It’s been a terrible time – for all of you, and all of us. Sometimes tough moments bring the best version in us. And, the ongoing pandemic is one of those moments;
it helps us to know that people are stronger than the scenarios, and the situations that they’re facing. At the moment, the entire company is rallying behind our mission to help our customers in tough times like this. For people at Hinduja Tech, it is never about just getting the ‘job done’, it is more of a personal commitment and ‘desire’ to serve the customer beyond odds. Here, we bring you the stories of our people – the heroes’ who were resilient and committed in this chaos.
Commitment towards helping  [Hinduja Tech](https://hindujatech.com/) Community
Have you ever imagined moving over 40 machines from one location to the other in just one day notice? Well, our man did it! Bharath (Head of Admin) said: “Though it was an uphill task, considering the situation, it was our top priority and we had to address it.” Yes, the odds were against him, particularly when the whole city was going to be in lockdown, moving the systems became a much bigger task. Apart from arranging and planning the delivery of machines, he also got UPS backup for all the systems within a short period. When we were only hoping for the systems to reach our employees, Bharath went the extra mile to get UPS, as well. He ensured that our people are fully operational without any disturbance. Round the clock, he worked and ensured the systems were packed and delivered to our employees so that they can start working from home from that day itself. By fulfilling the commitment, Bharath ensured that Hinduja Tech reassured to our customers: We’re completely operational and are here to serve you in crucial times.

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When our Engineer decided to take control of the situation
of our engineers who is an integral part an Electric project for a leading OEM decided to take control of the situation. He knows that his contribution is key to the project, so his main goal was to remain operational during this lockdown. Sunil went to the client’s office and discussed on shifting the workstation to his PG. Things didn’t turn out to be smooth even after shifting the workstation to his PG. He faced difficulties to set up a Wi-Fi connection. Sunil contacted his Wi-Fi service provider who informed him that they would require 40 meters of LAN wire to provide connection. Since most of the electronics shops were already closed, the service provider couldn’t help him. During situations like this, there are hurdles, and one must always find a way out and do the right thing, even if it is beyond one’s call of duty. So, he checked with his Wi-Fi provider if there was any other way he could help him, and he connected him to a vendor who was able to help him by arranging for a cable. Sunil directly coordinated with the vendor, and together took efforts to set up the Wi-Fi in his PG.

Soon after he gained access to the Wi-Fi, Sunil resumed work and completed the required task without losing time. His efforts signify how people @HT are focused on delivering our commitment to our customers. And, by doing this, Sunil has encouraged all our people to remain committed and emerge as a Hero.

Distance doesn’t stop us from performing
On 25th of March’20, we decided to shift the machines of our associates to their home. Sneha – our HR business partner took the responsibility of completing this action. It was a total lock-down and even housekeeping staff weren’t allowed inside ICCDGTP premises (Pune); rather than giving up, she checked if it was possible to move all the machines to employees’ homes using a single vehicle and also took a step forward to consult with the local police of Pune. There were strict government regulations in place and the guideline stated that only essential goods movement was allowed. And, the Police officers requested for a permission letter to allow movement of computers. With the help of our security personnel, Admin, and Quality team, and after several conversations with the police, Sneha finally arranged for a permission letter to deliver the systems. Also, even with the approval, there were several roadblocks to get the delivery done. The combined efforts of Admin, Quality and HR team ensured that there were no interruptions in our day-to-day business, and we anticipate that this will remain the case during this lockdown.

With the commanding efforts of our teams, Hinduja Tech has reassured that we’re always ready to provide seamless and uninterrupted service even during such difficult situations and beyond. Though we are connected remotely, we remain fully functional. Distance doesn’t stop us from performing and delivering on our commitment and our customers can expect the same kind of service from us as always.

Hinduja Tech continues to be proactive in taking necessary measures to keep our people safe and protected. People at Hinduja Tech are now staying home, staying safe and are fully operational.



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Our People Stories: When our Heroes went an Extra Mile Beyond the Call of Duty

Everything comes with a price. Most of the time, this price goes unnoticed. [Electric mobility](https://hindujatech.com/product-engineering-services/electric-and-future-mobility) has been a common tabletop discussion, but when you look at it intricately, there is more to it than what meets the eye. The main intention here is to help consumers see from a rational standpoint and to help visualize the broader picture.&nbsp; It is not just about developing electric cars but about establishing a conducive ecosystem which advocates development in a sustainable manner.

Electric cars have always been compared with their traditional IC siblings in terms of emissions from the tailpipe, i.e. from running the vehicle. But this comparison is irrational. Considering a Well-to-Wheel analysis is important to see the bigger picture. Well-to-Wheel emissions are the upstream emissions that accounts for the energy used and emissions generated from primary energy source (Well to Tank) through vehicle operation (Tank to Wheels). It discards the emissions from manufacturing, recycling and disposal.

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A WTW comparison between an electric and a combustion vehicle may seem like an apple to apple comparison. However, there are certain costs which go overlooked. These can be categorized into manufacturing costs, human costs, socio-economic costs, political costs and so on. This article specifically emphasizes on the hidden costs incurred while [manufacturing](https://hindujatech.com/product-engineering-services/manufacturing) an electric vehicle.

Electric vehicles depend primarily on their batteries. The battery is a USP for most manufacturers which is used to lure customers. With the rise in demand of electric vehicles, the demand for batteries also rise proportionally, and this has resulted in the increase in demand for raw materials which make a battery.

“Manufacturers have realized the key trade-offs as cost, range, safety and battery life which indirectly links to recycling.”

“Norway has the highest market penetration per capita in the world, and also has the world’s largest plug-in segment market share of new car sales (recorded 49.1% in 2018).”

Manufacturers strive to hit that sweet spot to tackle range anxiety in customers. They either offer high range (large capacity) or low range with quicker charging times, whilst pricing it competitively and at the same time, ensuring reliability
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Lithium-ion batteries are popularly used by many manufacturers with further up and coming technologies.  Lithium is obtained from Lithium carbonate, the raw form of the metal. We are not abundantly gifted with this metal. It’s found only in a handful of places. The ‘Lithium triangle’ which comprises of Argentina, Bolivia and Chile have more than half of the world’s supply. Andrew Barron, a professor who specialises in “Low Carbon Energy and the Environment” at Swansea University, has estimated that – to make the switch to electric vehicles (in Wales alone) would use up all of Bolivia’s annual lithium output. Consultancy Cairn Energy Research Advisors predicts that the lithium ion industry is expected to grow from 100 GWhs (Gigawatt hours) of annual production in 2017, to almost 800 GWhs in 2027. Let alone that, lithium extraction demands immense quantities of water – approximately 500,000 gallons per tonne.


The extraction process could inadvertently cause the leakage of chemical substances into the water supply, one such chemical could be Hydrochloric acid used in the processing of Lithium. Lithium can also be mined from rock using more traditional methods, but it would still require the use of chemicals to bring it into a usable form. Lithium could theoretically be extracted from seawater in the future but will be an energy intensive process.

“Like any mining process, it is invasive, it scars the landscape, it destroys the water table and it pollutes the earth and the local wells. This isn’t a green solution – it’s not a solution at all.”

In terms of carbon footprint, the production of lithium-ion batteries for light electric vehicles releases on average 150-200 kilos of carbon dioxide equivalents per kilowatt-hour battery. One of the smallest electric cars in the market, Nissan Leaf, uses batteries of approx. 30 kWh; many new models have batteries of 60 and 100 kWh.  An electric car with a 100kWh battery has thus emitted 15-20 tons of carbon dioxide even before the vehicle ignition is turned on. This calculation assumes a 50-70 per cent fossil share in the electricity mix. This data is according to a report published by Mia Romare et al. from IVL Swedish Environmental Research Institute.

Human costs – Electric vehicles have fewer components, which makes them easily manufacturable with less amount of workforce. With the advent of factory automation which will be a more plausible solution given the rising demand, lot of people are bound to lose their jobs to their robotic counterparts. Most of the extraction involved are via unethical means – child labor. Cobalt, which is another metal used to make up a battery is found abundantly in Congo where it is extracted from the ground by hand, often using child labor, without protective equipment.

Plenty of research has been conducted in this regard and most of them have concluded that electric vehicles eventually turn out to more beneficial to the environment compared to the conventional IC vehicles. United Nation’s sustainable development goals are focused on producing zero emissions and gives a foundation, upon which future vehicle protocols are built. It is essential that the aforementioned costs are taken into consideration for forthcoming studies. An organic growth rather than rapid commercialization of electric mobility is essential for a healthy and sustainable environment.




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The Hidden Costs of Electrification

Lightweighting has been an age-old industry go-to word for anything and everything connected to body weight of the vehicle to fuel efficiency ratios. Since the inception of the automotive, there has been a constant push to decrease the weight of this ‘metal structure on wheels’. During the inception phase, much of the components were cast iron or steel– which met two specific requirements at the time, one – the availability of iron ore and two, the robustness or sturdiness associated with the metal. As industrialization, and alternative alloys surfaced, the ratio of iron to other metals decreased in a vehicle. Though this phase had a long and glorious stretch in the automotive history, need for Lightweighting vehicles gained momentum towards the latter phase of the 20th century – let’s say 25 to 30 years ago; the term was heavily associated with supercars. Sporting an all-aluminum chassis or carbon fiber components meant edging out its nearest competitor by seconds on the drag strip – a world of difference in the automotive purist’s universe. Realistically this just made them go fast, not achieve fuel economies which the mass market craved for. However, today in the 21st century, this is not limited to the glitz and glamorous world of the supercar and hyper car segments but also in the humble world of mass market segments.

