Mahindra’s Chakan facility rolls out its three-millionth vehicle – the BE 6

Mahindra & Mahindra Ltd. has announced that its state-of-the-art manufacturing facility at Chakan has surpassed the cumulative production milestone of three million vehicles, marking another significant chapter in the company’s manufacturing journey. The landmark vehicle to roll off the production line was the BE 6, Mahindra’s most advanced flagship electric SUV, symbolising the evolution of the Chakan plant into a future-ready manufacturing hub supporting both internal-combustion engine (ICE) vehicles and electric mobility.

Since rolling out its first vehicle in December 2009, the Chakan facility has steadily grown into one of Mahindra’s most strategically important manufacturing centres. Reflecting the pace of this transformation, the facility produced its latest one million vehicles in just 27 months—nearly four times faster than it took to manufacture its first million.

Commenting on the milestone, 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.”

Spread across 657 acres, the Chakan manufacturing complex produces 19 vehicle models and more than 450 variants spanning passenger vehicles powered by internal-combustion engines, electric vehicles, and commercial vehicles. The facility has been designed to deliver manufacturing flexibility while supporting multiple product lines under one integrated production ecosystem.

The Chakan plant integrates advanced manufacturing technologies with Lean manufacturing principles and Total Productive Maintenance (TPM) methodologies to enhance quality, flexibility and operational efficiency.

Its manufacturing ecosystem includes Industry 4.0 technologies, artificial intelligence, the Internet of Things (IoT), 5G connectivity and end-to-end digital traceability across production operations.

Automation remains central to the facility’s capabilities, with approximately 1,500 robots deployed across operations. The body shop operates with more than 98 per cent automation, complemented by robotic painting and robotic sealer application.

Quality assurance is reinforced through 3D component scanning, real-time weld-integrity monitoring and interlocked “No Fault Forward” quality gateways that help maintain production standards throughout the manufacturing process.

Operational flexibility is further strengthened by seven multi-model assembly lines, while synchronised autonomous mobile robots streamline material movement across the facility.

In addition, AI-enabled systems provide real-time monitoring of personal protective equipment compliance and shop-floor safety, supporting safer manufacturing operations.

Sustainability continues to form a core pillar of Mahindra’s manufacturing strategy at Chakan.

More than 50 per cent of the facility’s total energy requirement is met through renewable energy sources, while electric vehicle manufacturing operations are powered entirely by 100 per cent renewable energy.

The facility is also water positive, returning the equivalent of 131 per cent of the water it consumes back to nature. This is supported by annual rainwater recharge of approximately 9.91 lakh kilolitres.

Further strengthening its environmental credentials, the Chakan plant has achieved Zero Waste to Landfill certification and is approaching its EP100 commitment to double energy productivity.

The Chakan manufacturing facility also plays an important role in Mahindra’s international growth strategy. Almost every vehicle model produced at the plant supports the company’s global operations, with exports reaching international markets including South Africa, Australia and New Zealand.

As Mahindra continues to expand its product portfolio across conventional and electric mobility, the Chakan facility remains central to its manufacturing ambitions, combining advanced technologies, sustainable production practices and flexible manufacturing capabilities to serve customers in India and across global markets.