Engineering Excellence: A Case Study on Light Commercial Vehicle (LCV) Development

India’s light commercial vehicle (LCV) sector stands as one of the fastest-growing segments in the commercial vehicle industry, propelled by the exponential rise in logistics, e-commerce, and last-mile delivery requirements. Automotive OEMs operating in the light commercial vehicle space face considerable challenges-demand for higher payloads, efficient urban maneuverability, fuel efficiency, strict regulatory requirements, and the need to deliver commercial vehicle programs faster than ever before.

At Hinduja Tech, we partnered with a global commercial vehicle OEM to re-engineer and launch a light commercial vehicle tailored for Indian roads and dynamic business needs. In this case study, discover how our integrated engineering delivered a >25% payload increase, significant reduction in development timelines setting a new benchmark for speed and performance in the Indian commercial vehicle market.

The Challenge: Reimagining a Light Commercial Vehicle for Indian Roads

The project presented an opportunity to set new standards in the Indian light commercial vehicle segments.

The goals:

• Outperform competitors on payload, cost, and durability in the light commercial vehicle domain
• Adapt to market specifications: congested cities, diverse rural routes, and harsh monsoon weather-key concerns for any commercial vehicle design
• Reduce time-to-launch: Complete light commercial vehicle development, from concept to engineering release, in record time
• Achieve seamless regulatory compliance: Catering to CMVR, AIS norms, essential for road country-ready commercial vehicles

Key engineering tasks included

• Converting a proven global commercial vehicle platform from Left-Hand Drive (LHD) to Right-Hand Drive (RHD)
• Enhancing chassis, cab, steering, and suspension systems for diverse Indian light commercial vehicle duty cycles
• Integrating localized supply chains for a greater extent of localization and aftersales readiness

Our Integrated Engineering Solution for Light Commercial Vehicles

Hinduja Tech deployed a cross-functional team, covering the entire commercial vehicle lifecycle: concept, detailed engineering, system selection, virtual validation, supplier management, and physical testing

Highlights

• LHD to RHD Conversion: We ensured ergonomic and safety compliance for Indian right-hand driving standards in commercial vehicles
• Market-Driven Redesign: New front fascia and body styling blends Indian consumer preferences with aerodynamic needs, optimizing light commercial vehicle aesthetics and function
• Supplier Ecosystem: Developed & onboarded multiple Indian suppliers, ensuring maximum localization for commercial vehicle components without any cost or quality track-off
• Structural & CAE Analysis: Multiple loop of virtual simulations for frame, cab, and load body, focused on the needs of the Indian light commercial vehicle market

Precision Engineering: Data-Driven Performance Gains for Commercial Vehicles

Through targeted systems integration and data-backed engineering interventions, Hinduja Tech achieved significant improvements across all critical vehicle parameters:

• 25% increase in payload capacity, allowing this light commercial vehicle to move significantly more cargo than earlier
• Only 7% increase in GVW, supporting higher loads while ensuring the vehicle remains efficient and compliant
• 5.6% improvement in turn radius, giving the vehicle standout maneuverability, crucial for urban mobility
• 33% reduction in development timeline, leading to a new benchmark in engineering release

Key Engineering Highlights

• Chassis and Frame Optimization: Advanced material application and smart redesign delivered higher payloads and superior performance
• Steering System Overhaul: Transitioned to a rack-and-pinion system, gaining industry-leading agility to the commercial vehicle, especially for congested Indian roads
• Suspension Reinforcement: A customized leaf-spring setup and new mounting points ensured rugged durability and ride comfort
• Advanced Braking and Safety: Integrated Load Sensing Proportioning Valve (LSPV) for superior braking control, reinforced cab visibility, and updated safety features exceeding stipulated commercial vehicle regulatory norms

These engineering improvements didn’t simply deliver incremental changes but set new industry benchmarks in many vehicular attributes for the light commercial vehicle segment in India

Results: Fast-Track Launch and Market-Ready Reliability in Light Commercial Vehicles

• 30% Faster Time-to-Market: Setting a new record for the India commercial vehicles industry
• Component Localization: Resulting in significant cost reduction, easier serviceability, and a robust supply chain for commercial vehicles
• Superior Driver Experience: Enhanced safety, ergonomics, and visibility for end-users across the Indian commercial vehicle market

Need tailored technical deep-dives, more commercial vehicle insights, or further evidence of our light commercial vehicle engineering expertise? Reach out to info@hindujatech.com —let’s drive your success together.