The future of mobility is being shaped by the convergence of electrification, autonomous driving, and sustainable manufacturing practices. With digital technologies revolutionizing production processes, the automotive industry is poised to lead the charge toward a greener, more efficient world, writes Sameer Jindal, Director at MG Motor India & SIAM Co-Chair for Connected Cars.
The future of mobility is being redefined by the convergence of electrification, CONNECTED CARS, SDVs or software driven vehicles, autonomous driving, and shared mobility solutions, driven by the urgency of sustainability and digital transformation. As the world shifts towards electric vehicles (EVs), reducing dependence on fossil fuels and lowering emissions, the need for sustainable manufacturing processes is growing exponentially. Digital manufacturing, through advancements such as Industry 4.0, automation, AI, and the Internet of Things (IoT), is playing a pivotal role in this transformation, enabling efficient production, reducing waste, and optimizing resources.
While we are currently living to see the fourth industrial revolution (also known as Industry 4.0) unfolding around us, the world is poised for the next big leap, the fifth industrial revolution or Industry 5.0. While Industry 4.0 focuses on technology-driven optimization, Industry 5.0 places humans at the center of operations, leveraging digital technologies to empower workers and improve their work-life balance. ndustry 5.0 is believed to bring humans back into the game for collaboration and introduce the human touch to manufactured products while simultaneously focusing on sustainable manufacturing
BIG DATA: In Industry 4.0, the exponential growth of Big Data posed significant challenges for organizations. The escalating volume of data, doubling annually according to a report by Oracle, created difficulties in storage and management. The key challenges included not only storing the data but also the intricate task of data curation. This involved processes such as cleaning up irrelevant data, processing, analysis, and ensuring security. The ultimate goal was to provide granular level access, enabling deeper insights and facilitating informed decision-making. Moving forward to Industry 5.0, these challenges have been addressed through advancements in technology and data management strategies. The integration of artificial intelligence, machine learning, and real-time processing capabilities has enabled more efficient handling of vast datasets. Improved data analytics techniques allow for better identification of patterns and correlations in the data, leading to more informed decision-making.
Industry 5.0 emphasizes the need for real-time processing to handle the massive amounts of data generated by artificial intelligence, sensor-based connected systems, social networking, and digital communication devices. This shift towards real-time processing facilitates quicker decision-making and prediction of outcomes..
In summary, Industry 5.0 addresses the challenges posed by Big Data in Industry 4.0 through the integration of advanced technologies and a more nuanced understanding of data characteristics. Real-time processing, enhanced analytics, and a broader perspective on data dimensions contribute to more effective data handling and decision-making processes in the fifth industrial revolution.
Industry 4.0 centers on collecting, processing, and analyzing digital data from various sources to enhance process efficiency, decision-making, and continuous improvement. AI and ML algorithms process data from connected sensors in a centralized location, providing insights into manufacturing processes. This understanding allows industries to optimize operations, achieve unprecedented efficiency, and improve product quality. However, challenges such as high implementation costs, skilled workforce requirements, and skepticism among organizations persist. The societal impact of these disruptive technologies raises concerns, urging business leaders and policymakers to explore ways of adopting them without adversely affecting communities. This recognition of the socio-economic impact sets the stage for Industry 5.0, emphasizing the need to involve humans in the integration of technologies to avoid potential disruptions to society.
Association for Advancing Automation has predicted that the need for greater customization and personalization would drive the fifth industrial revolution that would revolve around a larger collaboration between machines and humans to realize the dual benefits of cognitive computing and human intelligence.
The fifth industrial generation, characterized by Industry 5.0, is marked by a shift in the role of robots. Unlike their predecessors, these robots, known as collaborative robots or “cobots,” are designed to work in tandem with humans, under human guidance. Enabled by advancements in digital technologies such as artificial intelligence, machine learning, and conventional robotics, cobots possess the ability to sense and adapt to their surroundings, providing flexibility and adaptability for manufacturing tasks. This collaboration facilitates the production of small batch sizes and highly personalized products, aligning with the future needs of manufacturing. In contrast to traditional robots confined to predefined operations within fenced areas, cobots are released to coexist, cooperate, and collaborate (3Cs) with human counterparts. These lightweight, sensitive, and precise cobots are easily programmable and capable of handling various tasks, relieving humans from physically demanding or hazardous activities. Leading manufacturers like KUKA have introduced cobots, such as the “LBR iiwa,” which are actively employed in assembly and production lines of major automotive companies.
