Hyundai Motor India is more and more counting on real-time analytics to optimise manufacturing, with its Chennai plant producing over 20 billion annually by way of its Industrial Web of Issues (IIoT) community, in accordance with the carmaker’s newest annual report. The information generated is monitored by way of 200 sensible dashboards, offering operators and engineers with real-time insights.
These sensible dashboards are used to trace equipment efficiency, determine potential faults, and assist steady course of enchancment. In line with the report, the mixing of IIoT has allowed for extra exact decision-making on the shopfloor and helped Hyundai transfer in the direction of a extra data-centric manufacturing mannequin. On the firm’s facility in Sriperumbudur, close to Chennai, IIoT has been rolled out throughout seven main retailers, masking greater than 86 per cent of essential equipment.
The report underscores Hyundai’s continued funding in constructing what it phrases a Software program-Outlined Manufacturing unit (SDF). This initiative integrates synthetic intelligence, digital twin know-how, and autonomous cellular robots to allow a versatile and responsive manufacturing surroundings.
The SDF framework is being positioned as a manner to enhance operational agility by permitting for faster changes in manufacturing and higher integration between design, high quality management, and provide chain features. It additionally helps predictive capabilities that goal to scale back downtime and enhance total throughput.
Superior know-how integration
In parallel with IIoT, Hyundai can be exploring the mixing of generative synthetic intelligence, 5G applied sciences, and next-generation digital twins. These are anticipated to additional streamline the design-to-manufacture cycle, enhance materials choice, and automate high quality management workflows.
Whereas these applied sciences are nonetheless below analysis, the corporate notes that their deployment may play a big position in enhancing the responsiveness and effectivity of its Indian operations sooner or later.
Sustainability and vitality transition
The report additionally highlights Hyundai’s progress in the direction of its world carbon neutrality objective. The corporate has reported 88 per cent renewable vitality adoption in India throughout FY 2024–25 and stays on observe to attain RE100 by the top of 2025. This transition is being pushed by way of energy buy agreements for photo voltaic and wind vitality.
Additional measures have been taken throughout the plant to enhance vitality effectivity. These embrace the set up of a waste warmth restoration system and aerogel insulation within the paint store, each designed to scale back steam consumption and minimise warmth loss.
Hyundai has continued to extend localisation throughout its Indian portfolio. The report states that over 1,200 key elements have been localised, supported by partnerships with greater than 200 suppliers. As of FY 2024–25, the corporate has achieved 81.7 p.c localisation in inner combustion engine (ICE) automobile manufacturing.
This aligns with the Authorities of India’s Atmanirbhar Bharat initiative, which inspires home worth addition and native sourcing. Hyundai has additionally retained its place as the most important cumulative exporter of Made-in-India passenger autos, reflecting its twin technique of localisation and world competitiveness.
Electrical automobile readiness
To assist electrical automobile (EV) manufacturing within the nation, Hyundai has arrange a devoted battery meeting facility in partnership with Mobis India. Whereas the corporate has not detailed particular EV launch timelines within the report, the ability is predicted to strengthen the backend ecosystem for EV manufacturing and cut back dependency on imported battery packs.
A number of manufacturing strains have undergone upgrades aimed toward enhancing effectivity and reliability. Notable initiatives embrace the implementation of an augmented actuality (AR) meeting coaching system and 6 digital actuality (VR) coaching modules for workforce improvement.
Operational enhancements embrace improved wheel alignment accuracy, the set up of a sunroof loader to scale back meeting downtime, and the alternative of out of date machines to enhance uptime and sustainability metrics. A brand new manufacturing line for the Hyundai EXTER was established in the course of the 12 months, resulting in a 1.5 instances improve in capability.
The corporate has additionally added AI imaginative and prescient techniques in its powertrain store for real-time defect detection, and launched one hundred pc auto sealant verification and important gap inspection within the engine store.
Hyundai’s annual report displays a shift in the direction of a extra built-in and data-driven strategy to automotive manufacturing in India. With increasing IIoT connectivity, focused vitality transitions, and superior automation initiatives, the corporate seems centered on constructing a resilient and adaptive manufacturing footprint.
