Mahindra has set the ground running when it comes with its extensive range of Electric Origin SUVs starting with the BE 6 and XEV 9e unveiled late last year. We got the opportunity to visit the company’s new state-of-the-art manufacturing and battery assembly facility in Chakan where these two models and other battery-powered models will be built.
Strategically located within the company’s 2.83 square km, the Chakan manufacturing hub— this new facility is one of India’s largest greenfield projects, a water-positive facility- and 100% reliant on renewable energy. As announced earlier, Mahindra has allocated Rs 4.500 crore out of the total Rs 16,000 crore planned in the FY22 – FY27 investment cycle.
This includes manufacturing capacity, powertrain development, and two product top hats including software and tech. Mahindra’s EV manufacturing hub is a fully integrated, highly automated manufacturing ecosystem that leverages over 1000 robots and multiple automated transfer systems. Besides a strong focus on skill development and quality, this new EV manufacturing facility targets a 25% gender diversity ratio.
Next-gen Mahindra EV plant: Manufacturing
Spread over 88000 square metres, this new state-of-the-art facility utilizes a fully automated Press Shop, an AI-driven Body Shop, and one of India’s most sophisticated robotic Paint Shops to optimize quality and efficiency. Over 500 robots and fully automated transfer systems are deployed in the Body Shop, all monitored via an IoT-based “Nerve Center” for real-time process insights and end-to-end traceability.
The adoption of Industry 4.0 technologies, such as AMRs (Autonomous Mobile Robots) and AGVs (Automated Guided Vehicles), ensures seamless material movement, underscoring Mahindra’s commitment to safety, speed, and reliability in sustainable manufacturing.
Next-gen Mahindra EV plant: Battery Assembly
This fully automated plant operates as one of the world’s most compact battery assembly lines, employing patented processes and lean module assembly. It integrates world-class manufacturing processes developed and implemented indigenously to produce, store, and transfer high-performance, long-lasting batteries using Industry 4.0 technology.
The plant employs a patented pallet design for optimal insulation and geometric accuracy, alongside hidden cell terminal welding for enhanced connectivity and robust performance. Multi-layered end-of-line testing simulates real-world conditions, backed by IP67 ingress protection, real-time temperature monitoring, and automated anomaly isolation.
A no-fault-forward strategy coupled with proprietary switching technology underscores Mahindra’s superior product quality and reliability. This reinforces the homegrown carmaker’s pledge to deliver durability, safety, and peace of mind through best-in-class battery solutions tailored for electric 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.