Mahindra & Mahindra has achieved a significant manufacturing milestone, with its Chakan facility in Maharashtra rolling out its three-millionth vehicle. The landmark vehicle was the Mahindra BE 6, the brand’s flagship electric SUV, highlighting the facility’s growing role in both internal combustion engine (ICE) and electric vehicle production.
The announcement underscores the rapid expansion of Mahindra’s manufacturing operations, with the company revealing that the latest one million vehicles were produced in just 27 months, a substantial acceleration compared to the time taken to reach previous production milestones.
Chakan plant reaches 3 million vehicles
Since producing its first vehicle in December 2009, the Chakan facility has evolved into one of Mahindra’s most important manufacturing centres. According to the company, the latest million vehicles were produced nearly four times faster than the first million, demonstrating increased production efficiency and growing market demand for Mahindra products.
The facility now serves as a key production hub for Mahindra’s passenger vehicles, electric vehicles and commercial vehicles, supporting both domestic and international markets.
R Velusamy, President – Automotive Business, Mahindra & Mahindra Ltd., said the milestone reflects the company’s manufacturing capabilities and customer demand.
“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.”
He added that the facility combines advanced manufacturing technologies with lean production practices to deliver quality, flexibility and scale.
Producing 19 models and more than 450 variants
Spread across 657 acres, the Chakan manufacturing complex produces 19 vehicle models and more than 450 variants across multiple vehicle categories.
The facility supports the production of:
- Passenger vehicles
- Electric vehicles
- Commercial vehicles
Its flexible manufacturing setup allows Mahindra to build multiple products on shared production infrastructure, helping the company respond to changing market demand while improving efficiency.
Advanced manufacturing technology drives production
Mahindra says Chakan incorporates a range of Industry 4.0 technologies and digital manufacturing systems designed to improve productivity, quality and traceability.
Key technologies used at the facility include:
- Artificial intelligence (AI)
- Internet of Things (IoT) systems
- 5G connectivity
- Digital traceability systems
- Advanced robotics
The plant operates approximately 1,500 robots, with more than 98 per cent automation in the body shop. Robotic painting and sealer application systems are also employed throughout the production process.
Quality control measures include:
- 3D component scanning
- Real-time weld integrity monitoring
- Interlocked “No Fault Forward” quality checkpoints
Meanwhile, seven multi-model assembly lines and autonomous mobile robots help streamline production and material movement across the facility.
Mahindra also uses AI-enabled monitoring systems to improve workplace safety, including real-time tracking of personal protective equipment compliance.
Sustainability remains a major focus
Alongside manufacturing expansion, Mahindra highlighted the environmental credentials of the Chakan facility.
According to the company:
- More than 50 per cent of the plant’s energy needs are met through renewable energy sources
- Electric vehicle production operates on 100 per cent renewable energy
- The facility is certified as Zero Waste to Landfill
- The site is water positive
Mahindra says the plant returns water equivalent to 131 per cent of its annual consumption back to nature, supported by rainwater recharge initiatives that contribute approximately 991,000 kilolitres of water annually.
The facility is also nearing its EP100 commitment, which focuses on doubling energy productivity.
Supporting exports to Australia and other markets
The Chakan plant plays an important role in Mahindra’s global manufacturing strategy, with vehicles produced at the facility exported to multiple international markets.
Mahindra confirmed that almost all vehicle models manufactured at Chakan support its overseas operations, including exports to:
- Australia
- New Zealand
- South Africa
Several Mahindra vehicles currently sold in Australia, including the Mahindra XUV700 and Mahindra Scorpio, are produced at the Chakan facility.
BE 6 highlights Mahindra’s EV ambitions
The decision to mark the three-millionth vehicle milestone with the BE 6 also reflects Mahindra’s increasing focus on electric mobility.
As the company’s flagship electric SUV, the BE 6 represents the next phase of Mahindra’s product strategy, with Chakan positioned as a key manufacturing hub for both traditional and electrified vehicles.
The milestone demonstrates how the facility has evolved from a conventional vehicle production plant into a modern manufacturing centre capable of supporting Mahindra’s future growth plans across domestic and international markets.
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