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This article is authored by Saket Newaskar, Director & Head of AI Transformation, Expleo.

The EV transition, with its net-zero commitments, is often framed as a climate story. In 2025, Ember research found that electric vehicles displaced 1.7 million barrels of oil per day globally. Current geopolitical tensions have laid bare the vulnerabilities of fossil fuel dependence. And with global EV adoption on track to account for 25 per cent of all vehicle sales by 2030, the automotive landscape as we knew it is clearly shifting.

For a country that imports nearly 88 per cent of its crude oil, the EV transition is more than a green pledge. Reducing fuel import dependence, shielding economies from oil price shocks, and cutting transport emissions are, for once, the same goal. And the gigafactory is where that goal meets the ground.

From scale to strategy
Tesla's big bet in Nevada helped define the industrial infrastructure of our time. Battery manufacturing plants are being considered as a matter of national importance by governments and a country that makes batteries at scale not only builds a supply chain; it also builds a degree of control over its own energy future.

Gigafactories transform standard production models into fully integrated operations. With annual outputs often exceeding 30 GWh, they bring together battery manufacturing, component supply, and energy systems into one integrated operation and increasingly, into the energy grid itself, storing and releasing power as demand shifts. The result is lower unit costs, faster production cycles, and improved supply reliability. A gigafactory is far beyond a conventional factory. It functions simultaneously as a precision chemical plant, a high-speed assembly line, and a live data operation.

The ecosystem push
Gigafactories doesn't work in isolation. For a factory to work at full capacity, on schedule, it requires governments and industry to move together on permitting, grid access, critical mineral policy and workforce development. India's production linked incentive (PLI) scheme for advanced chemistry cell batteries, PM E-drive, Atmanirbhar Bharat localisation push, and customs duty relief on lithium-ion manufacturing equipment are laying the foundation for domestic capacity.

What turns direction into output is a connected ecosystem in which battery manufacturers, original equipment manufacturers (OEMs), and engineering and technology partners work in unison. No single organisation carries the full range of expertise a gigafactory demands.

The intelligence layer powering gigafactories
Besides scale, the other key differentiators of modern gigafactories are their intelligence. The hard part is not building the plant, but running it at yield. Artificial intelligence, data platforms, and connected systems are redefining how batteries are designed, produced, and optimised.

Digital twins allow manufacturers to simulate processes before physical deployment, reducing commissioning time and improving operational efficiency. They also address a major hurdle in battery production: waste. Scrap rates can soar to 30 per cent in early operations creating a drag on both economics and sustainability.

Factories are increasingly exploring AI to work smarter. Issued once and went unnoticed, now surfaces early. Thanks to computer vision, which spots defects in milliseconds, long before products reach the final line, while sensors pick up signs of AI-driven systems bring additional gains through predictive maintenance, automated quality checks, and real-time monitoring. Computer vision catches defects in milliseconds, well before they move down the line. Sensors flag early signs of machine wear, turning an unexpected shutdown into a planned maintenance window. By connecting IT and operational technologies, manufacturers create a closed-loop system where data continuously informs production decisions, improving yield, reducing downtime, and ensuring consistent quality.

Beyond quality, AI also helps modern gigafactories manage their energy footprint. A large battery facility consumes power at the scale of a small city. AI-driven energy management , on-site renewables, and advanced recycling of lithium, cobalt, and nickel promote a circular economy while safeguarding critical resources. On the supply chain side, real-time data helps manufacturers anticipate disruptions, diversify procurement, and build input control that becomes a competitive edge.

People are still the point
There is a version of the factory-of-the-future conversation that leaves people largely out. Gigafactories tell a different story. They are human-led technology-enabled environments where engineers and operators work alongside AI tools, using data to make faster, sharper decisions. This is creating demand for a new kind of industrial professional, someone who understands the process and the data, manages machines and systems, and can solve cross-functional problems on the floor. The gigafactory of 2030 needs people who are comfortable moving between physical and digital process signals. That is a training challenge as much as a hiring one.

Strategic assets in the EV era
The demand in India is visible. The policy direction is clear. The intent is strong. The next step is to build intelligent, integrated, and resilient gigafactories to support the EV transition, which is no longer just about replacing engines with batteries. It is about building systems that can withstand uncertainty, whether from fuel markets, supply chains, or geopolitics.

Industry estimates suggest India could have around 30 to 35 battery gigafactories by 2030; their role will extend beyond batteries to include anchoring clean energy ecosystems , generating skilled employment, and reducing exposure to volatile fuel markets. Piyush Goyal, Minister of Commerce and Industry, has urged India to move from being a consumer of technology to a creator of technology. And the gigafactory is one place where that shift can take shape.

Disclaimer: Views and opinions expressed in this article are solely those of the original author and do not represent any of The Times Group or its employees.