Mahindra and Mahindra’s Chakan manufacturing plant in Pune has crossed the cumulative production milestone of three million vehicles, with the milestone vehicle being the BE 6 – the company’s most advanced flagship electric SUV. This milestone underlines the plant’s evolution from a traditional car manufacturing plant into a future-oriented center capable of large-scale production of internal combustion engines and electric vehicles.
Chakan launched its first car in December 2009. It took 107 months to produce the one millionth car. The second millionth unit was achieved even faster, with the third millionth unit being achieved in just 27 months – almost four times as fast as the first millionth unit – reflecting Mahindra’s accelerated production growth driven by strong customer demand, particularly for its SUV and electric vehicle product lines.
Mr. R. Velusamy, President, Mahindra and Mahindra Automotive Business said, “The launch of Chakan’s 3 millionth vehicle, BE 6, marks a proud milestone in Mahindra’s manufacturing journey. Our acceleration from 107 months to the latest million vehicle in just 27 months reflects the growing trust of our customers and the unwavering commitment of our employees, partners and suppliers. Chakan integrates Industry 4.0, Artificial Intelligence, IoT, 5G connectivity, advanced robotics, digital traceability and flexible multi-model manufacturing, supported by lean and TPM practices, 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 core of our manufacturing excellence.”
The Chakan plant is spread across 657 acres and manufactures 19 models and over 450 variants spanning passenger cars, electric vehicles and commercial vehicles. Seven multi-model assembly lines and synchronized autonomous mobile robots for material movement give the factory the flexibility to produce various vehicle types in a single integrated manufacturing shop.
The facility’s technological backbone is built on Industry 4.0 principles. Approximately 1,500 robots are deployed in various operating departments, and the automation level in the body shop exceeds 98%. Robotic paint and sealant application is standard, and quality is enhanced with 3D component scanning, real-time weld integrity monitoring and an interlocking fail-forward quality gateway to prevent defective components from entering the production line. AI-enabled systems monitor personal protective equipment compliance and shop floor safety in real time, while 5G connectivity and digital traceability are present throughout operations.
Sustainability is equally important to Chakan’s business philosophy. More than 50% of the plant’s energy needs are met through renewable energy, and the plant’s electric vehicle manufacturing relies entirely on renewable energy. The plant is water positive, returning 131% of its water consumption to nature, supported by an annual rainwater replenishment of approximately 991,000 liters. Chakan has also achieved Zero Waste to Landfill certification and is on track to deliver on its EP100 promise of doubling energy productivity.
On the export front, almost all models produced at Chakan support Mahindra’s international operations, with vehicles shipped to markets such as South Africa, Australia and New Zealand, reinforcing the plant’s role not only as a domestic production hub but also as a platform for Mahindra’s global growth ambitions.