The Inevitable Trickle Down – a Reality Check!
Why this shift in priorities for a mass market OEM; one might ponder? As super/hyper cars have levelled up to carbon fiber, glass fiber, composites, and dare I say magnesium and neo-substrates! The mass market vehicles have started borrowing from earlier iterations, and that have become economical to produce in contemporary settings through a mix of trickle down and necessity. Trickle down of technology is iterative and generational, to put it in black and white, however, the reality is often in the grey. Lightweighting comes with its own set of challenges– one cannot use any or all materials just for its lightness, instead, one must also assess its strength and durability which is also closely related to safety, reaction to heat, stress, and other external vagaries of nature and physics. What works for a two door, carbon fiber, fuel guzzling-million-dollar super car will not make sense on a four door budget hatchback or will it?

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Why OEMs and Suppliers have to Bite the Bait?
Let’s pause and reflect; what works on a super car will work on a mass market vehicle, provided, the costs are evened out by economies of scale and cost of production is significantly lowered by these substitutes. Lightweighting is one of the top-of-mind concerns for most OEMs and hence their B2B suppliers. This necessitates a holistic reduction in weight across body, chassis, interiors, powertrain, and engine – not just in metals on body but across all materials used on the vehicle. How the B2B suppliers reduce the weight will heavily influence the cost of the vehicle and also the segment an OEM positions its vehicle. Now, one of the key automotive trends in recent years has been the focus on “Engine downsizing”. This is a simple yet effective technique to reduce fuel consumption, therefore emissions and weight of the vehicle – a step that doesn’t necessarily make use of light weight alloys or expensive composites but bypasses common nomenclature to achieve the end goal. On the B2B end of the spectrum, suppliers are increasingly using polymer composites, plastics, and magnesium structures in seating structures, lighting, and body panels to help OEMs achieve the goal of building lightweight vehicles.

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What Would Happen if I Crash?
Having established the need to lightweight for fuel efficiency, one must also pull out the checklist on associated effects of using such materials. Would the vehicle now be increasingly prone to crumbling in the event of a crash? What is the catch? – Well, the impact of using a lighter material does impact the robustness and the stiffness of the structure and therefore the vehicle – but, OEMs aren’t completely shifting from traditional metals for new age composites. OEMs are using a mix of multi-material structural components and joining techniques to achieve better scores on crash tests and real-world simulations. Today’s concerns revolve around reducing cost of materials and identifying techniques to hold composites and alloys of varying properties together under operating conditions. Reality dictates that OEMs continue to employ low carbon steel, aluminum, and iron alloys to build majority of their frames and structures while simultaneously incorporating neo-materials and composites as part of body structure that will ensure a combination of strength, durability, robustness along with light weighting and flexible incorporation. A win-win for now. In addition, new age EVs are increasingly adopting the Frunk! A feature made famous by the rear engine Porsche’s of yester years and the new age Tesla in the EV line of things. By carving out a section for extra storage, in the front end of the vehicle, the consumer definitely gets the added space however compromising on structural integrity in the case of a crash. A win-loss!

Regulatory Body’s Blue-Eyed Cause – Lightweighting and Emissions
The Lightweighting trend is also championed by multiple entities that have vested interest in the partial end goal of this crusade – fuel efficiency and reduced emissions. The crusader is the regulatory body of the various nations who are driving OEMs to achieve reduced emissions within a set timeframe. For instance CAFE or Corporate Average Fuel Efficiency/Economy, a regulatory body that chalks out regulatory policies; in this aspect for developed and developing economies including India has set forth regulations that mandates OEMs to check emissions and ensure reduced dependence on traditional fuels such as gasoline and diesel, and control exhaust end emissions – less than 130 gm per km till 2022 and below 113 gm per km beyond that. On the domestic front, India’s BSVI deadlines will work in tandem to realize this cause. One might argue that emission end output might not have causal derivatives from the existing vehicular bodies, as the weight of these structures have already reduced significantly over the decade – there is only so much an OEM can shave off to achieve the emission threshold through Lightweighting

The Electric Vehicle Conundrum
The regulatory bodies’ ulterior motive as some would suggest is to hasten the adoption of Electric vehicles (EVs). There is only so much bandwidth an OEM can do, to work within the realms of reducing emissions from engine downsizing and treating exhaust gases. Hence the realistic route would be to traverse the path of EV. The auto industry has already accepted this bitter expensive pill and is now heavily vested in increasing its EV portfolio globally. However, this presents a catch 22 situation. EVs might have put one concern to rest – the emissions end of the argument but it is simultaneously staring at a familiar foe in weight, pun intended. To the uninitiated, this might seem to be a very minor setback in the cause to achieve something greater. On the flipside, EVs now face the same problems faced by their conventional cousins – the IC engines, which is “Range” (read about it on our latest blog – EVs and Range Anxiety). The battery packs which make up the core of the EVs have significant weight associated with it, making an EV considerably heavier and putting a lot more stress on the energy source (battery). This causes drop in range, or in conventional engine terms – lower mileage. There is increasing pressure on EV manufacturers to reduce weight of the body structures through novel applications of lightweighting, one such instance is the integration of wheel end systems and motors independently while also having swappable batteries placed on storage beds, ensuring effective usage of space for purpose.

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Enter Hinduja Tech! – The Frugal solution to your heavy engineering burden

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Hinduja Tech’s unique frugal Engineering paradigm has helped multiple OEMs realize cost savings by shaving off sections on body panels by which the OEMs not only realized monetary gains but also significantly reduced the weight of the vehicle when replicated on both sides of the vehicle. Let’s get into the details- For this to work, the engineering team had to increase certain estate on the bumper module and decrease sections on the fender. Though the bumper module increased in cost and weight by ₹30 INR and 140gm respectively, Hinduja Tech’s BIW practice helped in reducing fender costs by ₹50 INR and weight by 400 gm, approximately half a kilo! If that puts things into perspective. This helped the OEM realize a net saving of ₹20 INR and weight savings of 260 gm per vehicle.
Another instance is the re-engineering and frugal engineering of seats and seat structures, by reducing the number of redundant components in the form of springs, and engineering it to perform at the same level as before or even better; OEMs realize savings on the B2B and sourcing aspect, reduce weight of the module, and ensure the portfolio is on the path towards lightweighting – all ensured through Hinduja Tech’s frugal engineering solution. During this engagement, Hinduja Tech helped the OEM save ₹200 INR and also reduce weight by 360 gm per vehicle.


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Hinduja Tech is also driven towards accelerating the adoption of EVs; its Electric Vehicle Engineering team is equipped to work on designing, building, prototyping, battery swapping, with the expertise and proven experience to find solutions to most of the engineering challenges that OEMs and suppliers are facing today when it comes to lightweighting; IC or EV.
For insights and details on how Hinduja Tech can add value and help solve your lightweighting concerns, write to us at info@hindujatech.com or you can browse through our corporate website to learn more about our Engineering Prowess.









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Lightweighting and Frugal Engineering go hand-in-hand

Evolution of [digital technology](https://hindujatech.com/digital-technologies) has transformed the business model of every industry. And, it has a huge impact on the automotive industry. In this digital age, to stay top of the line in the business spectrum, automotive companies should embrace digital disruption and adopt new business practices.

Innovation is behind the wheels of all the vehicles. Yes, connectivity is shaping the sector in a newer way. Some technologies are in the making, while a few of the technologies are in the verge of becoming mainstream. For an organization, it is quite difficult to keep track of all the technologies which are spread across the globe. For an organization, to keep track of all the technologies which are spread across the globe is quite difficult. Software like [SAP](https://hindujatech.com/digital-technologies/erp-sap) can generate a centralized database for all different applications running across your organization. A management-level member would always be interested to know the key data points from all major sources, in a nutshell, to compare and execute the business transactions. Further, it helps to identify current situation in the ground level of each functional unit.

Evolution of digital technology has transformed the business model of every industry. And, it has a huge impact on the automotive industry. In this digital age, to stay top of the line in the business spectrum, automotive companies should embrace digital disruption and adopt new business practices.

Innovation is behind the wheels of all the vehicles. Yes, connectivity is shaping the sector in a newer way. Some technologies are in the making, while a few of the technologies are in the verge of becoming mainstream. For an organization, it is quite difficult to keep track of all the technologies which are spread across the globe. For an organization, to keep track of all the technologies which are spread across the globe is quite difficult. Software like SAP can generate a centralized database for all different applications running across your organization. A management-level member would always be interested to know the key data points from all major sources, in a nutshell, to compare and execute the business transactions. Further, it helps to identify current situation in the ground level of each functional unit.

“90% of the manufacturing companies are satisfied using SAP implementation when it comes to IT cost reduction and 96% improvement is in productivity after implementing SAP in manufacturing companies”

Benefits of SAP for the Automotive Industry A single, centralized solution for all your manufacturing applications
Manufacturing companies can get a complete, 360-degree view with analytics to monitor continuous improvement
Speed up the design, make more-informed decisions and accelerate market introductions by collaboratively engaging all partners with a single set of product data Manufacturing and Supply Chain processes become easier Manage the supply chain better with a comprehensive system for production, sales and shipping to purchasing; goods receipt and communication management
Streamlines business processes to suit market needs as the company grows Improves integration and ensures that manufacturing companies are effective and efficient with time and resources.

Improving Our Customer’s Digital Experience Automotive companies are on a journey towards digital transformation. Wherever you are in your digital transformation journey, ‘SAP is your Destination’; Hinduja Tech has the expertise to give the right services and solutions you need.

When implementing Hinduja Tech’s SAP model, it easily helps to get rid of all the redundant legacy systems and multiple data source points to provide a centralized source of data. It increases the operational efficiency and gives transparency over the entire system which becomes the single reliable source of data.

Hinduja Tech’s SAP business process flow helps in speeding up the data process by eliminating unnecessary manual intervention and makes it less dependent. We made the business process in such a way to maintain standardization across the organization and channel them according to each unit. Also, the SAP business flow of Hinduja Tech avoids a high degree of repeated data entries and helps you in automating the reports.

