhydroxyalkanoates (PHA): PHA is another biodegradable plastic produced by bacterial fermentation of sugars or lipids. It offers similar properties to traditional plastics but with the added benefit of being environmentally friendly.

3D pinting and additive manufacturing

3D printing, also known as additive manufacturing, is revolutionizing the way automotive components are designed and produced. This technology allows for the creation of highly complex and customized parts with minimal material waste.

3D printing facilitates rapid prototyping, enabling manufacturers to rapidly produce and test new designs, accelerating development and reducing time to market for new vehicles. It also aids in on-demand manufacturing of replacement parts, reducing inventory costs and ensuring availability when needed.

Nanotechnology is opening up new possibilities for automotive plastics by enhancing their properties at the molecular level. Nanocomposites, which incorporate nanoparticles into plastic matrices, offer improved mechanical, thermal, and electrical properties.

Improved Strength and Durability: Nanocomposites can significantly enhance the strength and durability of plastic components, making them more suitable for demanding applications.

Enhanced Thermal Stability: Nanoparticles can improve the thermal stability of plastics, allowing them to withstand higher temperatures without degrading. This is particularly important for under-the-hood applications.

Conductive Plastics: Nanotechnology can be used to create conductive plastics, which can replace traditional metal conductors in some applications. This can further reduce vehicle weight and improve fuel efficiency. The use of plastics in automotive design is extensive, covering a wide range of applications from the interior to the exterior and under the hood. Some of the key applications include:

Interior components

Plastics are widely used in vehicle interiors due to their versatility and aesthetic appeal, particularly in dashboard and instrument panels, where they allow for intricate designs and advanced features.

Modern plastics provide comfort, durability, and ease of cleaning for seating and upholstery, while also being used for trim and molding components, offering high-quality finishes and customization options.

Exterior components

Plastics significantly enhance the exterior of a vehicle, offering weight reduction and design flexibility, with key applications including:

Bumpers and Fenders: Plastics offer excellent impact resistance, making them ideal for bumpers and fenders.

Plastics significantly enhance the exterior of a vehicle, offering weight reduction and design flexibility, with key applications including:

Under-the-hood components

Plastics are also used in various under-the-hood applications, where their durability and resistance to heat and chemicals are crucial. These applications include: Engine Covers: Plastic engine covers offer a lightweight alternative to metal, reducing overall vehicle weight.

Manifolds, such as air intake and fluid reservoirs, are typically made from plastics due to their durability in high temperatures and corrosive environments.

Challenges and future prospects

While the automotive plastics industry is expected to develop significantly, it confronts a number of hurdles. These include worries about plastic waste and environmental effect, as well as the necessity for ongoing breakthroughs in material qualities and manufacturing procedures.

Environmental concerns: The automobile sector is under growing pressure to lessen its environmental impact. While plastics can reduce weight and improve fuel economy, they also add to plastic trash. Developing more sustainable plastics and improving recycling methods are critical for tackling these issues.

Material Advancements: Continued research and development are needed to enhance the properties of automotive plastics, particularly in terms of strength, durability, and thermal stability. This will ensure that plastics can meet the demanding requirements of modern vehicles.

The automotive plastics industry is at the forefront of innovation, shaping the future of vehicle design. From innovative composite materials and sustainable bioplastics to cutting-edge production processes and nanotechnology, the possibilities are limitless. As the industry evolves, plastics will play an increasingly important role in automobile manufacturing, opening up new prospects for increased performance, economy, and sustainability. These breakthroughs are shaping the future of transportation, and the automotive plastics industry is poised to play a key part in that shift.

The collaboration for Mid-mile Logistics aims for 100 percent conversion of the fleet of trucks in this category over the next 5 years with support from government schemes & policies and in partnerships with OEMs and fleet operators.

Revfin, India’s pioneering digital lending platform that promotes sustainable mobility, disclosed a collaboration with Kalyani Powertrain Ltd (KPTL), Bharat Forge Ltd’s electric mobility arm, and Bluwheelz, a provider of sustainable logistical solutions, to introduce retrofitted electric trucks to the Indian logistics sector. It has developed novel financing instruments to facilitate the full conversion of truck fleets over the next five years, with government aid and collaboration with OEMs and fleet operators. This effort supports Revfin’s objective to transform the EV ecosystem and promote sustainable mobility.

KPTL has successfully homologated converted electric trucks with GVWs ranging from 10 to 16T for the N3 Goods Carrier market. These trucks are intended to sustainably service a variety of industries, including FMCG, e-commerce, cement, steel, and perishable items, increasing the availability of ‘Made in India’ solutions in the global automotive industry.

