The transition to electric vehicles (EV) in India is not coming — it is existing. As of mid-2025, EV sales were growing at an exceptional rate of greater than 45% annually while government level initiatives that fuel demand and incentives at a program level, such as the PM e-Drive or the Production Linked Incentive (PLI) programs, are spurring greater investment in the EV manufacturing space. But manufacturing is not about policy or demand; it is about the merging of automation and Industry 4.0 — in other words, a revolution changing the structure of EV manufacturing at the core.
To create faster, smarter, globally competitive EV manufacturing, India must leverage Industry 4.0 technologies, defined as a network of smart machines, data systems and connected platforms that allows factories to self-monitor, plan, predict and change stipulations in real time.
In this article, we will discuss how Industry 4.0 and automation are reshaping EV manufacturing processes in India and around the world about more efficient production lines, better quality control and more scalable solutions.
Materializing Industry 4.0 in EV Manufacturing
Industry 4.0 sometimes known as the Fourth Industrial Revolution — relates to the digitization of manufacturing using different technologies, including artificial intelligence (AI), Internet of Things (IoT), robotics, big data analytics, cloud computing, and cyber-physical systems. When applied to EV manufacturing, it results in smart factories where machines communicate, make decisions, and optimize performance with minimal human intervention.
Leading Indian EV OEMs like Tata Motors, Mahindra Electric, Ola Electric, and Ather Energy are investing heavily in smart production facilities that are equipped with Industry 4.0 frameworks. Automated ecosystems are making possible real-time quality assurance, predictive maintenance, and flexible assembly lines essential to rapid, efficient EV production.
Why is Automation So Important in EV Manufacturing
Unlike traditional internal combustion engine (ICE) vehicles, electric vehicles (EVs) have unique requirements – high-voltage batteries (with thermal management), power electronics, and lightweight frames. Because of this complexity and need for greater precision and repeatability, automation is essential to EV manufacturing.
Automation is providing repeatability, speed, and safety in battery module assembly, welding aluminum body frames, winding motors – including for software calibrations! By 2025, robots had become a dominant factor in India’s leading EV manufacturing factories.
For example:
- Tata Motors has implemented collaborative robots (cobots) for automated spot welding and battery handling at its Pune facility.
- MG Motor India is utilizing advanced AI and machine learning tools, in collaboration with SAIC, to reduce defects in production and human error.
- BYD India has applied more than 60% robotic automation in the bus and battery manufacturing units.
These developments indicate a strong movement toward Industry 4.0 ecosystems that will form the future of EV manufacturing in the India.
Key Industry 4.0 Technologies Reshaping EV Manufacturing
1. Digital Twins
Also a digital twin is a virtual real-time copy of a physical asset, or physical business process. In electric vehicle manufacturing, it has allowed engineers to simulate the production process, battery performance, and thermal characteristics of a finished vehicle by modelling aspects such as material performance and operational parameters before actual deployment. Digital twins can allow for reduced time-to-market and real-time remote monitoring of the processes at operational plant locations.
2. IoT and Smart Sensors
IoT sensors situated in machines or along assembly lines, can collect meaningful operational data related to temperature, vibration, energy usage, and torque so that parts can be evaluated for predictive maintenance and can also optimize processes by minimizing downtime and improving operational efficiencies in existing EV manufacturing units.
3. AI and Predictive Analytics
AI systems compute massive amounts of data to predict equipment failures and optimize inventory management, alongside maximizing yield. AI-based vision systems have also been adopted for real-time quality inspection of EV batteries and wiring.
4. Additive Manufacturing (3D Printing)
3D printing facilitates iterative development of EV components for prototyping and small-batch requirements like battery enclosures, housings, and custom cooling plates. Many EV manufacturing start-ups are now integrating additive manufacturing as an opportunity to reduce development costs and waste.
5. Cloud and Edge Computing
Data generated on the factory floor is now processed on edge devices for immediate insights, or stored in cloud data platforms for more traditional macro-level analytics. This hybrid system, where data is processed at the edge such as the manufacturing plant and aggregated in the cloud as necessary, allows for faster decision making across geographically dispersed EV manufacturing ecosystems.
Industry 4.0 and Supply Chain Integration
Another significant benefit of Industry 4.0 in EV manufacturing is the creation of smart, connected supply chains. Manufacturers can now track components in real-time, reduce lead times, and synchronize procurement with demand forecasting.
With EV components like lithium-ion batteries, semiconductors, and controllers often coming from diverse vendors, a digital supply chain helps reduce delays and avoid overstocking. Companies like Bosch, Bharat Forge, and Sona BLW have integrated smart supply chain platforms to enable seamless component flow into EV manufacturing plants.
Challenges to Adoption in India
While the benefits are immense, India’s EV manufacturing sector still faces hurdles in fully adopting Industry 4.0:
- High Capital Expenditure: Setting up smart factories with robotics, AI, and IoT infrastructure involves substantial initial investment.
- Workforce Skill Gap: There’s a significant lack of trained technicians, engineers, and operators familiar with Industry 4.0 tools.
- Legacy Systems: Many traditional auto manufacturers have outdated ERP systems that are not compatible with modern automation platforms.
- Cybersecurity: The connected nature of Industry 4.0 systems makes them vulnerable to cyber-attacks, requiring robust data protection protocols.
To overcome these, the government and industry bodies must collaborate on workforce skilling programs, offer tax incentives for tech upgrades, and promote standardized frameworks for smart EV manufacturing.
Government Push and Industry Partnerships
Recognizing the critical role of Industry 4.0 in boosting global competitiveness, the Indian government has included digital transformation under the PLI Auto Scheme. The Ministry of Heavy Industries has announced funding for pilot EV manufacturing projects that demonstrate end-to-end automation and data analytics integration.
Collaborations between OEMs and tech giants like Siemens, ABB, Bosch, and Infosys are also enabling smooth adoption of Industry 4.0 systems in EV assembly lines. Startups like Entuple E-Mobility and Numocity are developing India-specific solutions for real-time energy monitoring and digital diagnostics in EV manufacturing.
The Road Ahead: A Smarter EV Manufacturing Ecosystem
The journey toward fully automated and digitized EV manufacturing in India is just beginning, but the pace is picking up. In 2025, every major EV player is either scaling up its smart factory operations or investing in next-gen digital infrastructure.
The long-term vision is clear — India must become not just an EV consumer market but also a global hub for advanced EV manufacturing. To get there, embracing Industry 4.0 isn’t optional — it’s essential.
From AI-guided robots assembling battery packs to cloud platforms managing plant operations from thousands of kilometers away, the future of EV manufacturing lies in intelligent, interconnected systems. And with the right partnerships, investments, and policy support, India is well-positioned to lead this transformation.
Conclusion
The convergence of automation and Industry 4.0 is revolutionizing the landscape of EV manufacturing. It offers not just increased productivity and reduced costs, but also ensures higher precision, lower emissions, and scalable growth. As India accelerates toward its clean mobility goals, EV manufacturing powered by Industry 4.0 will be the cornerstone of this new industrial age.