Hinduja Tech’s SAP Offerings to the Automotive Industry: A Complete Solution Technology is not only about enabling automotive companies to embrace digital disruption, but it’s about driving fitness, reshaping business models and influencing innovations.
Our best-in-class SAP solutions help you to innovate faster, increase efficiency and stay on top of the industry trends. Hinduja Tech helps automotive companies to reimagine digitized business models with innovative solutions across the industry value chain, and drive sustainable revenue growth and maintain margins, powered by new generation technologies such as SAP S/4 HANA, Mobility, IOT, etc.

  1. Reduce the Operational cost, reduce time to market, and increase revenue from the market

  2. Companies must respond quickly and effectively to changes in demand and supply. Hinduja Tech offers SAP MRP LIVE production planning program which provides synchronization to changes in demand, that result in fewer material shortage and delays. Maximizes capacity utilization and real-time inventory management. Increases the Production Planning, Improves Order to Delivery and Production Cycle Times and Reduce Inventory &  Planning cost.

  3. Our Lead to Cash process improves customer satisfaction, reduces sales and service cost and increases the Revenue Growth

  4. Since we have decades of experience in the Automotive industry, our Analytics team helps to provide various dashboard reports to check the KPI’s and KPD

  5. We offer various dashboard reports which provide real-time information on the fly  

  6. Our Predictive Maintenance (PdM) Solution monitors the performance and condition of the fleet during normal operations and helps to reduce failures

  7. Talent Acquisition Solution reduces time to hire, cost per hire and quickens time to contribution

Going digital always starts from within. We believe digital is the future and it’s already here. Our SAP services have helped several global companies to adopt digital transformation and they found it to be the right platform to begin their digital journey. With data-driven customizable SAP solutions and services, make better decisions, meet enterprise goals with efficiency and unleash innovation & growth. Reimagine your business models, the way you work, and compete better with our suite of SAP Services and solutions that are opening an infinite world of new possibilities.



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SAP Automotive Industry

How Hinduja Tech’s SAP can improve efficiency in the Automotive Industry?

The first innings Electric vehicles outsold IC Engines by ten to one. Yes, I know you are thinking this is probably a lie or forecasting the future or even I’m out of my senses. It is a fact I had to check probably a hundred times from different sources, unfortunately, there wasn’t a way to call up my great grandfather. Early in the 18th century, Inventors like Thomas Davenport and Thomas Edison had been experimenting with electric motors, lead acid batteries and nickel alkaline batteries which led to the development of Electric carts and carriages. In 1896, the first car dealership was started exclusively for EVs, in fact, companies like Oldsmobile and Studebaker started out as Successful EV companies, only later did they transition to gasoline powered vehicles. Over the years, EV gained popularity, even though they were produced at a very small scale and mostly built by hand.

The downfall on the other hand, in the year 1913, Henry Ford, inspired by a butcher shop, invented the motorized assembly line for mass production of gasoline vehicles, then 90% of EV manufacturers perished due to individuality and the funds to source a large number of components. Further development of better road infrastructure and discoveries of petroleum fields, made long distance travels possible but due to non-existent infrastructure of electricity outside the city limits, severely limited the driving range of EVs, which in turn increased the popularity of IC Engine Vehicles due to their unmatched refueling infrastructure. With reduced range, the popularity and usage of EVs started to reduce, finally stopping the production of Electric cars, and EVs became niche vehicles- serving as delivery vans, freight handlers and golf carts.

The rebirth of EVs had a second chance during the Oil crisis in 1973, when the OPEC (Organization of Petroleum Exporting Countries) members, started an oil Embargo, creating a need for alternative sources of energy. Later in the 1990s, due to concerns related to increasing air pollution and depleting energy resources, major carmakers resumed the manufacturing of EVs – prompted by the CARBs( California Air Regulatory Board) ZEV (Zero emission vehicles) mandate. However, due to various reasons and conflicts, the ZEV mandate was slowly weakened and all the EVs were destroyed (the ones which were sold also).

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Slowly the support and prompt from EAA (Electric Auto Association) and others who were concerned about the environment, along with the technological advancement such as Lithium-Ion battery, Metal Oxide semiconductors, advanced battery management systems, ECUs which led to the production of the first BEV in 2008 with a range of 320 km and a charging time of 9.5 hours. Initially, only very few countries like the USA, Japan, and China welcomed the alternative mode of transport as a measure to reduce the emission levels. Over the years more than 20 countries have taken the initiatives and are planning to stop the use of ICE completely.

Pre – purchase cognitive Dissonance
‘Will I be able to reach office with the remaining charge/ fuel?’

‘What if I get stranded in the middle of the road?

‘How will I again recharge/refuel my car?

‘How long will it take to charge my car?

242 million searches related to distance and range of an EV, gives us a perspective on why people are hesitant or reluctant to go for EVs. Range is one of the main factors which affect the acceptance rate of EVs along with various factors that indirectly or directly influence range such as battery cost, purchasing cost and charging time.
. 
Cost of battery manufacturing and how it increases the retail price. 
The extraction of raw materials for the battery or the technology and infrastructure required to produce battery packs in full scale is nowhere near to the advanced technologies, supply chain and cost saving methods for the development of IC engines. That said, the cost of a battery alone comprises 40% of total EV cost. Also taking into account that it has taken hundreds of years for the ICE to evolve and achieve where we are today in terms of performance and efficiency, the EV industry will be able to achieve the same in a relatively shorter period of time considering the exponential adoption of EVs across the globe that is expected to happen in the coming years. With additional support from the International governments and the pressure of climate change hanging our human heads, it will be a reality in the near future.

Regulations and Impact
Repeated, widespread support and initiatives from governments are being taken to reduce the gap between the price range of EVs and ICE vehicles by providing support funds, implementing subsidy programs and VAT Exemptions. For instance, The American Recovery and Reinvestment Act (2009) was an unprecedented action to stimulate the economy. It included measures to modernize the nation’s energy and communication infrastructure and enhance energy independence for battery manufacturing projects, vehicle component production, construction of production facilities and demonstration projects. Initiatives such has FAME (Faster Adoption and Manufacturing of Hybrid & Electric Vehicle) in India, and EVI (Electric Vehicles Initiative) were launched with the goal of accelerating EV’s adoption. Despite such efforts, the adoption rate has been slow because it is important to understand possible and likely EV adoption trends and factors such as charging infrastructures, charging time, consumer perception and travel distance that more effectively affect rates of uptake of EVs.

The current state of infrastructure
Due to the limited range of EVs, the development of charging infrastructure plays a critical role in EV adoption. However, it is still not clear as to how and where the infrastructure should be and how optimized it should be. Recent research suggest that at least 1 charging station with 2 fast( 7- 22KW) charging ports (2-3 Hours for a full charge) and one rapid( 43- 120 Kw) charger (30-60 minutes) is necessary within a Grid of 3X3 kilometers for a well-planned charging network. It would be more appropriate if the government can invest in EV infrastructure as a public good which would be more suitable for subsidies and policies. Also, technologies like wireless charging similar to a wireless phone charger works on resonant magnetic induction, where it makes use of the air gap to transfer electricity from one magnetic pad which is placed on the ground to another placed on the bottom of the car which could be helping saving lot on infrastructure cost and space. Another example would be the Pantograph super chargers which can charge Electric buses within 3 minutes. Niche technologies like this are a boon and only a handful of organizations can do them. Check out this website for more. Hinduja tech

Long distance relationship – let’s not ignore the pun
The average distance travelled by an individual on a single day is 35 miles/ 56 Km while the average range of an EV is 90 Km which will further increase over the years with the development of better technology and ease of accessibility to charging infrastructure. The average distance an EV can travel on a single charge has doubled in the last six years. Optimization of existing lithium-ion batteries, along with the introduction of new materials for the battery cell materials will result in incremental improvements in reduced charging times, increased charge density and better thermal management resulting in a better range. Also, advanced Battery Management Systems developed by companies like Hinduja Tech can help in increasing safety, range and reducing the mass of the battery pack. The term range anxiety is sometimes laid thick because most of the times due to the way our brain functions, the anxiety transforms into fear.

The realistic future of mobility
EVs are disruptors – replacing IC Engines which has 400- 500 parts, with the electric motor which has only around 20 parts. The EVs single speed transmission replaces the multi geared gearbox and DGS clutch system which will together reduce the cost of manufacturing by a third. The high development cost of batteries can be reduced by ESPs, and the best pick would be Hinduja Tech which incorporates Frugal Engineering as their core value is to reduce Product cost and Engineering cost by 15 – 30%.


![The-realistic-future-of-mobility.jpg](https://storage.googleapis.com/htlwebsite/The_realistic_future_of_mobility_028247adb5/The_realistic_future_of_mobility_028247adb5.jpg)

Furthermore, new breakthrough products such as battery swapping, lithium-air batteries, alternative metal-ion batteries, solid state technology and high energy capacitors which are still developing at an exponential rate will increase the range and reduce the cost and charging time. The problem of Range is applicable only when the commute is twice or thrice the actual range of an EV, where there might be no access to charging infrastructure or even if there is one you will have to make multiple stops for more than an hour to charge it. Otherwise, it is just your daily commute to your workplace with the usual traffic but with smoother riding experience and less noisy vehicles. Oh also no Exhaust gases.

