Hyundai Motor India Ltd is transforming its manufacturing facilities into intelligent, future-ready ecosystems through its Software-Defined Factory initiative. This integrates AI, digital twins and autonomous mobile robots to enable agile, data-driven manufacturing.
Its Chennai Plant’s Industrial Internet of Things (IIoT) network connects over 2,000 critical machinery across seven major shops, generating over 20 billion data points annually. These vast datasets are analysed in real time across 200 smart dashboards, facilitating precision decision-making and driving continuous improvement, according to the company’s 2024-25 annual report.
Hyundai is actively exploring emerging technologies such as Generative AI, 5G and next generation digital twins to accelerate design cycles, enhance material selection and automate quality control, ultimately enabling a highly adaptive and responsive production environment, the report said.
The Chennai Manufacturing Plant comprises two fully integrated plants. The first manufacturing plant commenced commercial operations in 1997, while the second manufacturing plant commenced commercial operations in 2008. The Chennai Plant currently produces 14 passenger vehicle models with over 450 variants.
The Chennai unit has an annual manufacturing capacity of 8,24,000 units. Once The Company’s upcoming plant at Talegaon, Maharashtra will be fully operational, it will take the company’s total annual capacity beyond the 1-million mark, the report said.
“Our vision is to develop the Chennai manufacturing facility into a central hub for EV and SUV production. Additionally, with the upcoming Talegaon Manufacturing Plant, set to commence partial commercial operations in FY 2025-26, we are scaling up our manufacturing capabilities to enhance production volumes and achieve greater economies of scale. This will enable us to meet rising domestic market demand efficiently,” the report said.
The Chennai plants employ a sophisticated common platform architectural design. This innovative approach allows nine models to be produced at one facility and six other, with one model spanning both. This architecture not only facilitates dynamic production adjustments based on real-time market demand, enabling parallel manufacturing of multiple models, but also significantly reduces product development costs, shortens time-to-market, maximises capacity utilisation and enhances overall manufacturing agility, the report said.
Published on August 8, 2025
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