| India’s Electric Vehicle (EV) industry has a come long way since the launch of EVs such as Lovebird (by Eddy Electric) Reva (by Mahindra) to name a few. However, limited infrastructure and high costs kept electric vehicles from becoming mainstream, confining them to a niche market. Since then, the Indian EV industry has come a long way, and it’s experiencing a phase of rapid adoption. This has put India on the map for electric mobility.
Narayan Kumar,
Divisional Director – Industrial Devices Division,
Panasonic Life Solutions India
A major turning point came in 2015 with the launch of the Faster Adoption and Manufacturing of Hybrid and Electric Vehicles (FAME) scheme. This government initiative provided financial support for both EV adoption and charging infrastructure development. This gave the EV industry a significant boost and we may witness a surge in EV adoption, particularly in two- and three-wheeler segments, where four-wheelers are catching up fast.
In 2023, total EV sales reached 1.53 million, up from 1.02 million in 2022, showing a strong trend in EV adoption. According to the Economic Survey of India 2023, the domestic electric vehicle market is expected to grow at a robust compound annual growth rate (CAGR) of 49% from 2022 to 2030, with an estimated 10 million annual sales by 2030.
This upward trend is encouraging, isn’t it? But the question remains whether Indian OEMs can handle this strong demand and adapt to modern manufacturing practices that are agile, secure, and scalable. The answer is clear: it will be imperative.
EV manufacturers will have to employ intelligent, flexible, and economical production processes to increase productivity and efficiency. This calls for the need for smart automation!
Traditional manufacturing methods, although reliable, often struggle to keep pace with the high-volume production of complex EVs. Smart automation is one of the solutions. By integrating intelligent technologies like robots, data analytics, and machine learning, manufacturers can unlock a new era of efficiency and quality control.
One of the most substantial advantages of smart automation is its ability to enhance production speed and efficiency. Repetitive tasks like welding, battery pack handling, and component assembly can be automated using industrial robots. These tireless machines work with unmatched precision and consistency, significantly reducing production time compared to manual labor.
Furthermore, it elevates quality control. Sensors including Photoelectric, Programmable Controllers, Pressure/Flow Sensors, and Inductive Proximity sensors, amongst others embedded throughout the production line, gather real-time data, allowing for continuous monitoring and analysis while identifying potential defects and anomalies before they become problems, ensuring consistent quality in every EV.
Employee safety is paramount in any manufacturing environment. Deploying Light Curtains and Area Sensor can reduce the risk of workplace injuries significantly. Industrial robots like wielding robots keep the human workforce safe. Beyond efficiency and safety, smart automation offers remarkable flexibility. Human Machine Interface (HMI) panels can enhance operability and come preloaded with Web Server, and IIoT 4.0 features to facilitate the process of designing custom interfaces, eventually reducing the time and effort to reconfigure production lines to accommodate new models and variations, allowing manufacturers to respond swiftly to changing market demands.
Going forward, artificial intelligence (AI) will play a critical role in automated decision-making and advanced process control. “Digital twins” – virtual replicas of production lines – will be used to simulate and optimize processes before real-world implementation. Additionally, the Internet of Things (IoT) will enable seamless connectivity, allowing real-time data collection and analysis across the entire supply chain.
Even though smart automation holds immense potential for the future of electric vehicles, it also presents its own set of challenges including cybersecurity which should be addressed through robust encryption protocols and comprehensive cybersecurity measures. The initial investment costs for advanced technologies can be significant too. The transition towards smart automation requires upskilling the workforce to adapt to new technologies and roles in manufacturing and maintenance.
Leading manufacturers are addressing these challenges strategically. They are working closely with partners to explore cost-effective solutions and leverage economies of scale. More importantly, they are investing heavily in their workforce through comprehensive training programs that bridge the skill gap and empower employees to thrive in this new era of manufacturing. Collaborative efforts between academia, industry, and policymakers are essential to facilitate this transition and ensure a smooth integration of smart automation in the automotive sector.
Smart automation will redefine the electric vehicle industry, and drive advancements in safety, efficiency, and user experience and now it’s not just limited to new technologies; it will reshape how vehicles are designed, made, and used. From enhancing vehicle safety through advanced driver assistance systems to streamlining manufacturing processes with robotics and IoT, smart automation is reshaping every aspect of EV development and deployment. With the Production Linked Incentives (PLI) Scheme, the Indian manufacturing landscape will witness increased investment and technological advancement that is poised to drive further innovation in the EV industry.