References:
[https://en.wikipedia.org/wiki/History_of_the_electric_vehicle](https://en.wikipedia.org/wiki/History_of_the_electric_vehicle), History of Electric vehicle.
[https://www2.deloitte.com/content/dam/Deloitte/uk/Documents/manufacturing/deloitte-uk-battery-electric-vehicles.pdf](https://www2.deloitte.com/content/dam/Deloitte/uk/Documents/manufacturing/deloitte-uk-battery-electric-vehicles.pdf)
[https://thedriven.io/category/faqs/](https://thedriven.io/category/faqs/)
[https://eaa-1967.clubexpress.com/content.aspx?page_id=22&club_id=222684&module_id=296550](https://eaa-1967.clubexpress.com/content.aspx)
[https://www.zap-map.com/charge-points/](https://www.zap-map.com/charge-points/)











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EVs &amp; Range

EVs and Range – The long untold story

- Like mobile phone evolution automobile will change from hardware product to a software defined vehicle
- System / function-based architecture to transform into E / E central architecture
- As part of continuous improvement through OTA updates continuous co-ordination between OEM and supplier R&D team is required
- Suppliers will have to sell software and hardware as separate and in combo based on the OEMs software outsourcing strategy
- Customer centric optional (subscription based) and mandatory updates needs data driven decision making


Just like how cell phone has changed, cars are also going through a revolution, modern cars are being sold as hardware with a software package. Pushed by CASE (Connectivity, Automation, Shared and Electric) revolution along with development of 5G and Artificial Intelligence (AI). Traditionally cars were sold as a hardware unit and gets minor feature changes through service centres, which is now being changed to software defined vehicle with Over-the-Air (OTA) updates.

![Infographics-01-01.jpg](https://storage.googleapis.com/htlwebsite/Infographics_01_01_d9f5e92aee/Infographics_01_01_d9f5e92aee.jpg)

Moving away from conventional cars to software defined vehicle is an evolutionary process. This is four staged evolution of a vehicle as 1. Functional Vehicle, 2. Digital Vehicle, 3. Updateable-Vehicle and 4. Software Defined Vehicle. Each stage transition needs both hardware and software architecture changes which in effect demands an overhaul in conventional automotive research and development (R&D). That means shifting from the traditional scattered, embedded Electronic Control Units (ECU) to a domain focused system with central vehicle controllers. This requires sophisticated software including a software abstraction layer, Ethernet usage and large scale connectivity.

Traditional vehicle development period use to be 5-6 years, software defined vehicle demands R&D cycle of 3-4 years range. Main changes in R&D for the software defined vehicles are; change to agile systems engineering from component based waterfall development, change from embedded development for ECUs to centralised electrical-electronics (E/E) architecture and software, change from material cost optimisation at start of production to cost and revenue optimisation throughout the lifecycle, from product and technology focus to customer focus and change from experience based engineering to data enabled engineering and virtual engineering.

![Infographics-01-04.jpg](https://storage.googleapis.com/htlwebsite/Infographics_01_04_88d0f99eaf/Infographics_01_04_88d0f99eaf.jpg)

Conventionally OEMs use to get components/systems from suppliers and integrate, this will get sophisticated for software defined vehicle. OEMs and customers and looking for flexibility and agility, which in effect will make suppliers to sell hardware and software separately, so that OEMs and customers can pick and choose. As there will be OTA updates for both mandatory and subscription based systems and features, OEMs needs continuous co-ordination with supplier. The R&D team co-ordination that happens throughout continuous product updates makes this little difficult manage with conventional automotive organizational thinking and structure.

Conventional product focused R&D and product development processes discussions typically remain in their area of focus and have a few structured interactions with other functions such as marketing and sales. In case of software defined vehicle, OEM’s customer experience team needs continuous co-ordination with R&D team and some information has to be shared with software supplier R&D team. Customer experience should not be just from traditional surveys through service centers and third party but from data generated from vehicle and service centers.

Bringing automotive R&D organization fits to software defined vehicle is a sophisticated but necessary evolution for OEMs and suppliers, if they want to remain competitive to face CASE revolution and disruptive player entries.


Software Defined Vehicle demands R&D overhauling

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As technology evolves, the level of outsourcing to supplier partners has increased over time, with OEMs focusing on conceptualizing and building the vehicle, its integration, brand presence and establishing seamless customer connections. COVID-19 has exposed the vulnerabilities of global sourcing and emphasizes the need to localize as well as engage closely with suppliers as long-term business partners rather than a transactional interplay. The subsidies extended by the Government for EVs also emphasize the localization of aggregates. 


Diversifying the supply chain by engaging local suppliers and building redundancy in the sourcing of critical components reduces dependence on a single source and minimises the impact of supply disruptions. A localized supplier network to source components and materials closer to the manufacturing facilities reduces supply chain vulnerabilities and minimises logistics costs.

Supplier risk management strategy is essential for automotive companies to identify, assess, and be ready to face potential risks in their supply chain. This could start with onboarding a new supplier, managing supplier collaboration, integrating supply chains, and keeping in mind the impact of natural or geopolitical disasters and any other threats to the supply chain.

Therefore, Supplier Risk Management is an end-to-end activity, beginning with assessing the technical capability of the supplier, manufacturing process and productivity of the supplier, financial strength to run the operations, sustainable quality of the product and services, and competitive pricing to support the volumes and business growth plans of the OEMs.

## Managing Risks and Compliance Processes for OEMs

As OEMs are dependent on a complex supply chain that extends across the globe, market intelligence and predictive analytics are critical tools necessary to manage risks and ensure regulatory and other compliance aspects.

Supplier audits, interactions, and industry forums provide market intelligence. [Industry 4.0](https://hindujatech.com/industry-4-0), telematics, and other software tools help with predictive analysis at the product and process levels.
The decisions we arrive at with this data model will lessen the impact of challenges and pressures the automotive supply chain causes from time to time. Any stress in the automotive supply chain will impact sourcing, extending to Logistics, Technology, Regulations, Resource Availability, Environment, etc. Data Analytics driven by AI-based logic could circumvent all these issues paving the way for seamless operations.

![dn.png](https://storage.googleapis.com/htlwebsite/dn_5f33851001/dn_5f33851001.png)

 
 
### Action Plans by Hinduja Tech to challenge the contingencies

  1. Increased frequency of financial audits with relevant questionnaires. The data obtained is compared with the declaration. By assessing the financial ratios with relevant questions, the exact position of the supply partner is evaluated                             

      •	For instance, the current ratio, if less than 1, indicates short-term liquidity and solvency issues

      •	Not all the time; higher revenue translates to higher profit. Hence the profitability ratio gave us insights into how the organization can generate profits out of revenue. The contribution margin is an indicator of the profit after the costs of goods sold and services provided are considered

      •	Understanding the liabilities of the company against its net worth gives us visibility of how well an organization leverages against financial risks

  2. Continuous engagement with suppliers and developing a Risk Mitigation Plan    
  3. Alternate source development across commodities and technologies      
  4. Balance the inventory levels to have stock in place if there is an unexpected delay from the supplier   
  5. Ensuring positive free cash flow to the supplier, thereby ensuring smooth flow in operations across the supply chain   
 
Also, collecting the following information about the suppliers helps HT to comprehend their capability to ensure liquidity to meet current or short terms liabilities and their ability to sustain the business in the longer run.

  1. Sources of revenue and the weightage from each of its customers. As an example, if the supplier gets 25% of the revenue from one source, it might lead to a greater risk      
  2. Banks / Financial Institutions backing the supplier and its reputation      
  3. Debts committed to the Supplier by the Lender  
  4. Outstanding Debt / Capital   
  5. Financial Structure of the Supplier    
  6. Future Financing Options

Suppliers play a crucial role in the sourcing and supply of components, and their selection and management are vital for a robust supply chain. In the context of [electric powertrain engineering](https://hindujatech.com/product-engineering-services/powertrain), suppliers, particularly in the [EV industry](https://hindujatech.com/product-engineering-services/electric-and-future-mobility), such as battery suppliers, are key partners in ensuring the availability and quality of components.

Hinduja Tech (HT) recognizes the significance of suppliers and has developed a Supplier Risk Matrix assessment sheet. This tool enables HT to assess and evaluate the strength and reliability of the supply chain. The Supplier Risk Matrix assesses various factors such as financial stability, production capacity, quality control measures, and after-sales support. By using the Supplier Risk Matrix assessment sheet, HT can effectively evaluate the risks associated with potential suppliers, identify any vulnerabilities in the supply chain, and make informed decisions in selecting and managing suppliers. This assessment helps ensure that the chosen suppliers have the capabilities, resources, and commitment to meet the sourcing needs and provide reliable components for the electric powertrain engineering projects.

By deploying the Supplier Risk Matrix assessment sheet, HT can enhance supply chain resilience, minimize potential disruptions, and foster strong partnerships with suppliers, ultimately contributing to the success of electric powertrain projects.

 ![SRMchaert.png](https://storage.googleapis.com/htlwebsite/SR_Mchaert_ea27dab874/SR_Mchaert_ea27dab874.png)

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### Why is Supplier Risk Management Critical?

The COVID-19 pandemic, geopolitical problems like the Ukraine war, climate change, natural disasters, and others have badly impacted many companies and forced them to revisit their approaches towards supplier Risk Management. For instance, the COVID-19 pandemic is a prime example of how a health crisis can disrupt supply chains on a global scale. Similarly, Ukraine, the producer of copper, an essential input to many manufactured goods and electronics, could not cope with the promised schedules. These disruptions have required companies to gather information from suppliers with Ukrainian operations and adjust their production schedules and processes accordingly. Another recent example of an unanticipated supply chain disruption was when the Suez Canal was blocked by a giant container ship for 6 days. Recently China’s continuous cyber-attack attempts in Taiwan, the major chip source for global operations, pose a threat to hinder the global supply chain in terms of the availability of chips.

It is impossible to predict pandemics, wars, or disasters far in advance, but mitigating their impact on your organization is possible. With statistical data tests, every organisation must continuously work on identifying the vulnerable parts of the supply chain and the impact it would have on revenue generation. With the results, the organizations should identify alternate sources to have a smooth flow of operations.

### Our Strategic Matrix

Hinduja Tech works on the following 5*4 matrix, based on qualitative and quantitative data of any supplier, to assess the Risk in the Supply Chain. 

![SRMsup.png](https://storage.googleapis.com/htlwebsite/SR_Msup_030682cfe5/SR_Msup_030682cfe5.png)

 
A recommendation with a detailed action plan to mitigate the risks is offered to our customers.

