EV Battery Manufacturing Automation: The PLC SCADA Opportunity at Pune and AURIC (2026) (Updated July 2026)
India's electric vehicle sector is growing at 49% year-on-year (SMEV 2025-26 data) — and every EV manufactured needs a battery pack assembled with micron-level precision, controlled by PLCs. The AURIC corridor in Sambhajinagar already has Bajaj Auto's Chetak EV plant and Endurance Technologies' EV component lines. Pune has Tata Motors' EV assembly, Mahindra's electric SUV plant, and a cluster of Tier-1 battery suppliers. Here is what most automation students miss: EV manufacturing is more automation-intensive than conventional ICE vehicle production. A lithium-ion battery cell formation process runs at temperature-controlled chambers with PLC-managed charge-discharge cycles. Pack assembly uses robotic welding with torque-controlled PLC nutrunners. And quality inspection uses vision systems triggered by PLCs. If you are a PLC/SCADA engineer, the EV boom is one of the best career tailwinds you can ride in 2026.
- EV manufacturing is growing 49% YoY in India — every plant needs PLC/SCADA engineers for battery assembly, cell formation, and quality control
- Battery cell formation (charge-discharge cycling) is the most automation-intensive EV process — PLC-controlled temperature chambers, voltage monitors, and cycle sequencers
- AURIC Sambhajinagar: Bajaj Auto Chetak, Endurance Technologies EV parts, Hero Electric (proposed) — all hiring automation engineers
- Pune cluster: Tata Motors EV, Mahindra Electric, TPEM, BYD India, and 50+ Tier-1 EV component suppliers along Chakan-Talegaon corridor
- PLC engineer in EV manufacturing (Pune): ₹4–6.5 LPA entry, ₹8–14 LPA at 3 years with EV-specific battery automation experience
EV Manufacturing and PLC SCADA — Why the Automotive Shift Is an Automation Opportunity
The transition from internal combustion engine (ICE) vehicles to electric vehicles is not reducing the demand for automation — it is increasing it. ICE engine assembly had complex machining (cylinder boring, crankshaft grinding) but relatively straightforward assembly. EV manufacturing shifts complexity to the battery pack: lithium-ion cells require precision handling (cell voltage must be matched within 5mV for pack assembly), temperature-controlled formation, and robotic welding with exact torque verification. Every one of these steps uses PLC control. Additionally, EV drivetrains have fewer mechanical components but more electronic assembly steps (motor winding, inverter PCB handling, BMS integration) — each requiring automated stations with PLC-triggered test fixtures. For automation engineers, this means EV plants have higher automation density per unit area than equivalent ICE plants. A 2,000-unit/day EV plant at Chakan has more PLC-controlled stations than a 5,000-unit/day ICE plant next door.
The EV Battery Manufacturing Process: Where PLCs Do the Critical Work
The EV battery manufacturing process has seven distinct automation-heavy stages: (1) Cell receiving and sorting: incoming lithium-ion cells (typically from CATL, Samsung SDI, or Amara Raja Batteries) are tested for voltage and internal resistance using automated test benches with PLC-triggered measurement instruments — cells are sorted into matched groups for pack assembly. (2) Cell formation (for gigafactories): new cells undergo controlled charge-discharge cycling in PLC-managed formation chambers at 25–45°C for 24–72 hours — this stabilizes the cell chemistry. Chamber temperature is maintained via PLC-controlled HVAC with ±0.5°C precision. (3) Module assembly: cells are arranged in modules; a robotic laser welder (PLC-controlled) welds the busbars connecting cells. Weld quality is verified inline with vision systems. (4) BMS integration: the Battery Management System PCB is plugged in; a PLC-controlled test fixture runs BMS firmware tests and verifies communication protocols (CAN bus). (5) Pack assembly: modules are stacked in the pack housing; torque-controlled nutrunners (PLC-connected) tighten bolts to exact specifications — each torque value is stored in the SCADA historian with its station ID and timestamp. (6) Thermal management integration: coolant circuits are leak-tested with pneumatic PLC test rigs before the pack is sealed. (7) End-of-line testing: the complete battery pack is charge-tested and data-logged — SoC, SoH, cell balance — using a PLC-controlled charge-discharge tester. Every parameter is stored in the MES (Manufacturing Execution System) for traceability.