Cobots find application across various industrial settings, including laboratories, material handling, transportation, quality control, and packaging. Their adaptability reduces the reliance on conventional industrial robots, making them a cost-effective solution for manufacturing industries. Advancements in technologies like distributed artificial intelligence and edge computing enable cobots to make real-time decisions, contributing to their efficiency. The affordability, versatility, and ease of deployment of cobots level the playing field, allowing small-scale industries to compete with larger corporations.
Real-world examples demonstrate the positive impact of cobots on productivity and quality. In instances like Craft and Technik Industries in India and Stela Laxhuber in Germany, cobots have led to significant improvements in product quality, inspection processes, and welding operations. Industries spanning biomedical, agriculture, food processing, electronics manufacturing, warehousing, and logistics are increasingly realizing the benefits of cobots.
However, challenges such as safety concerns, issues of trust, potential loss of shared emotions between human workers, and the fear of job displacement still pose considerations that need to be addressed in the widespread.
Currently, the automotive industry is more focused on implementing upstream Sustainability practices to achieve its Sustainability goals. From the perspective of upstream, improving manufacturing practices, sourcing of green energy, and conducting supplier assessments have been top priority.
The government has introduced schemes and regulations to promote sustainability in the automotive sector, with a focus on electric vehicles (EVs) to reduce carbon emissions. Efforts include the Faster Adoption and Manufacturing of Electric and Hybrid Vehicles (FAME) scheme, circularity initiatives, and a Vehicle Scrappage Policy.
MG Motor, a key player, is highlighted for its sustainability efforts, incorporating solar and wind energy in manufacturing and producing environment-friendly EVs like ZS EV and COMET. The adoption of these measures aligns with the government’s push for a 40% penetration of EVs in various vehicle categories by 2030. Despite challenges such as inadequate charging infrastructure and high battery costs, the industry is striving to meet these targets. Also tied up with Battery Recycling companies like LOHAM for 2nd life usage and circular economy.
The sustainability strategies of automotive OEMs focus on reducing energy and water usage, circularity in manufacturing, and aligning with the government’s initiatives. The introduction of EVs is recognized as a crucial step, with efforts to make them affordable and integrate them into consumers’ lifestyles. Collaboration between OEMs and the government is seen as essential to achieving long-term sustainability goals and MG is working closely with SIAM for these efforts.
Challenges and gaps in achieving sustainability goals include obstacles to EV adoption, data management for sustainability reporting, and the neglect of downstream operations. Suggestions for improvement include promoting localization, developing new powertrain technology, utilizing government incentive programs, enhancing resilience in manufacturing and supply chain areas, creating focus departments for sustainability, and adopting a circular approach across the industry. In conclusion, there is need for a holistic and collaborative approach to sustainability in the automotive industry, with a focus on both upstream and downstream operations, circularity, and alignment with government initiatives. The incorporation of renewable energy sources and the production of environmentally friendly EVs are seen as critical steps in achieving a sustainable automotive ecosystem in India.
Sustainability lies at the heart of this movement. EVs are not just reducing tailpipe emissions but also reshaping the entire lifecycle of vehicles, from raw material extraction to recycling. With the implementation of smart factories, manufacturers can integrate green practices into their production lines, using digital twins, predictive analytics, and 3D printing to reduce the carbon footprint. These innovations allow for more precise resource allocation, minimizing energy consumption, and promoting circular economy practices such as second-life batteries for energy storage.
Moreover, digital manufacturing is enhancing the scalability and affordability of clean mobility solutions. For instance, by leveraging AI and machine learning, manufacturers can design more efficient EVs, optimize supply chains, and offer on-demand production that reduces waste. Simultaneously, these technologies are key to developing lighter, more sustainable materials and driving innovations in battery technology, one of the largest contributors to an EV’s cost and environmental impact.
The combined push for digitalization and sustainability is also transforming how cities envision mobility. Future urban environments will integrate electric fleets, autonomous public transport, and shared mobility platforms, all powered by clean energy sources. Smart cities will rely on digital infrastructure to manage these systems efficiently, ensuring smoother traffic flows, fewer emissions, and improved public health.
In conclusion, the future of mobility, digital manufacturing, and sustainability are intertwined in creating a greener, more efficient world. As these industries evolve, the potential to revolutionize transportation and manufacturing while addressing climate change grows, marking a pivotal era in human progress toward sustainable living.
Disclaimer: The views expressed by the author are his own and do not necessarily reflect the views of FMM magazine.
Sameer Jindal
Director and Co- Chair
MG Motor India and SIAM for Connected Cars