### Our Supplier Management Strategy brings the following benefits

  1. Lower Supplier / Sourcing Costs – 14%-38% Reduction achieved 
  2. Reduced Supplier Risk  
  3. Improved Competitive Position in the Market  
  4. Increased Operational or Financial Efficiencies   
  5. Transparency in Escalation  
  6. Early Detection of Risk  
  7. Ability to Respond to Contingencies   
  8. Ensuring Compliance   
  9. Avoid Fines and Penalties.    
 

## Conclusion  
  
The automotive industry has complex supply chains that involve multiple tiers of suppliers, making it difficult to track and manage risks. This complexity increases the likelihood of risks and results in quality issues, delivery delays, or disruptions due to natural disasters or geopolitical events.

Partnering with [Hinduja Tech](https://hindujatech.com) brings OEMs the benefit of multiple supplier relationships to manage the growing demands of the automotive industry in an efficient way. With its 700+ auto-specific supplier ecosystem, Hinduja Tech can help mitigate risk & losses due to supplier breaches and noncompliance. This also involves developing contingency plans to manage disruptions in the supply chain.




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Supplier Risk Management – How well are OEMs Managing Disruptions?

## The Need for Cost-Effective Automotive Development

EV startups and traditional OEMs in North America face rising costs in developing and commercializing electric vehicles. These costs include R&D for Electric powertrains, Battery systems, Vehicle platforms, and Unique features. Other cost pressures include Raw Materials, Talent Shortages, Engineering, Manufacturing, and Operational Costs. To manage these costs, many companies are using nearshoring to Mexico.


### Nearshoring vs. Offshoring

Nearshoring involves moving operations to a nearby country, such as Mexico. This offers several advantages over offshoring, including:

•	Reduced time zone differences

•	Improved communication and collaboration

•	Lower labor costs

•	Access to a skilled talent pool

•	Reduced risk from geopolitical unrest


### Why Nearshore to Mexico?

Mexico is an attractive nearshoring destination for the automotive industry due to several factors:

•	**Large, skilled workforce:** Mexico has a large and growing pool of engineers and technical professionals. The government is also investing heavily in education and training programs

•	**Proximity to the US market:** Mexico's proximity to the US makes it an ideal location for nearshoring operations. This reduces transportation costs and lead times

•	**Supportive government:** The Mexican government is actively supporting the growth of the automotive industry with initiatives such as scholarship programs and investment in higher education


### How Hinduja Tech Can Help? 

Hinduja Tech is a leading provider of Product Engineering Solutions for the automotive industry. We have a proven track record of helping companies nearshore their operations to Mexico. We offer a unique blend of nearshoring and offshoring services, with 70% of engineering work executed in Mexico and the rest supported by technical experts from India.


### Benefits of Nearshoring with Hinduja Tech

•	**Cost optimization:** We can help you save money on engineering costs by leveraging Mexico's lower labor rates

•	**Improved communication and collaboration:** Our nearshore teams work closely with the US-based teams to ensure seamless communication and collaboration

•	**Access to a skilled talent pool:** We can help you tap into Mexico's large pool of skilled engineers and technical professionals

•	**Reduced risk:** Nearshoring to Mexico can help you reduce your risk from geopolitical unrest


Download an entire blog to learn more about how we can help you nearshore your automotive engineering operations.


Mexico Nearshoring

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5 Ways Nearshoring Drives Success in Automotive Engineering

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.

![Light Commercial Vehicle (LCV) ](https://storage.googleapis.com/htlwebsite/Light_Commercial_Vehicle_LCV_25a08b5aa3/Light_Commercial_Vehicle_LCV_25a08b5aa3.jpg)


### 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](https://hindujatech.com/product-engineering-services/product-development/commercial-vehicle) lifecycle: concept, detailed engineering, system selection, [virtual validation](https://hindujatech.com/product-engineering-services/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](mailto:info@hindujatech.com) —let’s drive your success together.




A Case Study in Light Commercial Vehicle (LCV) Development

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

In today’s rapidly evolving automotive landscape, the need for agile, innovative, and resilient supply chains has never been greater. As the industry pivots towards electrification and sustainability, proto sourcing and development have emerged as critical drivers for accelerating product innovation and meeting the demands of a global market. This blog delves into how alternate supply chain development, powered by generative AI and digital transformation, is shaping the future of prototype (proto) vehicle programs, highlighting a recent case study in Proto EV Truck development by Hinduja Tech.  

![Protosourcing](https://storage.googleapis.com/htlwebsite/Protosourcing_a65b4a3e52/Protosourcing_a65b4a3e52.jpg)
Advanced Proto Sourcing Visualization – Team Collaboration. (AI-generated image)

### The Growing Demand for Alternative Supply Chains 
The automotive sector is facing huge challenges: global disruptions, semiconductor shortages, and evolving regulatory requirements. Traditional supply chains, often rigid and geographically concentrated, are struggling to keep pace with the demand for rapid prototyping and new product introductions. 
As a result, OEMs and Tier-1 suppliers are seeking alternate supply chain strategies that offer: 
- **Speed and Flexibility**: The ability to source diverse commodities and sub-systems quickly. 
- **Resilience**: Reducing dependency on single-source suppliers or regions. 
- **Innovation**: Leveraging digital tools and generative AI for smarter sourcing decisions. 
## 

![Protosourcing](https://storage.googleapis.com/htlwebsite/Protosourcing_cb5a049482/Protosourcing_cb5a049482.jpg)
Shifting global supply chains in the automotive industry, highlighting the role of alternative sourcing strategies. (AI-generated image) 

### Innovation in Motion: The Making of a Prototype EV Truck at Hinduja Tech 
When Hinduja Tech set out to develop its prototype electric vehicle (EV) truck, the journey began with a clear challenge: rapidly sourcing a vast variety of specialized components while adhering to aggressive timelines in a volatile supplier market. 

#### The Challenge we faced  
The project’s ambitions included not just sourcing but assembling a fully functional EV truck from scratch, with high standards for both quality and integration. 

#### The Journey we went through…
The team first mapped the requirements—from the interior, exterior, and chassis sub-systems to wiring harnesses, lighting, and cabin modules. Instead of following a conventional, linear approach, Hinduja Tech adopted an agile and collaborative model. Hinduja Tech’s qualified and experienced commodity managers reached out across their wide supply chain network, using supplier platforms enabled by digital tools to shortlist and negotiate with specialized vendors quickly. Real-time updates and rapid communication helped overcome geographic and tariff-related challenges, while concurrent engineering ensured development could progress on multiple fronts. 

#### Milestones That Redefine Possibility
##
- **Rapid Development**: Developed custom components in just 8–10 weeks, slashing traditional lead times.
- **Efficient Assembly**: Assembled, integrated, and commissioned the complete vehicle within 3–4 weeks, an operational triumph.
- **Quality Assurance**: Rigorous prototyping processes surpassed stringent automotive standards.

![Protosourcing](https://storage.googleapis.com/htlwebsite/Protosourcing_39b36b3b40/Protosourcing_39b36b3b40.jpg)
Advanced Prototype Assembly and Supplier Intelligence (AI-generated image) 

#### Benefits reaped  
Our approach didn’t just deliver a stunning prototype in under three months; it cut costs through optimized sourcing, eliminated bottlenecks, and ensured every component met or exceeded stringent automotive standards. Most importantly, the model proved adaptable for future vehicle programs, whether electric, hybrid, or conventional, setting a new benchmark for speed, quality, and innovation in automotive development.

![Prototype](https://storage.googleapis.com/htlwebsite/Prototype_4b6ae696c6/Prototype_4b6ae696c6.jpg)

### How Generative AI Is Transforming Prototype Development & Sourcing?
Generative AI is revolutionizing how automotive companies approach prototype development and sourcing. Key applications include: 
- **Supplier Discovery**: Hinduja Tech’s wide supplier local and global network, coupled with their readiness to leverage AI-driven platforms like GEP SMART, allows them to analyze global supplier databases. This approach enables them to recommend best-fit partners based on real-time cost, lead time, certifications, and risk metrics, empowering decisions that are both faster and more robust.  
- **Risk Mitigation**: Predictive analytics proactively identify and address potential disruptions, offering strong contingency planning. 
- **Design Optimization**: Design software like CATIA, UG NX, and supporting AI engineering Tools like Autodesk’s Fusion 360 Generative Design suggest innovative part architectures that simplify sourcing and manufacturing. 
- **Process Automation**: Procurement and logistics platforms now leverage AI for inventory management, reducing manual errors and increasing efficiency. 

By leveraging existing proven technologies and embracing AI-driven platforms for support, Hinduja Tech is not only enhancing its capability in prototype development and sourcing but also setting new benchmarks for the automotive industry. 

### Why Alternate Supply Chain Development Matters Now?

The shift to alternate supply chain development is more than a reaction to short-term disruptions; it is now a strategic imperative for long-term growth. Current global tariff volatility and shifting trade policies have made it clear: automotive companies must diversify their supply chains to remain competitive and resilient.  

Companies investing in digital transformation, generative AI, and agile supply models will be better positioned to: 
- **Meet Evolving Customer Expectations**: Deliver bespoke, innovative vehicles at pace. 
- **Navigate Uncertainty**: Build operations robust enough to withstand tariffs, trade policy shifts, and supply shocks. 
- **Drive Sustainability**: Source responsibly, supporting green manufacturing and circular-economy goals. 
## 
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Automated, AI-Powered Prototype Manufacturing Line (AI-generated image)
##

### Partner with Hinduja Tech for Next-Generation Prototype Development & Sourcing 
If your organization seeks to accelerate product innovation, reduce time-to-market, and future-proof your supply chain, Hinduja Tech provides end-to-end expertise in prototype development and sourcing. Our experience in all mobility and EV truck prototyping, access to a global supplier ecosystem, and advanced digital toolkit ensure seamless project execution—from concept through commissioning. 

