From Simple Automation to Global Visibility: ZF Rane’s Digital Transformation in Action

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“With SCADA-based monitoring, if a machine stops in India, my boss in Germany knows instantly. Real-time global visibility is powerful but it demands robust data systems and skilled teams to make it work.” - Arun S, Vice President- Operations, ZF Rane Automotive (India) Pvt. Ltd

November 2025 : For many manufacturers, digital transformation often begins with small, focused interventions before scaling to enterprise-wide impact. Mr. Arun S, Vice President – Operations, ZF Rane Automotive (India) Pvt. Ltd., shared how his organization has followed a step-by-step, application-driven approach to embed impactful digital technologies across operations.

“We started with the simplest of robotic process automation for financial bill processing,” Mr. Arun recalled. “From there, we gradually moved into AI applications, developing in-house solutions using the creativity of our young engineers.”

Early AI deployments focused on quality control systems, addressing gaps that existing camera systems couldn’t detect. By integrating AI into vision systems, ZF Rane moved from mere detection to prevention of quality defects. Mr. Arun shared practical shop-floor innovations like using AI-enabled cameras to verify mandatory PPE compliance, ensuring workers wear goggles in restricted zones, and integrating AI with imported Swiss machinery to prevent unsafe human-machine interactions. Remarkably, the machine manufacturer later adopted this Indian-developed solution globally.

ZF Rane’s transformation journey has since evolved to embrace MES and SCADA systems for end-to-end production control. At its Trichy plant, which manufactures inflators for airbags, SCADA-based monitoring provides real-time visibility to global teams. “If a machine stops in India, my boss sitting in Germany will know instantly,” Mr. Arun noted. This level of transparency allows for synchronized operations across geographies.

However, leveraging data at this scale brings new challenges. Mr. Arun highlighted data security, synchronization across time zones, and resource capability as key hurdles. “Data must flow seamlessly between local operations and global applications,” he said. “Managing this in real time, across three shifts and multiple locations, is not trivial. It requires robust data infrastructure and skilled manpower.”

Despite these challenges, Mr. Arun stressed that the key is to match technology with the right application. “Start simple, identify where it fits, and scale where impact is clear,” he advised, reinforcing that impactful digitalization is as much about judicious application as it is about advanced technology.

Mr. Arun shared these insights as a panelist during the 3rd Edition of the ACMA Automotive Smart Manufacturing Think Turf, powered by Pro MFG Media, in a discussion on “Driving Manufacturing Transformation: Strategies for Success.”

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