Maruti Suzuki has commenced commercial production at Plant D (fourth plant) of its Hansalpur facility in Gujarat. The fourth plant has an annual production capacity of 250,000 units. It takes the overall annual production capacity of the facility from 750,000 units to 1 million units. This is the first time in the automaker’s history that a single manufacturing facility has reached the 1 million units mark. The Hansalpur facility also becomes the largest single-location passenger vehicle manufacturing facility in India.
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Maruti Suzuki: Leading the pack when it comes to production
With the commencement of production at Hansalpur’s Plant D, Maruti Suzuki’s annual production volume across all facilities sits at 2.9 million units. Here is a quick breakdown.
| Plant | Capacity |
| Hansalpur | 1 million units |
| Manesar | 900,000 units |
| Gurugram | 500,000 units |
| Kharkhoda | 500,000 units |
| Total | 2,900,000 units |
Maruti’s Hansalpur facility in Gujarat is spread across 640 acres. The automaker has invested Rs 25,288.7 crore into the project. The investment in Plant D alone stands at 3,900 crore. This plant will initially produce the Maruti Suzuki e Vitara, the automaker’s first all-electric offering in the country. The Hansalpur facility also produces the Fronx, Baleno, and Swift. It is a major export hub for the company, accounting for 47% of the shipments in FY 2025-2026.
Plant A in Hansalpur is responsible for the production of the Maruti Suzuki Baleno. It began operations in February 2017. The Maruti Suzuki Fronx and Swift are rolled out of Plant B. This plant started production in January 2019. The third plant, Plant C, produces the Fronx and e Vitara. It came into action in April 2021. As mentioned earlier, Plant B will initially roll out the e Vitara before incorporating other models.
Here are some of the production milestones that the Hansalpur facility has hit so far.
| Units Produced | Date |
| 1 million | October 21, 2020 |
| 2 million | August 18, 2022 |
| 3 million | December 4, 2023 |
| 4 million | March 4, 2025 |
| 5 million | May 7, 2026 |
Speaking on the expansion, Mr Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India Limited, said, “Gujarat has emerged as a manufacturing and export hub for Maruti Suzuki, backed by strong infrastructure and a progressive industrial ecosystem. 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 added, “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.”
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Final Thoughts
In March 2024, the Hansalpur facility commissioned India’s first automobile in-plant railway siding under the Prime Minister’s GatiShakti programme. In February 2026, the in-plant railway siding became the World’s First Modal Shift Transportation Project to be registered under Verra’s Verified Carbon Standard (“VCS”) program.
