Kinetic Communications Inaugurates Fully Automated Controller Line in Pune to Produce High-Efficiency EV Motor Units with Enhanced Quality
In a significant boost to India’s electric vehicle manufacturing capabilities, Kinetic Communications Ltd. (KCL) has inaugurated a fully automated motor controller manufacturing line at its facility in Pune, Maharashtra. The new line will manufacture advanced motor controller units (MCUs) and related assemblies—critical components in electric vehicles—while aligning with Industry 4.0 smart manufacturing practices.
The facility was inaugurated by Dr. Arun Firodia, Chairman of Kinetic Group; Deepak Shikarpur, Director of KCL; and Ajinkya Firodia, Vice Chairman of Kinetic Group.
Smart Manufacturing for Smarter Mobility
Kinetic’s new production line integrates surface mount technology (SMT) and automated assembly platforms driven by human-machine interface (HMI) and programmable logic controllers (PLC). These technologies ensure real-time production monitoring, data traceability, and minimal manual intervention, setting a new benchmark for precision and efficiency in EV component manufacturing.
At the heart of this innovation is the motor controller unit (MCU)—a device that manages the interaction between an EV’s battery and motor, controlling essential functions like acceleration, regenerative braking, energy efficiency, as well as advanced features like hill-hold assist, cruise control, and onboard diagnostics.
High Output, Global Standards
The SMT line boasts the capacity to place 40,000 components per hour, with comprehensive verification. Final assemblies undergo rigorous testing, including software flashing, IP67 leak testing, and functional validation.
- Current output: 300 units per shift
- Scalable capacity: Up to 1.8 lakh units annually across two shifts
- Redundancy systems: Alternate lines and contingency protocols ensure production continuity during fluctuations in demand
Built-in Quality and Compliance
KCL’s new line is equipped with high-end quality assurance systems including Solder Paste Inspection (SPI), Automated Optical Inspection (AOI), and In-Circuit Testing (ICT) to meet IPC and JESD22 standards.
The manufacturing process uses lead-free soldering and reflow ovens to ensure reliable solder joints, while Poka Yoke mechanisms at assembly stations help reduce human error. All components undergo end-of-line testing, pre-dispatch inspection, and must pass incoming quality checks with RoHS and REACH-compliant certifications from suppliers.
Leadership Speaks
Ajinkya Firodia, Vice Chairman, Kinetic Group, stated:
“This fully automated controller line marks a major leap toward Industry 4.0-led smart manufacturing. Every process is data-driven and aligned with international quality benchmarks.”
Deepak Shikarpur, Director at KCL, added:
“This facility is a shining example of advanced-level Make in India. It empowers us to produce world-class, feature-rich EV controllers right here in Pune, strengthening India’s position in the global EV supply chain.”
Kinetic Communications’ automated production line is a clear signal that India’s EV component manufacturing ecosystem is evolving rapidly. By merging cutting-edge automation with scalable production and stringent quality control, KCL is helping lay the foundation for a robust and globally competitive EV industry. This move not only enhances local supply chain capabilities but also aligns with India’s broader push for self-reliance in EV technology.
