Hyundai Leverages 20 Billion Data Points for Smart Manufacturing in Chennai

Hyundai Motor India is making big strides in refining its manufacturing operations, as highlighted in its latest annual report. 

Central to this transformation is the company’s investment in a Software-Defined Factory (SDF) framework, which leverages artificial intelligence, digital twin technology, and autonomous mobile robots. 

The company’s Chennai plant now generates over 20 billion data points annually through its Industrial Internet of Things (IIoT) network. This vast amount of data is monitored via 200 smart dashboards, giving operators and engineers immediate access to actionable insights.

This initiative aims to create a flexible, responsive, and highly integrated manufacturing environment, enabling Hyundai to swiftly adapt production lines and seamlessly connect design, quality control, and supply chain functions.

As per Hyundai, the SDF approach is designed to boost operational agility, allowing for rapid adjustments in production and improved predictive maintenance. 

Digital Integration

As per the annual report, Hyundai is also exploring the integration of cutting-edge technologies such as generative AI, 5G connectivity, and next-generation digital twins. 

These advancements are expected to further streamline the design-to-manufacture cycle, optimise material selection, and automate quality control processes. 

Sustainability and Localisation Drive

The report underscores Hyundai’s commitment to sustainability, with the company achieving 88 per cent renewable energy adoption in India during FY 2024-25. Hyundai remains on track to reach RE100 by the end of 2025, primarily through solar and wind power purchase agreements. 

Energy efficiency measures, such as waste heat recovery systems and aerogel insulation in the paint shop, have also been implemented to reduce energy consumption.

Localisation remains a key pillar of Hyundai’s strategy, with over 1,200 components now sourced locally and partnerships established with more than 200 suppliers. 

The company has achieved 81.7 per cent localisation in internal combustion engine vehicle production, aligning with the Government of India’s Atmanirbhar Bharat initiative. 

EV Readiness and Operational Upgrades

To support the growing electric vehicle (EV) market, Hyundai has established a dedicated battery assembly facility in collaboration with Mobis India. This move is expected to strengthen the EV manufacturing ecosystem and reduce reliance on imported battery packs.

Production lines have been upgraded with augmented reality assembly training, virtual reality modules for workforce development, and AI vision systems for real-time defect detection.

Operational enhancements, as per the company, include improved wheel alignment, the installation of a sunroof loader, and the replacement of outdated machinery to boost uptime and sustainability. 

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