Contact: [info@hindujatech.com](mailto:info@hindujatech.com) 

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Proto Sourcing and Development - The World Is Looking for an Alternative Supply Chain Development 

In today’s competitive automotive landscape, optimizing inventory at storage areas and on the line, along with inbound and outbound logistics, is essential for success. Production delays, testing bottlenecks, and suboptimal space utilization not only impede operational efficiency but also lead to increased costs. To overcome these challenges, Hinduja Tech utilizes advanced material flow simulation to help manufacturers optimize their plant operations, making logistics smarter, processes faster, and investments more impactful. 

### The Challenge
Modern manufacturing involves balancing multiple constraints in material flow, from raw material to finished goods. Hinduja Tech’s recent project illustrates the complexity of optimizing plant operations and capacity planning. With three production lines feeding two roll-test stations operating under different takt times, the objectives were clear yet challenging: 

- **Optimize parking capacity** for trucks arriving after roll-test stations  
- **Synchronize production lines** converging on limited roll-test capacity 
- **Manage increasing roll-test demands** without creating backlogs 
- **Conduct spatial analysis** of offline areas and truck parking zones  
- **Identify critical bottlenecks** impacting inventory flow between End-of-Line (EOL), test areas, and finished vehicle storage
## 
Without the right insights and planning, achieving these objectives would have been difficult, risking longer cycle times, inventory pileups, and production slowdowns. 

### Advanced Simulation for Smart Solutions
Hinduja Tech utilizes plant simulation tools to validate, digitally model, and test operational scenarios before implementing any physical changes. By running “what-if” analyses, the team assessed impacts on Tecnomatix Plant Simulation tool throughput, space, and timing, avoiding costly trial errors on the shop floor. 

**The simulation approach involved:**
- Validating production and testing sequences digitally  
- Modelling takt time variations and capacity limits 
- Analysing inventory levels between key stages 
- Optimizing offline spaces for truck parking and storage 
## 
Digital simulation provided clarity and confidence for optimizing processes and investments. 

![Material Flow Simulation](https://storage.googleapis.com/htlwebsite/Material_Flow_Simulation_a13048cf18/Material_Flow_Simulation_a13048cf18.jpeg)


### Measurable Benefits Achieved 
With insights derived from simulation, Hinduja Tech proposed strategic improvements that enhanced operational performance. 
- Highlighted roll test bottlenecks and recommended an additional test station to increase capacity 
- Improved offline space utilization by 20%, better managing truck parking and staging 
- Confirmed offsite parking could handle inventory accumulation up to 5 days, reducing disruption risks 
## 
This approach also enhanced collaboration across logistics, production, and facility teams, driving aligned improvements. 

### Driving Sustainable, Profitable Innovation 
Manufacturers today must embrace smarter, sustainable production. Hinduja Tech’s material flow simulation enables: 
- Precise logistics automation and optimization 
- Waste elimination and identifying the Bottlenecks 
- Resource utilization charts and optimizing buffer sizes 
- Enhanced throughput and operational flexibility 
- Inventory cost containment without production impacts 
- Confident, data-backed planning 
## 
By linking simulation with real-world actions, Hinduja Tech fosters resilient, profitable manufacturing transformations. 

### Why Hinduja Tech is Your Trusted Simulation Partner?
Across automotive manufacturing ecosystems, Hinduja Tech’s material flow simulation capabilities unlock operational transparency, risk mitigation, and strategic capacity planning. By partnering with Hinduja Tech, enterprises gain a trusted advisor poised to deliver: 
- Proven methodologies for bottleneck resolution and capacity optimization 
- Tailored solution frameworks aligned with complex plant architectures 
- Scalable engineering expertise to support evolving production demands 
- Robust validation protocols minimizing project risk and maximizing throughput 
## 
Embark on your journey towards operational excellence and supply chain agility with Hinduja Tech’s integrated simulation solutions. Discover how our expertise can elevate your manufacturing operations to new levels of efficiency and profitability. 

**Contact:** [info@hindujatech.com](mailto:info@hindujatech.com) 

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Material Flow Simulation

Streamlining Your Shop Floor: How Material Flow Simulation Drives Operational Efficiency

Efficient, safe, and worker-friendly automotive assembly processes are critical in today’s manufacturing industry. On the shop floor where vehicle dashboards are installed, operators must navigate through confined spaces, handle bulky components, and coordinate precisely with upstream and downstream tasks. Assembly of dashboards often requires technicians to work within tight ergonomic zones, repetitively reach across complex fixture setups, and adapt to varying vehicle models, all while maintaining speed and quality. Hinduja Tech’s expert application of human simulation and ergonomic analysis sets a benchmark for these outcomes. 
 

### Why Ergonomics and Human Simulation Matter?
Ergonomics and human simulation are crucial for modern manufacturing because they help design the work environment around the worker, rather than forcing the worker to adapt to a predesigned system. This human-centric approach yields significant benefits in terms of safety, productivity, and cost optimisation. Ergonomics minimizes strain and injury while driving operational efficiency by aligning tasks with human capabilities.  

As production complexity increases, ensuring that each assembly task is ergonomically sound becomes vital for driving productivity, improving safety, and reducing costs. On the shop floor, ergonomic challenges can include awkward body postures, sustained overhead reaches, and the manipulation of heavy dashboard modules. When these factors are unmanaged, they increase the risk of fatigue and musculoskeletal disorders, resulting in inefficiencies and operational disruptions. Forward-looking manufacturers leverage virtual simulation not only to validate designs, but also to safeguard their workforce and bottom line. 


### Hinduja Tech’s Approach: Digital Simulation for Real Results 
Hinduja Tech employs advanced digital manufacturing tools and domain expertise to optimize assembly processes for global OEMs. Using virtual human modeling, they simulate real-world movements and posture during dashboard installation, identifying risk points and optimizing workstation layouts. This simulation-driven approach provides actionable insights long before physical implementation, avoiding costly iterations and ensuring each process step meets global ergonomic standards. 


### Our expert teams leverage
- Digital human modeling software (Posture, reach, force, visibility, and fatigue analysis) 
- Task simulation and process optimization 
- Anthropometric data to tailor workflows for diverse operators 
- Automated reporting aligned with regulatory and industry benchmarks 
### 


### Case Study: Dashboard Sub-Assembly Analysis 
In a recent dashboard sub-assembly project, Hinduja Tech collaborated with a leading manufacturer to address key ergonomic challenges: 
- Manual installation tasks with complex reach and access zones 
- Variability in operators' physical profiles 
- Balancing cycle time with safe, repeatable movements 
- Need for rapid feedback on workstation layout redesigns 
### 


### Applying simulation expertise, Hinduja Tech
- Modeled tasks using digital human avatars representing multiple percentiles and postures 
- Ran ergonomic risk assessments on critical motions, force application, and reach analysis 
- Provided recommendations to adjust assembly sequence, optimize part orientation, and redesign workstation geometry to reduce risks 
- Delivered actionable 3D work instructions that improved operator training and process efficiency 
### 


### Measurable Business Impact 
The results were immediate and quantifiable: 
- 10% reduction in ergonomic risk scores across dashboard installation steps 
- Cut cycle time on key tasks, improving overall workstation throughput 
- Enhanced operator safety and comfort, reducing long-term injury potential 
- Clear digital documentation for ongoing process improvement and compliance 
### 
Manufacturers benefited from fewer work-related injuries, improved productivity, and significant reductions in downtime and associated costs. 


### Why Hinduja Tech?
With years of automotive manufacturing expertise and cutting-edge simulation capabilities, Hinduja Tech delivers scalable ergonomic solutions tailored to complex production environments. Serving over 100 global OEMs and Tier-1s, our multidisciplinary teams specialize in: 
- Process simulation and digital validation 
- Ergonomic workstation and line design 
- End-to-end engineering support, from design through execution 
### 
Hinduja Tech partners with clients to advance both operator well-being and sustainable manufacturing performance. 


### Partner with Hinduja Tech for Ergonomic Excellence 
Ergonomic risks in assembly lines can be mitigated before they become costly realities. By integrating human simulation into process design, automotive companies can protect workers and unlock new productivity gains. 

Learn how Hinduja Tech’s ergonomic analysis and human simulation services can empower your next program. 

Contact us today at [info@hindujatech.com ](mailto:info@hindujatech.com )

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Ergonomic Human Simulation Study: Design for Assembly of Dashboard in Vehicle

As sustainability moves from a hopeful idea to an urgent global mission, engineering services companies are stepping up as powerful drivers of change. They’re not just building for today—they’re shaping the future by making industries cleaner, more efficient, and better for the planet.


### Innovation at the Heart of Change
Engineers are problem solvers, and the latest advances demonstrate how central they are to achieving net-zero goals. Modern tools, such as digital twins—virtual models that replicate real-world systems—help companies test and refine their operations before implementing significant changes, leading to reduced waste and more efficient resource utilization. Artificial intelligence now predicts when machines require repairs, preventing unnecessary downtime and extending the lifespan of equipment. These innovations enable organizations to save energy and money while reducing their environmental impact.


### Designing with Sustainability in Mind
Engineering isn’t just about inventing things—it’s also about rethinking how we make them. Sustainable design means choosing materials that don’t harm the earth, making products easy to recycle, and using energy wisely in every step of the process. Some engineering firms are leading the way by creating manufacturing plants that recycle their waste or operate on renewable energy, demonstrating that it’s possible to produce goods without harming the planet.


### Energizing the Renewable Revolution

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Nowhere is the impact of engineering clearer than in the energy sector. From huge wind farms and solar parks to smarter ways of storing electricity, engineers are making it possible for communities and companies to use clean power every day. They're also experimenting with green hydrogen—a clean fuel—and developing systems to catch and reuse carbon, so less ends up in the atmosphere. These breakthroughs are crucial for shifting away from coal and oil and accelerating the global transition to renewable energy sources.


