Digitally-Integrated, Partner-Ready Manufacturing: Lucas TVS Charts Its Transformation Path

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“Digital transformation isn’t only about technology- it’s about changing mindsets. Overcoming cultural barriers and aligning partners is as critical as the systems themselves.” - Ramanathan V - President (Automotive Business Head), Lucas TVS

November 2025 : For Lucas TVS, embracing smart manufacturing is not just about technology adoption-it’s about re-architecting infrastructure, processes, and partnerships to stay ahead of disruption. Speaking at a recent industry panel, Mr. Ramanathan V, President (Automotive Business Head), Lucas TVS, outlined how the company is building a digital-first foundation to support a rapidly diversifying business portfolio.

On the business front, Lucas TVS has expanded well beyond its traditional product lines. “From three to four products, we now have a complete motor portfolio for both ICE and EV vehicles. We are entering industrial motors, consumer goods, and moving into software-defined vehicle controllers,” Mr. Ramanathan shared. This diversification is both a growth strategy and a risk mitigation measure against industry disruptions.

To enable this shift, Lucas TVS began by strengthening its digital infrastructure and workforce capabilities. The company transitioned from traditional ERP systems to SAP HANA with advanced business intelligence tools, enabling real-time analytics across operations. Manufacturing lines are now automated with real-time data capture, AI-powered inspection, and Digital Production Management Systems that provide visibility into line efficiency and productivity losses.

“We use AI-based videos for both inspection and operator training. They highlight mistakes and accelerate learning,” Mr. Ramanathan explained. Additionally, the company is adopting flexible manufacturing systems to support multi-product lines, ensuring agility as product portfolios expand.

Equally critical is the partner ecosystem integration. Lucas TVS has developed a dedicated digital supplier portal that manages schedules, quality performance, scorecards, and collections- eliminating the need for manual follow-ups. On the customer side, the company is part of digital PPAP processes and uses EDI (Electronic Data Interchange) to automate schedule sharing directly into its ERP systems. Robotic Process Automation (RPA) tools further streamline these interactions, embedding Lucas TVS into a seamless digital supply chain.

Transformation, however, comes with its challenges. “When interfacing two systems, there are initial process hurdles ,people often try to revert to old ways,” he noted. Lucas TVS addressed this through dedicated change management teams and strong top management sponsorship. Cultural shifts were equally important: moving employees away from paper-based workflows to digital systems required sustained leadership push and clear communication of objectives.

Mr. Ramanathan 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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