Mahindra & Mahindra Ltd.’s state-of-the-art Chakan manufacturing facility has crossed cumulative production of three million vehicles, with the landmark unit being the BE 6, the company’s most advanced flagship electric SUV. Located near Pune and spread across 657 acres, the integrated hub now stands at the intersection of rapid volume growth, cutting-edge Industry 4.0 adoption and ambitious sustainability commitments.
The latest one million vehicles have been produced in just 27 months, nearly four times faster than the first million, underscoring surging demand for Mahindra’s SUVs and EVs as well as the plant’s growing efficiency. Since the first vehicle rolled out in December 2009, Chakan has evolved into one of Mahindra’s most strategically important facilities, supporting both internal-combustion and electric mobility for India and global markets.
Velocity of growth and manufacturing scale
In its early years, Chakan took 107 months to reach the first million vehicles, but subsequent ramp-up has been aggressive, aligning with India’s SUV boom and Mahindra’s refreshed product portfolio. The plant crossed the 10 lakh mark in 2018, hit 20 lakh units by March 2024, and has now reached the 30 lakh milestone in July 2026, compressing each additional million into ever-shorter timeframes.
Today, the hub manufactures 19 models and more than 450 variants across ICE passenger vehicles, electric SUVs and commercial vehicles, giving Mahindra the flexibility to respond quickly to shifting market mixes. Almost all of these models support Mahindra’s international operations, with exports to key markets such as South Africa, Australia and New Zealand, reinforcing India’s role as a global manufacturing base.
Intelligent, flexible manufacturing ecosystem
Chakan has been steadily transformed into a future-ready ecosystem that blends advanced manufacturing technologies with Lean and Total Productive Maintenance practices. The facility is infused with Industry 4.0 tools, including artificial intelligence, IoT, 5G connectivity and end-to-end digital traceability, enabling real-time visibility and faster decision-making across operations.
Automation is deployed at scale, with around 1,500 robots and over 98% automation in the body shop, supported by robotic painting and sealer application for consistent build quality. Quality is engineered into the process through 3D component scanning, real-time weld integrity monitoring and interlocked “No Fault Forward” gateways that prevent defects from moving down the line.
Operational flexibility comes from seven multi-model assembly lines and synchronised autonomous mobile robots that handle material movement, allowing the plant to switch models and variants with minimal disruption. AI-enabled safety systems monitor PPE compliance and shop-floor conditions in real time, reinforcing Mahindra’s focus on worker safety in a highly automated environment.
Sustainability at the core
Beyond volume and technology, Chakan has been positioned as a benchmark for responsible manufacturing at scale. More than half of the plant’s total energy requirement is currently met through renewable sources, while electric-vehicle manufacturing lines operate on 100% renewable energy, directly supporting Mahindra’s ESG ambitions.
The facility is water positive, returning around 131% of the water it uses back to nature, aided by an annual rainwater recharge of approximately 9.91 lakh kilolitres. It is also certified as Zero Waste to Landfill and is close to meeting its EP100 commitment to double energy productivity, signalling that higher output is being achieved with more efficient energy use.
BE 6: Symbol of Mahindra’s EV future
That the three-millionth vehicle is the BE 6 is symbolic of Mahindra’s pivot towards electric SUVs and technology-led products. Built on the INGLO platform under the BE sub-brand, the BE 6 offers 59 kWh and 79 kWh battery options, with prices starting around ₹18.90 lakh (ex-showroom), targeting a wide spectrum of urban and semi-urban EV buyers.
Inside, the BE 6 showcases Mahindra’s premium intent with dual 12.3-inch screens, a 16-speaker Harman Kardon sound system, 5G connectivity, AR head-up display and a panoramic sunroof, positioning it as a tech-forward electric SUV. As deliveries ramp up across India, the BE 6 emerging as the milestone unit from Chakan reinforces the plant’s role as the backbone of Mahindra’s “built in India, for India and the world” electric strategy.
For India’s automotive industry, Chakan’s 30 lakh milestone with an EV at the centre underlines how domestic manufacturing is scaling up not just in quantity, but in quality, digital sophistication and sustainability key themes shaping the next decade of mobility.
