Inside UCAL’s Talent Playbook as Automation, Software and Electrification Hit the Shop Floor

As AI, machine learning, Industry 4.0 and automation reshape how vehicles are designed and built, the real battleground for suppliers is about  how fast their people can skill, reskill and upskill. In this interview, Adithya Jayakar, deputy managing director at UCAL Ltd, explains how the company is strengthening deep electronics and software capabilities while hard-wiring structured learning into everything from PPAP and traceability to digital quality and MES. He also outlines how UCAL is using OEM-led academies, supplier-cluster programs and ROI-driven, low-cost learning models to future‑proof its own teams and Tier 2–3 partners against the next wave of automation-led disruption.

As a supplier, what new skill demands are coming from OEMs, both in terms of product technology (e.g., electronics, sensors, battery components) and process capability (PPAP, traceability, digital quality systems)?

OEMs are pushing deep technical skills in vehicle electronics (ECUs, communication buses like CAN/FlexRay), sensors (LiDAR, ultrasonic, IMU — calibration and validation), high-voltage systems and battery-pack components, BMS interfaces and power electronics, software-defined features including OTA and basic cybersecurity awareness. On the process side, they require stronger PPAP discipline for electronic and high-voltage assemblies, end-to-end traceability (serialization, barcode/RFID, batch genealogy), automated/digital inspection (machine vision, inline data capture), SPC with real-time dashboards and integration capability with OEM PLM/ERP landscapes.

How are you supporting Tier 2 and Tier 3 vendors in your own supply chain to meet rising skill and quality expectations?

We run targeted capability-building programs such as joint audits, capability roadmaps and prioritized gap-closure plans focused on quality, testability and EHS. We provide hands-on technical assistance including shared test fixtures, calibration support and co‑engineering for sensor and battery subassemblies. To accelerate digital adoption we subsidise basic MES/traceability modules, share standardised SOPs and inspection criteria and mentor suppliers through first-article approvals to improve PPAP hit-rates.

Are you using OEM-run training centres or joint programs (e.g., TPM, lean, electrification modules) to upgrade your teams? What has worked and what has not?

Yes, we participate in OEM and sector programs (TPM, lean, electrification) and host joint workshops with customers and suppliers. What’s worked for us is blended learning that combines classroom content with shopfloor coaching and live project application; vendor-cluster trainings where multiple suppliers learn together and short modular certifications tied to KPIs. What hasn’t worked is one‑off classroom sessions without on‑job follow-up, overly generic content not tailored to shopfloor realities and long centralized courses that keep critical staff off the line too long.

Given margin pressures, how do you justify training budgets internally and what innovative, low-cost models have you adopted (shared trainers, online modules, cross-company programs)?

We justify training by linking it to measurable outcomes such as fewer defects, faster PPAP approvals, lower warranty expense and improved OTIF, and present ROI cases showing break‑even from defect reduction and uptime gains. We use low-cost models like shared trainers across supplier clusters and OEM consortia; modular e-learning and micro‑learning for shopfloor staff; train‑the‑trainer using internal SMEs; short on‑site skill sprints and peer-learning circles besides leveraging OEM-subsidized programs and government/sector skilling grants to defray costs.