Maruti Suzuki has achieved a major manufacturing milestone with the commencement of commercial production at Plant D of its Hansalpur facility in Gujarat. With the fourth plant now operational, Hansalpur’s annual production capacity has increased from 7.5 lakh units to 10 lakh units, making it not only India’s largest passenger vehicle manufacturing facility at a single location but also the first Suzuki manufacturing site anywhere in the world to reach an annual capacity of one million vehicles.
The newly commissioned Plant D adds 2.5 lakh units of annual production capacity and will initially manufacture Maruti Suzuki’s flagship electric SUV, the e Vitara. With this expansion, Maruti Suzuki’s total manufacturing capacity across India has risen to 29 lakh units per annum.
Hansalpur Leads Maruti’s Manufacturing Network
Located in Gujarat, the Hansalpur facility spans 640 acres and has attracted a cumulative investment of Rs 25,288.7 crore, including an estimated Rs 3,900 crore for the newly inaugurated Plant D. The facility now houses four manufacturing plants that collectively produce Baleno, Fronx, Swift and e Vitara.
Hansalpur has steadily expanded over the years. Plant A commenced operations in February 2017, followed by Plant B in January 2019, Plant C in April 2021 and now Plant D in July 2026. The facility has also emerged as Maruti Suzuki’s largest export hub, accounting for nearly 47% of the company’s total overseas shipments during FY2025-26.
Maruti Suzuki’s overall manufacturing footprint now comprises four facilities with a combined installed capacity of 2.9 million vehicles annually. Hansalpur contributes one million units, while Manesar has a capacity of 9 lakh units and the Gurugram and Kharkhoda plants have capacities of 5 lakh units each.
Milestone Reached In Less Than A Decade
Hansalpur has scaled up rapidly since production began in 2017. The plant produced its first one million vehicles by October 2020 and crossed the five-million cumulative production milestone in May 2026, underlining its growing importance within Maruti Suzuki’s global manufacturing operations.
Speaking on the expansion, Hisashi Takeuchi, Managing Director & CEO of Maruti Suzuki India, said Gujarat has evolved into a key manufacturing and export hub for the company. He added that the fourth plant will help meet growing domestic and international demand while supporting the company’s “Make in India, Make for the World” strategy. Takeuchi also noted that Hansalpur, together with the upcoming Sanand facility, will play a crucial role in helping Maruti Suzuki achieve its long-term target of producing four million vehicles annually in India.