### Building a Circular Economy
A significant aspect of sustainability is learning to reuse what we already have. Engineering services companies design processes that recover and recycle metals, plastics, and electronics, keeping valuable resources out of landfills. By using digital tools to track materials and manage their lifecycles, they ensure that products continue to circulate, which saves costs and protects the environment.


### Positive Economic Impact
Sustainable engineering doesn’t just help the environment—it boosts business, too. Companies that adopt these practices find they use resources more efficiently, cut costs, and gain the trust of customers and investors. The global demand for technology-driven sustainability is growing fast, and with it comes new opportunities for innovation and leadership.

As nations and businesses raise their climate ambitions, the role of engineering services companies is only getting bigger. By focusing on innovative ideas, responsible design, clean energy, and efficient resource management, engineers are helping industries worldwide move closer to achieving net-zero. Their work demonstrates that protecting the planet and growing the economy can be mutually beneficial.

As a leading E R&D partner, Hinduja Tech plays a crucial role in the push toward global net-zero goals by providing advanced engineering solutions for sustainable mobility. Through collaborations with automotive OEMs and Tier-1 suppliers worldwide, Hinduja Tech has co-developed multiple vehicle models, resulting in 14 electric vehicles being brought to market. It is actively involved in battery and powertrain innovation, manufacturing cost reduction, and lightweighting to lower emissions. The company’s “Frugal Engineering” approach enables efficient product development, helping clients balance performance, cost, and environmental impact without sacrificing quality. By supporting the scaling of next-generation EV platforms, designing smarter supply chains, and enabling digital transformation for greener manufacturing, Hinduja Tech ensures that sustainability is integrated into every stage from concept to deployment. The company’s global project track record and dedication to engineering excellence position it as a key driver in speeding up the transition to a low-carbon, sustainable future of mobility.


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The role of engineering services companies in accelerating global net-zero goals

In the automotive industry, optimizing engine efficiency while controlling emissions is a constant challenge. At Hinduja Tech, we believe the solution lies in smart engineering, robust simulation, and a commitment to continuous improvement. This philosophy is exemplified in our case study on EGR (Exhaust Gas Recirculation) Cooler Analysis, where our simulation-led design engineering approach helped deliver a solution for a modern 3-cylinder engine with increased efficiency and compact cooling. 


### The Importance of EGR Coolers in Modern Engines 
Global regulatory norms and customer expectations have driven OEMs to enhance fuel efficiency and reduce emissions. EGR coolers play a pivotal role in this transformation, helping engines recirculate exhaust gases at controlled temperatures to minimize NOx emissions without sacrificing performance. However, inefficient or oversized coolers can result in energy losses, increased costs, and integration challenges. Recognizing this, manufacturers are increasingly seeking intelligent design backed by simulation rather than trial and error. 


### Objective: Precision in Design through Simulation 
Our project began with a clear objective: to define the ideal geometry for an EGR cooler by leveraging 3D flow and thermal analysis. The goal was not only to match but also to exceed benchmark performance standards while ensuring a best-fit design for the intended 3-cylinder engine. Utilizing leading-edge simulation software, including Ansys CFX, our engineers conducted a comprehensive study to optimize every aspect of the EGR cooler’s design. 


### Simulation-Driven Solution 
The analysis began with the initial EGR cooler design, which underwent a rigorous steady-state conjugate heat transfer assessment. This detailed virtual evaluation revealed that the initial unit was overdesigned, resulting in excessive material use and space requirements that did not align with the engine’s actual thermal needs. 


Armed with this insight, our engineers systematically refined the design by: 
- **Optimizing Core Dimensions:** Adjusting the length of the cooler, the diameter of tubes, and the number of tubes, all tailored precisely to the thermal parameters required for engine efficiency.
- **Smart Inlet and Outlet Placement:** Engineering the positions of the inlet and outlet ports to deliver the most effective cooling while reducing size and minimizing pressure drop. 
### 

The use of high-fidelity CFD (Computational Fluid Dynamics) enabled us to visualize temperature and velocity distributions within the cooler. Our team generated detailed contour plots and flow simulations, capturing both macro and micro-level thermal behaviours and identifying where enhancements would yield the greatest impact.  


### Benefits Delivered 
The results were significant, both technically and commercially: 
- **Compact, Right-Sized Solution:** The optimized EGR cooler perfectly matched the 3-cylinder engine’s needs, providing effective thermal management in a smaller, easier-to-integrate form. 
- **Cost and Time Efficiency:** By digitally simulating and comparing options with supplier benchmarks, our engineers identified the most suitable EGR cooler eliminating the cost and delays associated with multiple prototypes. 
- **Reduced Overdesign:** Precise optimization ensured elimination of unnecessary material or space, translating directly to manufacturing savings. 
- **Validation through Simulation:** All changes were validated virtually, supporting a smooth transition from concept to production with minimal risk. 
### 


### A Digital Approach to Engineering Challenges 
This project showcases the power of simulation-driven design in modern automotive engineering. By moving analysis and optimization into the virtual world, Hinduja Tech enables clients to achieve superior results with greater speed and certainty. Every parameter is tested before a part is even built, drastically reducing development cycles and minimizing costly setbacks at later stages. 


### Partner with Hinduja Tech for Engineering Innovation 
Hinduja Tech is committed to pushing the boundaries of engineering excellence in the mobility sector. Our expertise in advanced simulation, digital manufacturing, and thermal analysis delivers measurable value to our clients through improved designs, faster time-to-market, and real cost savings. 

Are you facing similar engineering challenges in your projects? Discover how our simulation-led solutions can make a difference.  

Email us at [info@hindujatech.com](mailto:info@hindujatech.com) to learn more about our integrated engineering and digital services. 

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Engineering Excellence: EGR Cooler Analysis through Advanced Flow and Thermal Simulation

When people talk about sustainable mobility, electric vehicles (EVs) are often the first thing that comes to mind. However, the truth is that EVs are just one part of a much larger picture. Solving how we move people and goods more cleanly isn’t about finding a silver bullet—it’s about combining many different solutions in smart ways.


### What is the multi-pathway approach?
A multi-pathway approach means using a mix of technologies, policies, and habits to make mobility more sustainable. Instead of betting everything on one option, it brings together many tools: electric cars, hydrogen vehicles, improved fuels, public transportation, walking, cycling, and even smarter transport apps and data systems. The goal is straightforward—to achieve net-zero emissions while making cities and rural areas more liveable and equitable for everyone.


### Why no “One size fits all”?
Every place has unique needs. What works in a busy city may not make sense in a remote village. Some people might switch easily to cycling and public buses; others might need cleaner cars or better ride-sharing apps. By connecting modes—such as linking trains and buses or making it easy to park and bike—people have choices that fit their lives.


### Technology: more than just EVs
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- Electric vehicles are key, especially as batteries improve and charging gets easier.
- Hydrogen and biofuels offer hope for trucks, buses, and places where batteries can’t reach.
- Intelligent transport systems use data and digital tools to cut traffic jams, boost safety, and help cities plan smarter.
- Smart mobility services (like ride-hailing, shared bikes, or integrated ticketing) make travel smoother.
### 


### Moving people, not just cars
A multi-pathway strategy sparks a shift away from car-focused thinking. Building safe footpaths, cycling lanes, and reliable public transport helps people pick active, greener options. This isn’t only good for the planet—it can also make cities healthier and less crowded.


### Planning with data
Better decisions are made when cities share transportation data. Collecting and analysing how people move—not just cars—means planners can spot patterns, fix bottlenecks, and invest where it matters. It’s also crucial to guard privacy and ensure everyone benefits, not just those with access to tech tools.


### Closing the gaps: policy and local needs
Strong policies can push things forward, but they must recognize that urban and rural areas differ. Cities may focus more on congestion, while rural regions might struggle with access or long distances. Tailored plans, informed by local voices, work better than copying and pasting one big idea.


### Innovation and change, together
New vehicle technology and digital mobility services can only succeed if we support them with effective rules, incentives, and social changes. It’s about more than building smart cars—it’s about reshaping how and why we travel.

In short, getting to sustainable mobility isn’t easy, and electric cars alone won’t get us there. By combining various solutions—technology, data, improved planning, and smarter travel habits—a multi-pathway approach enables progress for all. This strategy helps us move towards cleaner air, fairer cities, and a future where everyone can get where they need to go—without leaving the planet behind.

At Hinduja Tech, the commitment to sustainable mobility goes beyond electric vehicles alone. As an ER&D leader, we help our clients and partners adopt a multi-pathway strategy—combining advanced engineering, digital innovation, and domain expertise to deliver greener solutions across every mode of transportation. Whether it’s accelerating EV design and manufacturing, pioneering hydrogen and biofuel systems, enabling smart public transport, or supporting data-driven urban planning, we work to ensure every community can access mobility that matches local needs and global climate goals. By collaborating across industries and supporting the tailored adoption of technology, Hinduja Tech empowers businesses to move towards net-zero mobility and a future where transportation works for people and the planet.


Email us at [info@hindujatech.com](mailto:info@hindujatech.com) to learn more about our integrated engineering and digital services. 


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Beyond EVs: The multi-pathway approach to sustainable mobility

As the automotive industry accelerates its transition to electrification, the need for robust, cost-effective power management solutions has never been more critical. Hinduja Tech, a leader in digital product engineering and automotive innovation, has recently partnered with a top UK Tier 1 customer to develop a high-performance, bidirectional DC-DC Converter and Supercapacitor ECU for advanced electric vehicle architectures. This case study illustrates how Hinduja Tech delivers state-of-the-art solutions that address evolving OEM requirements while optimising costs and development time.


