Kinetic Communications Limited (KCL), a leading name in advanced electronic manufacturing, has inaugurated a state-of-the-art, fully automated controller manufacturing line at its Pune facility.

The event was graced by Padmashri Dr. Arun Firodia, Chairman, Kinetic Group; Mr. Deepak Shikarpur, Director, Kinetic Communications Ltd; and Mr. Ajinkya Firodia, Vice Chairman, Kinetic Group.

The newly launched line features cutting-edge Surface Mount Technology (SMT) and automated assembly, integrated through Human Machine Interface (HMI) and Programmable Logic Controller (PLC) systems. This advanced setup allows real-time process control, complete traceability, and minimal manual intervention—ensuring higher efficiency and reduced error rates.

At the heart of this new facility lies the production of Motor Controller Units (MCU)—the core of an electric vehicle that controls the interaction between the battery and motor. These MCUs manage critical functions such as acceleration, braking, regenerative energy recovery, and advanced rider features including hill-hold assist, cruise control, and diagnostics.

The facility manufactures Power and Driver Board Assemblies and Complete Controller Box Assemblies using high-speed SMT lines capable of placing up to 40,000 components per hour with 100% verification. Each unit undergoes software flashing, IP67 leak testing, and functional validation to meet the highest quality standards.

With an annual capacity of 1.8 lakh units and contingency systems in place, the plant ensures uninterrupted production and delivery even during market fluctuations.

This new fully automated controller line represents a major leap toward Industry 4.0–driven smart manufacturing. Every stage is data-driven and benchmarked to global quality standards,” said Ajinkya Firodia, Vice Chairman, Kinetic Group. “It’s not just about automation—it’s about intelligence, speed, and scalability.

Deepak Shikarpur, Director, Kinetic Communications Ltd, added, “This facility showcases the true potential of ‘Make in India’. With automation, precision, and innovation at its core, KCL is positioning India as a global leader in next-generation EV electronics manufacturing.”

The plant integrates advanced 3D Solder Paste Inspection (SPI), Automated Optical Inspection (AOI), In-Circuit Testing (ICT), and lead-free dual-wave soldering to ensure durability and precision. Each production stage features Poka Yoke systems to eliminate human errors, while end-of-line testing and pre-dispatch inspections guarantee zero-defect products.

Aligned with JESD22 reliability standards, all components meet RoHS and REACH compliance, with suppliers required to provide Certificates of Conformance.

With this milestone, Kinetic Communications Ltd. aims to achieve Zero PPM defects, increase productivity, and enhance customer satisfaction through cutting-edge automation.