In a recent conversation with Nishant Jairath, Director of Metalman Auto Ltd., Rajesh Rajgor explored how the company has evolved and thrived through constant innovation and digital solutions. Metalman Auto is a prime example of a company that has embraced change, adapting its services, investing in advanced technologies, and expanding into new markets to become a leader in the auto manufacturing sector.
Metalman Auto Ltd. stands out as a dynamic and forward-thinking player in the automotive manufacturing industry. Known for its extensive expertise in two-wheeler fabrication and contract manufacturing, Metalman has evolved significantly over the years, expanding its operations from basic frame fabrication to more complex sub-assembly and contract manufacturing services. Specializing in producing essential components such as frames, mufflers, and swing arms, the company has grown into a trusted partner for Original Equipment Manufacturers (OEMs) across India.
“Originally, our focus was purely on frame fabrication. But we have expanded into sub-assembly and contract manufacturing, offering a more integrated operation,” says Nishant Jairath, Director of Metalman Auto Ltd. This shift reflects the company’s commitment to adapting to the ever-evolving demands of the automotive industry. By broadening its scope, Metalman is able to offer its customers a seamless, high-quality production process that simplifies their supply chain management.
A key element driving Metalman’s success is its emphasis on digital innovation. The company has made significant strides in integrating modern technologies like Internet of Things (IoT) and Quick Response (QR) codes into their manufacturing process. These technological interventions ensure that OEMs have real-time visibility into the production process, allowing them to track every component’s progress and quality. “By implementing digital systems, we can ensure that every bolt, every screw, and every weld is captured digitally,” Nishant explains. This level of traceability provides crucial data on factors like torque strength, enhancing product quality and safety, and securing intellectual property by safeguarding sensitive manufacturing processes.
While Metalman has made notable advancements in contract manufacturing, their primary focus remains on two-wheeler fabrication, which still accounts for approximately 70% of their total revenue. “We continue to produce high-quality components for the two-wheeler industry, including frames, mufflers, and swing arms, while also making strategic moves into the off-highway vehicle (OHV) sector,” reiterates Nishant. He adds, “With a compound annual growth rate (CAGR) of 25%, our OHV segment is growing rapidly too, and Metalman is positioning itself as a key supplier of critical components such as driver cabins and heavy-duty parts for industries like construction and material handling.”
AI-Driven Automation and Lightweight Innovation
One of the standout innovations in Metalman’s portfolio is its patented process for producing aluminum handlebars without the need for hydroforming, a typically costly technique. “We’ve found a way to achieve weight reduction without driving up production costs,” he adds. This innovation is particularly appealing to customers looking for lightweight solutions without compromising on the durability and performance of their vehicles.
Automation is another area where Metalman has made significant investments. The company now operates over 500 robotic welding systems across its facilities, automating nearly all aspects of the welding process. “The introduction of automation was just the beginning. Now, we are incorporating AI into our systems to identify and correct welding defects in real-time,” says Nishant. This shift towards AI-enhanced quality control has been instrumental in maintaining high standards and improving manufacturing efficiency. By continuously adopting cutting-edge technologies, Metalman is solidifying its position as a leader in automotive manufacturing, capable of meeting the stringent demands of the industry.
The company’s focus on technological innovation was on full display at the Bharat Mobility Global Expo, where Metalman demonstrated its advanced manufacturing capabilities. The expo showcased how digitalization and automation are at the heart of their operations, enabling the company to meet the growing demands of OEMs and stay ahead in an increasingly competitive market. Through this commitment to innovation, Metalman continues to set new benchmarks in the automotive sector.
Digital Platforms Driving Seamless OEM Interactions
Metalman’s dedication to digital transformation extends beyond production; it also influences how the company interacts with its customers. With the use of digital platforms, OEMs can gain immediate access to production data, which not only improves transparency but also helps streamline decision-making processes. By providing live production updates, Metalman ensures that OEMs can track their orders, monitor quality control, and respond to changes in real-time, all of which enhance operational efficiency.
In addition to serving the two-wheeler and OHV sectors, Metalman has shown an interest in expanding into the electric vehicle (EV) market. While internal combustion engine (ICE) vehicles remain a significant part of the market, the rise of EVs has created new opportunities for innovation. “We are focusing on EVs because we see the future of mobility shifting towards electric-powered vehicles,” he notes. Metalman is not only producing components for prominent EV brands but also positioning itself to provide advanced manufacturing solutions for the growing electric mobility sector. By staying ahead of the curve in EV-related technologies, Metalman is positioning itself as a key enabler of the future of electric two-wheelers and three-wheelers.
Looking ahead, Metalman plans to continue leveraging its technological investments to expand its footprint across various sectors. As the automotive industry moves toward more integrated solutions, companies like Metalman are well-positioned to offer complete systems of manufacturing, sub-assembly, and contract manufacturing services. “We are not just a product manufacturer. We are a solutions provider,” says Nishant, emphasizing Metalman’s shift towards offering more comprehensive solutions that align with the evolving needs of OEMs.