Pune: Kinetic Communications Limited (KCL), a leading name in advanced electronic manufacturing solutions, has inaugurated its state-of-the-art, fully automated controller manufacturing line at its Pune facility. The new line was inaugurated by Padmashri Dr. Arun Firodia, Chairman, Kinetic Group; Mr. Deepak Shikarpur, Director, Kinetic Communications Ltd; and Ajinkya Firodia, Vice Chairman, Kinetic Group.
The line integrates cutting-edge Surface Mount Technology (SMT) and automated assembly, orchestrated through Human Machine Interface (HMI) and Programmable Logic Controller (PLC) systems. This end-to-end digital setup ensures real-time process control, seamless traceability, and near-zero manual intervention, minimizing errors and maximizing throughput.
At the heart of this facility is the production of the Motor Controller Unit (MCU) the brain of an electric vehicle that manages the relationship between battery and motor. The MCU governs acceleration, braking, and energy efficiency, and enables advanced rider features such as hill-hold assist, cruise control, regenerative braking, coasting and diagnostics.
The facility manufactures Power and Driver Board Assemblies and Complete Controller Box Assemblies. These are built on high-speed SMT lines placing up to 40,000 components per hour with 100% verification. Final assemblies undergo software flashing, IP67 leak testing, and complete functional validation to meet stringent durability and quality standards.
With a current capacity of 300 units per shift and an annual output of 1,80,000 units under two shifts, the line is built for rapid scale-up. Alternate SMT and assembly lines, along with contingency systems, ensure seamless delivery against fluctuating market demand.
Ajinkya Firodia, Vice Chairman, Kinetic Group, said, “The new fully automated controller line marks a significant stride toward Industry 4.0-driven smart manufacturing. It’s a high-throughput, precision-engineered facility that brings intelligence, speed, and scalability to our operations. Every stage is data-driven and benchmarked to global quality standards. This is more than a technological leap—it’s a statement of our commitment to innovation and operational excellence.”
Deepak Shikarpur, Director, Kinetic Communications Ltd. added, “This facility is a true reflection of Make in India at its most advanced. With its automation, precision, and capability to manufacture smart, feature-rich motor controller units, it positions India on the global map for next-generation EV electronics manufacturing.”
The KCL plant is equipped with 3D Solder Paste Inspection (SPI) conforming to IPC J-STD-005, Automated Optical Inspection (AOI) per IPC-A-610 Class 2 standards, and In-Circuit Testing (ICT) for complete electrical validation. Through-hole components are soldered using lead-free dualwave technology, with reflow ovens ensuring optimal solder joint quality.
Advanced Poka Yoke mechanisms eliminate human error during assembly. Each station is connected via HMI and PLC for synchronized data flow and traceable software flashing. End-of-Line (EOL) testing and rigorous Pre-Dispatch Inspection (PDI) ensure every product meets final engineering parameters.
Incoming Quality Control (IQC) aligns with JESD22 reliability standards. All components undergo performance testing, with suppliers mandated to meet RoHS and REACH compliance and provide Certificates of Conformance (CoC).
With this expansion, KCL aims to achieve Zero PPM (Parts Per Million) defects, boost productivity, enhance quality, and increase customer satisfaction, while reducing costs through automation and process efficiency.