Hydrogen Propulsion for Heavy Commercial vehicle Applications in India : A Quality-Driven Approach from Tata Motors

As the global commercial vehicle sector searches for innovation in propulsion technologies that deliver sustainability and zero tail pipe emissions, hydrogen (H₂) mobility is gaining momentum—especially in heavy duty segments where battery electric drivetrains still face constraints. Tata Motors, recognized in India for its pioneering work in commercial vehicles, has launched an ambitious programme to engineer hydrogen powered solutions custom built for the nation’s heavy trucks and buses that underpin logistics and infrastructure. This paper outlines Tata Motors’ structured approach on ‘Failure mode avoidance’ for a safe and reliable H₂ propulsion, anchored in the ‘Quality by Design’ approach through Design Failure Mode and Effects Analysis (DFMEA) at a very early stage. Every critical vehicle system and sub-system—storage, fuel delivery, control and the propulsion unit itself—is subjected to DFMEA at the concept stage so that potential risks are detected and addressed before vehicle launch. The goal is to produce H₂ systems that are robust, safe and dependable under real world duty cycles and Indian operating conditions. The paper will cover details of the major technical challenges, the risk management framework, reliability planning activities and insights from ongoing validation and integration trials. It will further illustrate how close collaboration with system and component suppliers, regulators and internal cross functional teams is accelerating on India’s hydrogen roadmap for commercial transport. By presenting this case study, the paper seeks to enrich the global body of knowledge on hydrogen mobility and underline India’s growing role in zero emission heavy commercial vehicles.