Retrofitting of EVs is crucial in the evolution of urban transport, significantly contributing to sustainable and smart cities. As global efforts to combat climate change and reduce vehicular emissions intensify, retrofitting offers a practical step towards a fully electric future as it helps extend the lifespan of old vehicles by up to 5 to 7 years and helps them in avoiding scrappage as endowed by regulations.

However, faster acceleration and adoption of retrofitted EVs and EVs in general would be achievable only if lower-cost funding is made available by different financial and climate-focused organisations in India and throughout the world. Furthermore, supporting programmes and incentives for obtaining carbon credits can dramatically lower financing costs, allowing for more widespread EV adoption.

Sameer Aggarwal, CEO and Founder, Revfin, said“We are dedicated to revolutionizing sustainable mobility and strengthening the EV ecosystem. Retrofitting is key to achieving decarbonization and net-zero goals worldwide, making EV adoption more accessible while fostering a greener future. It extends vehicle lifespan, integrates recycling principles, and reduces operating costs. By financing retrofitted vehicles, Revfin supports broader sustainability goals. However, we advocate for regulations that simplify retrofitting processes and extend the vehicle registration period beyond 15 years. Deep research on battery life extension will also help this sector. The scope of retrofitting isn’t limited to fleets but extends to school buses, chartered buses, travel, tourism, and beyond.”

CP Sethi, CEO and Co-founder, Bluwheelz, said, “This marks the launch of India’s first medium-duty retrofitted electric trucks for the mid-mile logistics segment in India. These trucks are capable of carrying a payload ranging between 7-10T and are designed to operate on intercity routes. We are deploying these trucks to serve a wide clientele base across various sectors to ensure fulfilling their green and clean mobility goals. We appreciate both Revfin and KPTL for their invaluable support in making this journey possible towards achieving sustainability in the logistics sector,” 

Amit Kalyani, the Vice-Chairman & Joint Managing Director, Bharat Forge Ltd, said, “KPTL is dedicated to developing sustainable transportation infrastructure. The company is committed to innovation and sustainability in addressing the needs of heavy electric vehicles in India. By introducing ground-breaking EV products and promoting retrofitted vehicles, we aim to make these vehicles the preferred choice for customers as these trucks can result in a 24 percent reduction in the Total Cost of Ownership (TCO) as compared to new electric models,” 

While the shift from internal combustion engine-powered automobiles to electric vehicles is currently challenging, a concerted effort incorporating government efforts, business collaboration, and public participation can assist overcome these obstacles. They may work together to create a more sustainable future and lead the drive towards a cleaner, greener planet.

The Indian Army has partnered with Indian Oil Corporation Limited (IOCL) to conduct demonstration trials of Hydrogen Fuel Cell Bus technology, demonstrating a commitment to green and sustainable transportation.

The Indian Army has partnered with Indian Oil Corporation Limited (IOCL) to conduct demonstration trials of Hydrogen Fuel Cell Bus technology, demonstrating a strong commitment to discovering green and sustainable transportation solutions. The Indian Army is renowned for its dedication to innovation and environmental sustainability.

A Memorandum of Understanding (MoU) was signed by the Indian Army and the IOCL in the presence of General Manoj Pande, Chief of the Army Staff (COAS), and Shrikant Madhav Vaidya, Chairman of Indian Oil. During the ceremony, the Indian Army got one hydrogen fuel cell bus. This signals the beginning of a mutually beneficial cooperation between the Indian Army and IOCL. The MoU underlined the parties’ commitment to encouraging innovation and improving sustainable transport solutions in the future.

Hydrogen Fuel Cell technology provides a clean and efficient alternative by turning hydrogen gas into power via an electrochemical method. The technique generates just water vapour as a byproduct, resulting in zero emissions. The Hydrogen Fuel Cell Bus offers seats for 37 people. It boasts an amazing mileage of 250-300 on a full 30 kilogramme onboard hydrogen tank.

Significantly, the Indian Army signed an agreement with National Thermal Power Corporation Renewable Energy Limited on March 21, 2023, making it the first government body to do so for the construction of microgrid power plants based on green hydrogen along the country’s northern borders. A pilot project is being setup at Chushul, where a 200 Kilo Watt Green Hydrogen based Microgram will provide 24×7 clean electricity to troops deployed in inhospitable terrain and extreme climatic conditions.  

The Indian Army and IOCL’s Hydrogen Fuel Cell Bus project, which focuses on innovation and environmental responsibility, is a big step forward in the direction of cleaner and greener transportation options.