| EV Manufacturing Stage | Automation Type | Key PLC/SCADA Function |
|---|---|---|
| Cell Sorting and Testing | PLC + automated test bench | Voltage/IR matching, sorting control |
| Cell Formation (Gigafactory) | PLC + HVAC cascade | Temperature ±0.5°C, charge-discharge cycle |
| Module Assembly (Welding) | Robot PLC + vision system | Laser weld quality, busbar position |
| Pack Assembly Torque | PLC + torque nutrunner | Bolt torque (Nm), angle, sequence traceability |
| Coolant Leak Test | PLC pneumatic test rig | Pressure decay, leak rate threshold |
| End-of-Line Battery Test | PLC + SCADA historian | SoC, SoH, cell balance, MES upload |
EV battery manufacturing PLC automation stages — India 2026. Each stage's data is stored in the MES for full traceability.
EV Assembly Line Automation — From Body Shop to Final Quality Check
Beyond the battery line, EV assembly plants use PLC/SCADA automation across the full vehicle production flow. Body shop: robotic spot welders and adhesive dispensers with Fanuc or Kuka robot controllers, coordinated by Allen-Bradley safety PLCs. Paint shop: conveyor systems, bake ovens, and spray robots — all PLC-controlled with Siemens S7 PLCs for temperature and conveyor logic. Powertrain marriage: the battery pack, e-axle, and motor are lifted and mated to the body on an automated AGV (Automated Guided Vehicle) line; PLCs coordinate the AGV dispatch, lifter alignment, and bolt tightening. Final line: PLC-controlled test bays for ADAS calibration (camera alignment, radar sensor calibration), software flashing of ECUs, and a rolling road dynamometer for final QC drive test. SCADA in EV plants provides real-time OEE (Overall Equipment Effectiveness) monitoring — cycle time, downtime cause codes, and first-pass yield for each station.
AURIC Sambhajinagar and Pune Chakan: India's EV Manufacturing Hubs in 2026
AURIC (Auric City), the ₹71,343 crore industrial township in Sambhajinagar, has EV-related companies at multiple plots: Bajaj Auto's electric vehicle manufacturing facility (Chetak and Pulsar EV models), Endurance Technologies (EV drivetrain and chassis components at Plot E-92), and several Tier-2 battery component suppliers in the ancillary zones. The Chakan-Talegaon corridor in Pune is India's most concentrated EV manufacturing cluster — Tata Motors EV (Tigor EV, Nexon EV, Punch EV), Mahindra Electric (BE 6, XEV 9e), TPEM (Tata Passenger Electric Mobility), BYD India (assembly of Atto 3 and Seal), and Mercedes-Benz India (EQS, EQB assembly at Chakan). Each of these plants has on-site automation teams and uses third-party automation integrators for capital projects. The Chennai cluster (Hyundai Ioniq, Ola Electric gigafactory in Krishnagiri) adds further demand for PLC engineers who are willing to relocate.
Automation Companies and Vendors Active in India's EV Sector
The automation ecosystem around Indian EV manufacturing involves three tiers of companies. OEM automation integrators: Siemens Digital Industries, Rockwell Automation India, ABB Robotics, FANUC India, and KUKA Robotics — these companies commission EV plant automation systems and hire PLC engineers for project execution. Test equipment companies: National Instruments (NI), Chroma ATE, and Digatron — specialists in battery formation and end-of-line EV test systems, all PLC/LabVIEW-based. Battery technology suppliers: Amara Raja Advanced Cell Technologies (building a gigafactory in Tirupati), Exide Energy (lithium cell plant in Bengaluru), and Tata Chemicals (LFP cells) — each planning automation-intensive production lines. For a PLC/SCADA engineer targeting EV, the best entry path is through a system integrator that serves automotive OEMs — companies like Quick Response Manufacturing Systems (Pune), Electronica Industries (Pune), or Tata AutoComp Systems — because you get exposure to multiple OEM plants in your first two years.
PLC SCADA Salaries in EV and Automotive Manufacturing — 2026 Data
EV manufacturing offers among the highest salaries in Indian automation engineering, driven by the combination of automotive OEM pay scales and the genuine scarcity of engineers with battery automation knowledge. Entry-level (BE/Diploma, 0–2 years): ₹4–6.5 LPA at a Pune or AURIC EV plant or automotive system integrator. Mid-level (3–5 years, EV battery automation specialist): ₹8–13 LPA. Senior / lead automation engineer (5+ years, EV production line ownership): ₹13–22 LPA at an OEM like Tata Motors EV or Mahindra Electric. Robot programmers (Fanuc/Kuka, with EV body shop experience) earn 15–25% above equivalent non-robot PLC engineers. Compared to non-automotive manufacturing, EV/automotive pays 20–35% more for equivalent experience — and the work complexity (safety PLCs, torque monitoring, vision systems, MES integration) builds a resume that is highly transferable across the automotive sector globally.
