Mahindra has launched its new dedicated state-of-the-art manufacturing and battery assembly facility at its Chakan plant, marking a significant milestone in the company’s electric vehicle (EV) journey. This new facility is part of Mahindra’s ongoing commitment to building a fully integrated ecosystem for producing Electric Origin SUVs. The plant is located within the company’s expansive 2.83 km² Chakan manufacturing hub, one of India’s largest greenfield projects, which is also a water-positive and 100% renewable energy-dependent facility. This demonstrates Mahindra’s dedication to innovation and sustainable manufacturing practices.
As part of its larger investment plan, Mahindra has allocated ₹4,500 Crores out of the ₹16,000 Crores earmarked for the F22-F27 period. This investment will go towards powertrain development, product innovation, software and technology improvements, and expanding manufacturing capacity. The new EV facility is a highly automated and integrated manufacturing ecosystem, utilizing over 1,000 robots and various automated transfer systems to ensure efficiency and precision throughout the production process. In addition, Mahindra is placing a strong emphasis on skill development and quality, with the facility aiming for a 25% gender diversity ratio, reinforcing an inclusive and future-ready work environment.
The next-generation EV plant covers an area of 88,000 m² and features cutting-edge technology to optimize manufacturing processes. The plant houses a fully automated Press Shop, an AI-driven Body Shop, and one of India’s most advanced robotic Paint Shops. These areas focus on maximizing quality and efficiency, with the Body Shop alone using over 500 robots and automated transfer systems, all monitored through an IoT-based “Nerve Center” for real-time process insights. The plant also employs Industry 4.0 technologies, including Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs), ensuring smooth material handling and enhancing safety, speed, and reliability in production.
The facility also features a cutting-edge battery assembly line, which is among the most compact in the world. This highly automated line employs patented processes and lean module assembly to produce high-performance, long-lasting batteries. The battery assembly process is designed for optimal insulation and geometric accuracy, using a unique pallet design, along with hidden cell terminal welding to improve connectivity and ensure robust performance. The batteries undergo extensive multi-layered end-of-line testing that simulates real-world conditions, with features such as IP67 ingress protection, real-time temperature monitoring, and automated anomaly detection. The assembly line also follows a no-fault-forward strategy and incorporates proprietary switching technology, ensuring superior product quality and reliability.
With this new facility, Mahindra is taking a major step in shaping the future of mobility. By combining localized battery assembly with high-end automation and a strong focus on innovation, Mahindra is reinforcing its commitment to the “Make in India for the World” initiative. This development also aligns with India’s COP26 targets for 2030, further contributing to the nation’s efforts to promote sustainable and clean energy solutions in the transportation sector.
