AI, ML, and robotics power manufacturing agility at Chennai and Talegaon.
21 Apr 2025 | 7233 Views | By Ketan Thakkar & Kiran Murali
The automobile industry is no stranger to automation, having been one of the first to incorporate the use of robots. But now, Hyundai Motor India has gone one step further, empowering the robots with artificial intelligence to carry out tasks that they were simply not equipped to earlier.
Many ...
This is an Autocar Pro Plus article. Subscribe to continue reading.
The automobile industry is no stranger to automation, having been one of the first to incorporate the use of robots. But now, Hyundai Motor India has gone one step further, empowering the robots with artificial intelligence to carry out tasks that they were simply not equipped to earlier.
Many of the 790 or so robots working at its Sriperumbudur facility now come with AI, giving them novel capabilities.
An example is the AI-powered exterior confirmation system. Earlier, operators manually inspected car parts against specifications — a time-consuming and error-prone process. With a tablet-based interface and barcode scanning, the AI system verifies over 30 exterior parts in under a minute with near-zero error rates.
"This ensures consistency in quality without relying on the operator's memory, significantly improving the inspection process," points out Gopala Krishnan CS, Chief Manufacturing Officer, Hyundai Motor India.
Hyundai has also introduced vision-based robots for engine inspection, leveraging high-speed cameras to automate quality checks further. These solutions not only reduce fatigue but also enhance precision and reliability.
However, it is not just the products that get the attention of AI, it’s also the machines in the factory.
The company has implemented a predictive maintenance system in the plant.
By placing sensors on robots, fans, and drop lifters, Hyundai collects data on pressure and vibration, which is processed using R and Python to predict failures before they occur.
“These AI-ML tools help us avoid unplanned breakdowns and improve efficiency,” said Krishnan, adding that dozens of data projects are now undertaken annually across maintenance, supply chain, and quality functions.
Hyundai began its digital transformation journey in 2016 and has trained over 50 engineers in data analytics and IoT.
Talegaon Plant
The upcoming plant in Talegaon, Maharashtra, acquired by General Motors, is also being given a digital overhaul, emphasizing flexibility, digitization, and sustainability.
“The plant will be at par with any other Hyundai plant worldwide regarding software integration, IoT usage, and AI implementation,” said Krishnan. The new plant will also support Hyundai’s electrification roadmap, with shared internal combustion engine (ICE) lines and electric vehicles (EVs), including readiness for skateboard EV platforms.
Like Chennai, the Talegaon plant is also being designed for the production of multiple powertrain products.
At the Chennai plant—which already makes a whopping 450 variants for domestic and international markets—Hyundai has put integrated EV-specific stations, such as battery loading, within existing assembly lines. Talegaon will inherit these learnings and scale them up with enhanced digital infrastructure.
Currently, Hyundai's Chennai plant has a capacity of 8.24 lakh units. In comparison, Talegaon will add up to 2.5 lakh units annually in its second phase, taking the total to over 1.1 million units.
Battery localization is also underway. The Hyundai Group firm Mobis has commissioned a battery assembly facility with a 75,000-unit capacity in Phase 1. At the same time, Hyundai Motor Group has partnered with Exide for LFP batteries to meet long-term electrification needs.
Workforce Upskilling
Hyundai’s digital push extends to its workforce as well. Engineers, supervisors, and operators undergo structured training programs, including VR-based modules for new product introduction. This enables faster skill development and product readiness, according to Krishnan.
Besides digitalization, the company is also focused on reducing its energy and emissions footprint. The Chennai plant already sources 75% of its energy from renewables and targets 100% renewable energy by year-end. Talegaon, which is still under development, will also get a major part of its energy from green sources.