As India leapfrogged from BS4 straight to BS6, heavy trucks quietly crossed a tipping point. Emissions compliance was only one part of the change. Electronics and mechatronics have begun to reshape how trucks are engineered, monitored and operated.
03 Feb 2026 | 243 Views | By Mukul Yudhveer Singh
BS6 has fundamentally altered the role electronics play in commercial vehicles, shifting the focus from mechanical robustness alone to uptime, diagnostics and operational efficiency, Sanjeev Kumar, President, M&HCV at Ashok Leyland, told Autocar Professional.
Earlier-generation trucks, largely mechanical in nature, depended heavily on operator intervention. In contrast, BS6 platforms ...
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BS6 has fundamentally altered the role electronics play in commercial vehicles, shifting the focus from mechanical robustness alone to uptime, diagnostics and operational efficiency, Sanjeev Kumar, President, M&HCV at Ashok Leyland, told Autocar Professional.
Earlier-generation trucks, largely mechanical in nature, depended heavily on operator intervention. In contrast, BS6 platforms are built on a connected electronic architecture that allows OEMs to monitor vehicle health in real time. Kumar said Ashok Leyland now tracks BS6 trucks through its uptime solution centre in Chennai, staffed by nearly 100 engineers, enabling predictive diagnostics and early fault detection.
“The expectation today is that manufacturers manage uptime while operators focus on running their fleets,” Kumar said, underlining how responsibility is gradually moving upstream to OEMs.
Electronics have also increased bill-of-material costs, largely due to engine after-treatment systems and sensors. However, Kumar argued that productivity gains compensate for the higher costs. Where older trucks typically ran around 7,000 km a month, new-generation BS6 trucks now operate at 14,000–15,000 km per month, driven by better reliability and utilisation.
While electronics act as a key enabler, Kumar stressed that efficiency and reliability still depend on core engineering. Engines and gearboxes remain central, supported by mechatronics. Ashok Leyland continues to develop its engines in-house, without technical collaborations, a strategy the company links to its Atmanirbhar Bharat approach.
The shift toward electronics is also reshaping the wider ecosystem. Dealers increasingly recruit engineers with electronics expertise, while suppliers work closely with the OEM on advanced systems rather than purely mechanical components.
Beyond hardware, connected systems now generate driver scorecards, allowing operators to analyse driving behaviour and address fuel efficiency issues through training rather than mechanical intervention. Large fleet operators, Kumar added, are setting up command centres to track vehicle location, downtime and turnaround times.
As BS6 matures, Kumar said electronics will play a growing role in improving operational efficiency, marking a structural shift in how heavy trucks are designed and managed.
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