How to Get Into EV Manufacturing Automation — Career Entry Guide
To enter EV manufacturing automation, your PLC/SCADA training is the entry ticket — EV-specific process knowledge is layered on top. ABC Trainings' Industry 4.0 with AI & Industrial Automation course covers Siemens S7 and Allen-Bradley (both used extensively in Pune automotive plants), SCADA fundamentals, and Industry 4.0 integration — exactly what automotive OEMs look for. Target automotive system integrators (Quick Response Manufacturing, Electronica Industries, Tata AutoComp Connectivity and Solutions) for your first role — not the OEMs directly. The integrators will expose you to 4–6 different plant environments in your first 2–3 years, building the diverse experience that makes you attractive to an OEM at ₹10–15 LPA. Specialized certifications that add value in EV: Allen-Bradley safety PLC (for robot safety circuits), Siemens TIA Portal training (S7-1500 used heavily in new EV plants), and basic CAN bus protocol knowledge (for BMS integration understanding). WhatsApp 7774002496 for the current PLC/SCADA batch schedule at ABC Trainings.
Maharashtra's Mukhyamantri Yuva Karya Prashikshan Yojana pays ₹6,000–10,000/month stipend during approved PLC/SCADA training. ABC Trainings' Industry 4.0 course qualifies. Call 7039169629 to check eligibility and start your CMYKPY application.
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💬 Get Brochure on WhatsApp📞 Call 7039169629About the author: Rahul Patil. 12 yrs experience training mechanical and automation engineers across Maharashtra.
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FAQs
What PLC systems are used in EV battery manufacturing?
EV manufacturing plants in India use Allen-Bradley (Rockwell Automation) PLCs in Tata Motors and Mahindra plants, Siemens S7-1200/1500 in European OEM-influenced plants (Mercedes, VW, Bosch Tier-1s), and Mitsubishi PLCs in some Japanese-tech battery assembly lines. Safety PLCs (Allen-Bradley GuardLogix, Siemens F-series) are mandatory for robot cells. For battery formation chambers in gigafactories, Yokogawa and Honeywell DCS systems are sometimes used due to their temperature loop expertise.
Are there EV manufacturing automation jobs in Pune and Sambhajinagar?
Yes — the AURIC Sambhajinagar corridor has Bajaj Auto EV (Chetak plant), Endurance Technologies EV components, and related Tier-2 suppliers. Pune's Chakan-Talegaon corridor has Tata Motors EV, Mahindra Electric, TPEM, BYD India assembly, and 50+ Tier-1 EV component suppliers. All of these companies hire PLC/SCADA engineers directly and through automation system integrators. The AURIC companies are particularly attractive for Sambhajinagar-based students who want local placement with automotive OEM exposure.
What is the salary of a PLC engineer in an EV plant in India?
Entry-level (0–2 years) PLC engineers at Pune EV plants earn ₹4–6.5 LPA. With 3 years of EV battery automation experience (cell sorting, pack assembly, torque monitoring), this rises to ₹8–12 LPA. Senior automation engineers with EV-specific expertise (battery formation, BMS test systems) earn ₹13–20 LPA. Robot programmers (Fanuc, Kuka) in EV body shops earn 15–25% more than equivalent PLC-only engineers. These ranges are 20–35% above equivalent non-automotive manufacturing automation roles.
Do I need a specific EV or battery degree to work in EV automation?
No — EV automation engineers come from the same Electrical, Electronics, Instrumentation, and Mechanical Engineering backgrounds as any other manufacturing automation engineer. The EV-specific knowledge (battery chemistry basics, CAN bus, BMS communication) is learned on the job. What you need is solid PLC/SCADA training, with preference for TIA Portal (Siemens) and Studio 5000 (Allen-Bradley) — both used extensively in Indian EV plants. A basic understanding of electric vehicle drivetrain components helps in interviews but is not a formal prerequisite.
