HCLTech Drives EV OEM Success with Manufacturing Engineering Expertise

The Overview

A new automotive manufacturer set out to build a greenfield assembly plant for a new generation of electric vehicles. These advanced machines required an innovative approach to their production lines.

To ensure a successful launch of their first EV, the company needed robust manufacturing engineering support. The company partnered with HCLTech to design and validate the processes, equipment and layout for the new plant.

The Challenges

Lack of engineering talent and vehicle launch experience within the OEM
Everything about the project was new. The company planned to set up the new plant in a new geography, but the core problem was ready access to engineering talent. The OEM also needed the agility to adapt manufacturing quickly as market needs evolved. Advanced product specifications and a complex assembly line required professionals with hands-on experience in vehicle manufacturing and product launches. All the expertise to build both the plant and the vehicles had to be sourced externally.
Strong engineering experience needed in multiple locations
The work called for quick, simultaneous engineering support across body shops, paint shops and general assembly areas. The plan called for a quick ramp-up of digital engineering support from India, with intermittent travel to the development center and site in the Saudi region.
Eventually, key personnel would be required onsite to support plants, equipment and product build activities – from installation, commissioning and pilot production to mass production in every shop.

The Solution

Solutions draw on the partner’s deep automotive manufacturing experience

HCLTech's proven experience in offshore development centers and global engineering support was demanded for the project. The OEM appreciated the robust HCLTech infrastructure and compliance protocols - a foundation that built trust from day one. With over three decades of experience supporting automotive clients, including major auto OEMs in the US, Europe and APAC regions, our team brought deep manufacturing engineering knowledge and expertise in leading software platforms used globally.

Two concurrent paths to plant and product launch
The initiative had two fronts: facility building and designing complex manufacturing processes. The client wanted to kickstart the digital manufacturing scope of the project with remote engineering support. Meanwhile, teams planned and executed the physical building to launch the first EV from the new plant within a set timeline. Simultaneous engineering support made all the difference in the initiative's success. Some teams worked remotely, others onsite - orchestrating the different teams and their work required the experience of an experienced partner. Our team worked with multiple department leaders on the client side, ensuring the on-time delivery of simultaneous engineering and building phase milestones.
Quick remote ramp-up accelerates engineering delivery
We mobilized teams with deep expertise in assembly processes for body shops, paint shops, general assembly and controls engineering. Drawing on experience from past projects, our engineers quickly aligned with the engineering requirements of this greenfield initiative.

HCLTech built an Offshore Development Center with a team of engineers experienced in:

Automotive assembly planning
Simulation
Controls engineering
Robot programming
Equipment commissioning
Industrial engineering
BIM

Our remote team in India handled critical engineering tasks — from process and tool design to simulation — using secure virtual desktops to deliver seamless offsite support

On-site engineers provided for the plant build and product launch

Onsite expertise was essential for both plant construction and product launch. Over six months, our teams transitioned to the client’s location to coordinate

Equipment specification and evaluation
Supplier interactions
Production line installation and commissioning

The Impact

Nimble, market-ready EV production in a growth market

With a rapid ramp-up and an experienced team, the new facility launched without a hitch and electric vehicle innovation began flowing off the production lines on schedule. And when future market opportunities demand a nimble response, the OEM can flex to meet the need. Because the OEM strategy requires market-ready versatility, our manufacturing engineering support continues. With this partnership, the OEM remains confident that the production line can adapt quickly to evolving market requirements.

Positioned for long-term growth in the electric vehicle market

This vision of long-term EV innovation requires a solid foundation in technology, staffing and manufacturing. HCLTech supported the manufacturing process from plant design to product launch and beyond. The OEM is now poised to capture market share and lead the next wave of electric mobility.