The facility utilises Industry 4.0 technologies, including Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs), for efficient material movement. Mahindra unveiled a new electric vehicle (EV) manufacturing and battery assembly facility at its Chakan plant. The facility is dedicated to producing its Electric Origin SUVs and reflects the company's commitment to sustainable manufacturing and innovation in India. The plant leverages advanced automation and integrates a cutting-edge battery assembly line within a larger, environmentally conscious manufacturing ecosystem.
The new EV facility is located within Mahindra's 2.83 km² Chakan manufacturing hub, described as a water-positive facility entirely powered by renewable energy. Mahindra has invested INR 4,500 crore in this project, part of a larger INR 16,000 crore investment plan from FY22–27. This investment encompasses powertrain development, product development including software and technology, and expanding manufacturing capacity.
Automated manufacturing facility
The EV manufacturing hub is highly automated, utilising over 1,000 robots and multiple automated transfer systems. Mahindra aims for a 25% gender diversity ratio at the facility, emphasising an inclusive work environment. The company is now prepared to launch its next generation of Electric Origin SUVs.
The EV facility occupies approximately 88,000 m² within the larger Chakan hub. It incorporates a fully automated Press Shop, an AI-driven Body Shop, and a sophisticated robotic Paint Shop to maximise quality and efficiency. The Body Shop alone deploys over 500 robots and fully automated transfer systems, all managed through an IoT-based “Nerve Center.” This system provides real-time process insights and end-to-end traceability.
Industry 4.0 technologies
The facility utilises Industry 4.0 technologies, including Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs), for efficient material movement. This underscores Mahindra’s commitment to safety, speed, and reliability in sustainable manufacturing.
A patented pallet design ensures optimal insulation and geometric accuracy. Hidden cell terminal welding enhances connectivity and robust performance. Multi-layered end-of-line testing simulates real-world conditions, with IP67 ingress protection, real-time temperature monitoring, and automated anomaly isolation.
EV Battery plant
The battery assembly plant incorporates a no-fault-forward strategy and proprietary switching technology. These ensure superior product quality and reliability, reinforcing Mahindra’s focus on durability, safety, and delivering best-in-class battery solutions for electric mobility.
The battery assembly plant is designed as one of the world's most compact battery manufacturing lines. It employs patented processes and lean module assembly within a fully automated environment. The plant integrates indigenously developed and implemented manufacturing processes for producing, storing, and transferring high-performance, long-lasting batteries using Industry 4.0 technology.
With this new facility, Mahindra aims to contribute to the future of mobility and supports India's COP26 targets for 2030. The combination of localised battery assembly, advanced automation, and a focus on innovation reinforces Mahindra's "Make in India for the World" commitment.
“With this new state-of-the-art Chakan-based manufacturing and battery assembly facility, Mahindra takes another major step toward shaping the future of mobility. By combining localised battery assembly, high-end automation, and a dedication to innovation, Mahindra is reinforcing its commitment to "Make in India for the World" and contributing to India's efforts to meet its COP26 targets for 2030,” stated the company.
