Mahindra’s Chakan Plant Crosses 3 Million Production Milestone

Mahindra & Mahindra has announced that its Chakan manufacturing facility has crossed the cumulative production milestone of three million vehicles. The milestone vehicle to roll out from the facility was a Mahindra BE 6 electric SUV, reflecting the facility’s versatility, producing everything from internal combustion to electric models. The Chakan plant produced its maiden vehicle in December 2009, and has evolved into one of Mahindra’s most strategically important facilities since then. The most recent million vehicles were produced in just 27 months, nearly four times quicker than the first one million, the company said. 

Speaking about the achievement, R Velusamy, President – Automotive Business, Mahindra & Mahindra Ltd, said, “The rollout of our three-millionth vehicle, the BE 6, from Chakan marks a proud milestone in Mahindra’s manufacturing journey. The acceleration from 107 months for our first million vehicles to just 27 months for the latest million reflects the growing trust of our customers and the unwavering commitment of our people, partners, and suppliers. Chakan combines Industry 4.0, artificial intelligence, IoT, 5G connectivity, advanced robotics, digital traceability, and flexible multi-model manufacturing, underpinned by Lean and TPM practices. Together, these capabilities enable us to deliver world-class quality, agility, and scale while advancing responsible manufacturing. As we continue to build world-class products in India for India and the world, Chakan will remain at the heart of our manufacturing excellence.”

Mahindra's Chakan plant is spread across 657 acres and manufactures 19 models amounting to over 450 variants across ICE and electric passenger cars as well as commercial vehicles. 

The facility combines advanced manufacturing technology with Lean and Total Productive Maintenance methodologies to drive quality, flexibility and operational excellence. It also adheres to Industry 4.0 standards, ensuring a highly automated process. The company uses about 1,500 robots and has achieved over 98 per cent automation in body shop, robotic painting, and sealer applications. The manufacturing plant also uses 3D component scanning, real-time weld-integrity monitoring, and interlocked “No Fault Forward” quality gateways.

Mahindra says over 50 per cent of the plant’s energy requirements are fulfilled by renewable sources, and all EVs at the plant operate on 100 per cent renewable energy.

The Chakan plant is also a major manufacturer for Mahindra’s export operations. Vehicles produced here are exported to several global markets including South Africa, Australia and New Zealand.