Kinetic Communications Unveils Fully Automated Controller Manufacturing Line in Pune, Elevating India’s EV Electronics Capabilities!

In a bold move towards embracing Industry 4.0 and reinforcing India’s position in global EV electronics manufacturing, Kinetic Communications has inaugurated a fully automated controller manufacturing line at its state-of-the-art facility in Pune. This advanced production line is engineered to deliver high-throughput, precision manufacturing of Motor Controller Units (MCUs)—critical components that manage the interaction between the battery and motor in electric vehicles, controlling acceleration, braking, and overall energy efficiency.

The manufacturing setup integrates cutting-edge Surface Mount Technology (SMT) and automated assembly systems, managed through a combination of Human Machine Interface (HMI) and Programmable Logic Controllers (PLCs). This digital ecosystem ensures real-time process control, seamless data traceability, and near-zero manual intervention, resulting in significant reductions in errors while maximizing production efficiency.

The new line not only produces MCUs but also manufactures Power and Driver Board Assemblies and Complete Controller Box Assemblies. These components go through a meticulous validation process, including software flashing, IP67 leak testing, and functional testing—ensuring they meet stringent quality and durability benchmarks. Currently operating at a capacity of 300 units per shift, the plant is equipped to scale up to an annual output of 180,000 units under two shifts, reinforcing its role as a high-volume production powerhouse.

To guarantee world-class quality, the facility incorporates advanced testing tools such as 3D Solder Paste Inspection, Automated Optical Inspection (AOI), and In-Circuit Testing for comprehensive electrical validation. It uses lead-free dual-wave soldering technology for through-hole components and employs robust Poka Yoke mechanisms to eliminate the possibility of human error. With synchronized HMI-PLC integration, every production station ensures smooth digital communication and traceable software implementation.

Each unit undergoes End-of-Line Testing and Pre-Dispatch Inspection (PDI), while Incoming Quality Control (IQC) aligns with JESD22 reliability standards, validating the performance of every component. The ultimate goal: zero PPM defects, increased productivity, elevated customer satisfaction, and cost optimization through smart automation.

Ajinkya Firodia, Vice Chairman of Kinetic Group, emphasized the transformational nature of this launch: “The new fully automated controller line marks a significant stride toward Industry 4.0-driven smart manufacturing. It’s a high-throughput, precision-engineered facility that brings intelligence, speed, and scalability to our operations. Every stage is data-driven and benchmarked to global quality standards. This is more than a technological leap—it’s a statement of our commitment to innovation and operational excellence.”

Echoing this sentiment, Deepak Shikarpur, Director of Kinetic Communications Ltd, added, “This facility is a true reflection of Make in India at its most advanced. With its automation, precision, and capability to manufacture smart, feature-rich motor controller units, it positions India on the global map for next-generation EV electronics manufacturing.”

With this milestone, Kinetic Communications sets a new benchmark in smart manufacturing, reinforcing its role as a pioneer in India’s electric mobility ecosystem and showcasing how advanced automation can drive both quality and scale in future-ready production systems.