Precision fastening, robotic assembly and digital monitoring systems are becoming increasingly important in automotive manufacturing, particularly as vehicle manufacturers seek tighter production tolerances and greater traceability across assembly operations.
Speaking at the Autocar Professional India EV Conclave 2026, Vikas Bhat, India Service Leader, Power Tools and Industrial Lifting, Ingersoll Rand, detailed the company's work in automotive assembly, including electric two-wheelers, three-wheelers, passenger vehicles and commercial vehicles.
Bhat said Ingersoll Rand commands more than 80% market share in equipment supplied for EV manufacturing in India. Its solutions cover precision fastening, robotic integration, material handling and manufacturing execution systems.
A significant part of the presentation focused on fastening accuracy, particularly in critical automotive joints involving suspension, chassis and wheel assemblies. Bhat said the company's transducerised DC fastening tools offer accuracy levels of approximately 2–3%, while recording tightening parameters for quality monitoring.
The tools are Industry 4.0-compatible, allowing manufacturers to capture torque values, tightening timestamps and other production parameters. These records enable manufacturers to trace individual fastening operations, particularly where incorrect tightening could affect vehicle safety or assembly quality.
Ingersoll Rand also supplies cordless, Wi-Fi-enabled fastening tools for applications where access to joints is restricted. These include locations beneath vehicle chassis and within complex assemblies where conventional cable-connected equipment can be difficult to operate. The wireless systems retain torque monitoring and traceability capabilities.
Bhat also discussed the integration of fastening tools with industrial robots. The company's equipment can be mounted on robotic arms from manufacturers including FANUC, KUKA and ABB, allowing programmed tightening operations to be performed without manual intervention.
Such installations are particularly relevant to high-volume automotive production, where assembly cycle times are critical. Bhat cited two-wheeler production lines operating at intervals of approximately 13–14 seconds per vehicle, highlighting the need for automated fastening operations that can maintain accuracy at high production speeds.
Another technology discussed was Ingersoll Rand's PICO manufacturing execution system (MES), which provides centralised monitoring and control of production equipment.
According to Bhat, the software can integrate fastening tools, industrial robots, servo motors and other connected manufacturing devices. Manufacturers can monitor operating parameters, record production data and modify tightening sequences or cycle times from a centralised control station. He said the system can be configured and made operational in less than two days.
Beyond fastening, Ingersoll Rand supplies material handling equipment, including electric hoists, balancers, handling arms and rail-mounted systems. These assist operators in lifting and positioning heavy components during repetitive assembly operations, reducing physical strain on production lines.
Bhat cited installations at automotive manufacturers including Maruti Suzuki, Honda, Tata Motors, Hyundai, Ather, Ola Electric and Yamaha. He also referred to customised handling solutions supplied to TVS Motor Company and Volvo Eicher Commercial Vehicles.
On localisation, Bhat said the company manufactures industrial power tools and lifting equipment at its Sahibabad facility in Ghaziabad. The location also houses engineering, service and customised solutions capabilities, supported by NABL-accredited calibration facilities.
The company maintains a nationwide service network to support installed equipment, with Bhat emphasising the importance of aftersales support in managing the total cost of ownership for automotive manufacturers.