Maruti Suzuki's Hansalpur plant becomes Suzuki's first global facility to hit 1 million capacity
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Maruti Suzuki India has commenced commercial production at the fourth plant of its Hansalpur manufacturing facility in Gujarat, making it the first Suzuki production site globally to achieve an annual manufacturing capacity of one million vehicles and strengthening the automaker's push to meet rising domestic and export demand.
The newly commissioned Plant D has an annual production capacity of 2.5 lakh units, taking the Hansalpur facility's total capacity from 7.5 lakh units to one million vehicles a year. With the expansion, Maruti Suzuki's overall annual manufacturing capacity has increased to 2.9 million units across its facilities in Gujarat, Manesar, Gurugram and Kharkhoda.
The company said the milestone marks the first time in Suzuki Motor Corporation's history that a single manufacturing facility has reached an annual production capacity of one million units. It also makes Hansalpur India's largest passenger vehicle manufacturing facility at a single location.
Maruti Suzuki has invested a cumulative ₹25,288.7 crore in the Hansalpur facility, including an estimated ₹3,900 crore for the fourth plant. Plant D will initially manufacture the company's flagship battery electric vehicle, the e VITARA, as Maruti prepares to expand its electric vehicle portfolio.
The Hansalpur complex currently manufactures the FRONX, Baleno, Swift and e VITARA, while also serving as a key export base. The facility accounted for nearly 47% of Maruti Suzuki's total vehicle exports during FY26.
Capacity expansion aligned with long-term growth plans
Commenting on the development, Hisashi Takeuchi, managing director and CEO of Maruti Suzuki India, said Gujarat has emerged as a critical manufacturing and export hub for the company.
"The start of commercial production at the fourth plant of our Hansalpur facility augments its annual production capacity to one million vehicles, making it India's largest passenger vehicle manufacturing facility at a single location. The new line will further strengthen our ability to meet the growing demand from customers in India and overseas while advancing our 'Make in India, Make for the World' vision and expanding our global footprint," he said.
Takeuchi added that the Hansalpur facility, along with the upcoming Sanand plant, would play a key role in achieving the company's long-term production target.
"Together, the Hansalpur and the upcoming Sanand facility in Gujarat will play a pivotal role in achieving our long-term ambition of producing 4 million units annually in India. These projects reflect our commitment to strengthening India's manufacturing competitiveness, creating employment, boosting exports and contributing towards Viksit Bharat," he said.
Following the commissioning of the fourth plant, Maruti Suzuki's annual production capacity now stands at 1 million units in Hansalpur, 0.9 million units in Manesar, and 0.5 million units each at Gurugram and Kharkhoda.