### Project Scope: Delivering High-Efficiency Power Management
The challenge involved designing a 700W, 12V to 48V bidirectional DC-DC converter, a core enabler for electric Anti-Roll Control (eARC) systems in next-generation vehicles. This converter, operating in tandem with an ultra-efficient super capacitor module, not only powers fast-reacting eARC actuators but also ensures consistent voltage stability by buffering transient loads and protecting the 12V bus. Built on the Infineon AURIX TC23X microcontroller platform, the solution was engineered to meet the strictest ASIL B functional safety and ASPICE compliance standards, reflecting Hinduja Tech’s commitment to quality and reliability.

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### Methodology: End-to-End Engineering Excellence
Hinduja Tech’s engineering approach draws on in-depth domain expertise, collaborative program management, and a proven digital thread strategy. The team executed a comprehensive methodology that included:
- Detailed requirements capture and function safety planning.
- Application software development and seamless integration with AUTOSAR-compliant Basic Software (BSW) and MicroSAR stack.
- Development and configuration of MCAL drivers, Secure Boot Controllers (SBC), Intersil SOCs, and a robust vector flash bootloader stack.
- FlexRay communication, network management, and non-volatile memory configuration.
- Diagnostic implementation using Unified Diagnostic Services (UDS).
- Rigorous unit, integration, and function testing aligned with international automotive standards.
### 

By closely integrating each hardware and software layer, Hinduja Tech ensured quick validation and risk mitigation, which is essential for OEM programs that require complete lifecycle traceability and compliance.


### Measurable Impact: Accelerating Time-to-Market, Optimizing Cost
The DC-DC Converter and Super Capacitor ECU solution not only met the client’s technical and safety requirements but also delivered significant commercial benefits. Through optimized digital development and value analysis, Hinduja Tech achieved a 70–75% reduction in product design and development costs compared to global benchmarks. Additionally, the use of advanced virtual validation techniques and the seamless integration of physical prototypes resulted in substantial cost optimization and a reduced time-to-market for the customer’s platform.


### Why Global OEMs Trust Hinduja Tech?
Hinduja Tech’s end-to-end product engineering capabilities empower OEMs and Tier 1 suppliers to innovate with confidence:
- Comprehensive domain expertise from vehicle electronics, software, and embedded systems to powertrain and compliance.
- Agile, customer-centric engagement models tailored for business-critical timelines.
- Proven track record delivering high-performance, production-ready solutions to leading brands worldwide.
### 


### Partner With Us
Ready to accelerate your next vehicle program or electrification initiative? Learn how Hinduja Tech’s advanced vehicle electronics and software solutions can help you optimize cost, improve quality, and bring innovative products to market faster.

Email us at [info@hindujatech.com](mailto:info@hindujatech.com) to learn more about our integrated engineering and digital services. 


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Driving Innovation in Electric Mobility: DC-DC Converter & Super Capacitor ECU Development by Hinduja Tech

### Introduction
Powerful global forces are shaping the future of mobility. As technology, sustainability, and consumer expectations converge, transportation systems are evolving rapidly. At Hinduja Tech, we’re not just adapting to these changes—we’re engineering them.

This article examines five global megatrends that are reshaping mobility and showcases how Hinduja Tech is leading the way in developing sustainable transportation solutions for OEMs, Tier-1 suppliers, and mobility disruptors around the world.

### 1.Electrification Goes Mainstream
Electric vehicles (EVs) are transforming the automotive industry. With global EV sales projected to reach 44% of passenger car sales by 2030 (BloombergNEF), electrification is no longer optional—it’s inevitable.

### Key Drivers:
- Declining battery costs
- Government incentives and regulations
- Consumer demand for clean mobility
###
### 2.Autonomous & Connected Mobility
Autonomous vehicles (AVs) and connected car technologies are revolutionizing how we think about safety, efficiency, and user experience. Over $100 billion has been invested globally in AV technologies, and this momentum is expected to continue.
### Key Technologies:
- ADAS (Advanced Driver Assistance Systems).
- V2X (Vehicle-to-Everything) communication
- Digital twins and simulation platforms
###
 ### 3.Mobility-as-a-Service (MaaS)
The rise of Mobility-as-a-Service (MaaS) reflects a shift from vehicle ownership to shared, on-demand mobility. The MaaS market is expected to reach $500 billion by 2032, driven by urbanization and digital transformation.

 


### Key Features:

- Integration of public transit, ride-hailing, and micro-mobility
- Seamless digital platforms for trip planning and payments
- Real-time fleet management and analytics
###
### 4.Sustainability & Circular Design
Sustainability is now a strategic priority. The automotive sector contributes nearly 9% of global GHG emissions, prompting a shift toward circular design and eco-friendly engineering

### Key Focus Areas:
- Eco-material selection and recyclability
- Lifecycle engineering and carbon footprint reduction
- Energy-efficient manufacturing
###
 
### 5.Global Supply Chain Reinvention
Global supply chains are being reimagined for resilience, transparency, and localization. A McKinsey study shows that 45% of automotive executives are prioritizing supply chain agility and digital transformation.
### Key Trends:
- 	Predictive analytics and demand forecasting
- 	Digital BOMs and traceability
- 	Supplier collaboration platforms
###
### Conclusion
The future of mobility is not just about vehicles—it’s about ecosystems. Electrification, autonomy, shared mobility, sustainability, and supply chain innovation are converging to redefine how we move people and goods.

At Hinduja Tech, we’re not just observing these megatrends—we’re actively shaping them. Our comprehensive suite of sustainable mobility engineering services empowers automotive players to innovate responsibly and scale efficiently.

Whether you're an OEM, Tier-1 supplier, or mobility disruptor, Hinduja Tech is your partner in building a future that is intelligent, inclusive, and environmentally responsible.
Let’s engineer the future of mobility—together.

 

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The Future of Mobility: 5 Global Megatrends Driving Sustainable Transportation Innovation

Electrification is revolutionizing mobility, and batteries play a central role in this transformation. Yet, as the adoption of electric and hybrid vehicles rises, so does the demand for reliable and efficient battery thermal management. Ensuring batteries remain within optimal temperature ranges, regardless of real-world driving scenarios, is crucial for safety, service life, and vehicle performance. 

At Hinduja Tech, we partner with leading OEMs and Tier 1 suppliers to address these evolving engineering challenges with innovation and speed. Our recent project for a prominent automotive client exemplifies our commitment to leveraging advanced simulation for pragmatic and cost-effective results. 

![Simulation-Driven Thermal Solution ](https://storage.googleapis.com/htlwebsite/Simulation_Driven_Thermal_Solution_0161d0142c/Simulation_Driven_Thermal_Solution_0161d0142c.png)


### Understanding the Challenge: Real-World Complexity
Thermal management systems for batteries must handle a broad spectrum of operating conditions from energy-intensive acceleration in dense city traffic to steady-state cruising on highways. In this program, our client needed to ensure that battery surface temperatures would remain within design limits under two critical operating modes: traffic jam conditions and cruise scenarios. 

The stakes were high. Overheating can accelerate battery degradation, shorten usable life, and threaten safety, while under-cooling can compromise power delivery. The challenge? Deliver a validated solution that not only achieves thermal targets but also balances cost, weight, and packaging constraints, essential in today’s competitive automotive landscape. 


### Our Approach: Simulation-Led, Data-Driven 
Hinduja Tech deployed industry-standard tools, ANSYS Fluent and ICEMCFD, for a rigorous Computational Fluid Dynamics (CFD) simulation study. The project’s primary objectives included: 

- Estimating blower flow rates required to maintain optimal cooling, using detailed pressure drop analysis 
- Assessing airflow distribution and cooling performance both in stop-and-go (traffic jam) and continuous (cruise) conditions 
- Modelling complex real-world scenarios such as flow impingement on the battery box and interactions with the vehicle’s underbody and cooling components 
### 

The first round of simulation revealed a challenge: temperatures in some regions surpassed the specified maximum under certain conditions. Rather than returning to the drawing board, our engineering teams proposed a series of targeted design enhancements, including the addition and refined positioning of air guides, to direct cooling air more effectively to critical battery surfaces. 

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### From Model to Reality: Results You Can Trust
The power of our approach lies in its iterative nature and its rigorous validation methodology. We worked hand-in-hand with the client to incorporate proposed changes in the virtual model, rapidly testing multiple design iterations in the digital domain, long before committing to costly physical prototypes. 

The result? The updated simulation achieved battery surface temperatures well within the defined targets for both urban and highway use cases. When the final, optimized model was subjected to physical testing, the measured results closely matched simulation predictions, a testament to the accuracy of our CFD process and real-world engineering experience. 


**Key benefits realized by the customer:**
- Significant reduction in costly real-world testing, since multiple concepts were virtually validated before a single prototype was produced 
- Accelerated program timelines, thanks to rapid digital iterations and data-driven decision-making 
- Enhanced confidence in thermal system performance, directly supporting overall battery safety, warranty, and customer satisfaction 
### 

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### Why Hinduja Tech? 

This project exemplifies Hinduja Tech’s commitment to delivering transformative engineering services, achieving actionable results through deep domain expertise, advanced tools, and a collaborative client approach. Our teams combine simulation expertise with practical automotive experience to reach targets more quickly, mitigate risks, and optimize investment in new technology programs. 

Whether designing next-generation EV architectures, developing robust thermal systems, or enabling digital transformation, Hinduja Tech stands ready to partner with organizations worldwide. 


### Ready to Future-Proof Your Battery Technology? 
Don’t let thermal challenges slow your electrification journey. Hinduja Tech helps OEMs, suppliers, and mobility innovators accelerate product launches and exceed customer expectations. If your organization is evaluating ways to optimize battery, power electronics, or vehicle cooling systems, let’s talk. 

Reach out to us at [info@hindujatech.com](mailto:info@hindujatech.com) to discuss how simulation-led engineering, proven process, and automotive domain depth can create a step-change in your next vehicle program. 





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Optimizing Battery Cooling for Modern Mobility: Hinduja Tech’s Simulation-Driven Thermal Solution

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