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Kinetic Communications opens automated controller manufacturing line in Pune
Industry News- Jul 07,25
The new advanced automated controller line in Pune leverages Industry 4.0 technology to drive high-speed, precision manufacturing for next-generation smart EV electronics.
Pune, Maharashtra
Kinetic Communications Limited (KCL), a key player in advanced electronic manufacturing solutions, has launched its fully automated, state-of-the-art controller manufacturing line at its Pune facility. The new line was inaugurated by Padmashri Arun Firodia, Chairman, Kinetic Group; Deepak Shikarpur, Director, Kinetic Communications Ltd; and Ajinkya Firodia, Vice Chairman, Kinetic Group.
The setup combines modern Surface Mount Technology (SMT) and automated assembly, managed via Human Machine Interface (HMI) and Programmable Logic Controller (PLC) systems. This digitalised process ensures real-time control, complete traceability, and minimal manual handling, reducing errors and increasing output.
Central to this facility is the production of the Motor Controller Unit (MCU), the electric vehicle’s brain that controls battery and motor interaction. The MCU manages acceleration, braking, and energy efficiency, and supports features such as hill-hold assist, cruise control, regenerative braking, coasting, and diagnostics.
The plant produces Power and Driver Board Assemblies and full Controller Box Assemblies. Built on high-speed SMT lines, it places up to 40,000 components per hour with full verification. Final units undergo software flashing, IP67 leak checks, and complete functionality tests to meet top durability and quality norms.
The plant currently produces 300 units per shift with an annual capacity of 1,80,000 units over two shifts. Backup SMT and assembly lines, along with contingency systems, are in place to handle changing market demand.
Ajinkya Firodia, Vice Chairman, Kinetic Group, commented, “The automated controller line is a major move towards Industry 4.0-enabled smart manufacturing. It’s a precision-driven, high-output setup delivering intelligent operations, speed, and scalability. Every phase is data-backed and matches global quality benchmarks. This represents our dedication to innovation and excellence.”
Deepak Shikarpur, Director, Kinetic Communications Ltd. said, “This is Make in India at its finest. With its automation, precision, and smart controller manufacturing capability, this plant showcases India’s readiness in EV electronics on the global platform.”
The KCL facility is equipped with 3D Solder Paste Inspection (SPI) to IPC J-STD-005, Automated Optical Inspection (AOI) per IPC-A-610 Class 2, and In-Circuit Testing (ICT) for full electrical validation. Lead-free dualwave soldering handles through-hole components, with reflow ovens ensuring solid solder joints.
Smart Poka Yoke mechanisms remove human error during assembly. All stations are linked via HMI and PLC for integrated data exchange and traceable software flashing. End-of-Line (EOL) and Pre-Dispatch Inspection (PDI) ensure every unit complies with engineering criteria.
Incoming Quality Control (IQC) meets JESD22 reliability benchmarks. All parts are tested for performance, and suppliers must comply with RoHS and REACH norms while submitting Certificates of Conformance (CoC).
With this expansion, KCL targets Zero PPM defects, better output, elevated quality, and increased customer satisfaction—while reducing costs through enhanced automation and efficiency.
Kinetic Communications Limited (KCL) is a pioneer in India’s Electronics Manufacturing Services (EMS) and Electric Vehicle (EV) industries. As part of the historic Kinetic Group, which transformed personal mobility in India, KCL champions innovation, automation, and sustainability.
Formed to speed up India's electric mobility shift, KCL delivers advanced and dependable solutions to top Original Equipment Manufacturers (OEMs). Its nimble production, strong infrastructure, and client-first model have pushed it past key milestones, including ?100 crore in revenue.
KCL today leads India’s push for clean mobility and tech-driven self-sufficiency, energising the future of automotive electronics.
Kinetic Communications
Arun Firodia
Ajinkya Firodia
Deepak Shikarpur
EV manufacturing
Pune
India
electronics manufacturing
Industry 4.0
Kinetic Group
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