Maruti Suzuki India Limited today began commercial production at its fourth manufacturing unit, known as Plant D, located at the Hansalpur facility in Gujarat. This significant expansion boosts the Hansalpur plant's annual production capacity to 1 million vehicles. It also increases Maruti Suzuki's total manufacturing capacity across India to 2.9 million units per year.[autopunditz+10]
Hansalpur Becomes India's Largest Production Site
The new Plant D adds 250,000 units to the Hansalpur facility's annual production capability. This raises the site's total from 750,000 units to 1 million vehicles per annum.This milestone makes Hansalpur the first Suzuki manufacturing facility globally to reach an annual production capacity of 1 million units. It now stands as India's largest passenger vehicle manufacturing facility at a single location.[autopunditz+25]
Maruti Suzuki has invested a cumulative ₹25,288.7 crore in the Hansalpur facility. The estimated investment specifically for Plant D is ₹3,900 crore. Thenew plant will initially produce the e Vitara, which is Maruti Suzuki's flagship Battery Electric Vehicle (BEV). Other popular models like the Baleno, Fronx, and Swift are also manufactured at the Hansalpur complex.[angelone+18]
Bolstering National Output and Exports
With the commissioning of Plant D, Maruti Suzuki's overall production capacity across its Indian facilities now reaches 2.9 million units annually. This capacity is distributed among Hansalpur (1 million units), Manesar (0.9 million units), Gurugram (0.5 million units), and Kharkhoda (0.5 million units). This expansion is crucial as the company continues to grow its SUV and electric vehicle portfolio and strengthens its export operations.[autopunditz+6]
The Hansalpur facility has become a significant export hub for Maruti Suzuki. It accounted for nearly 47% of the company's total overseas shipments during the fiscal year 2025-26. This emphasizes India's growing role as a global manufacturing and export base for the Japanese automaker.[autopunditz+9]
Leadership's Vision for Growth
Hisashi Takeuchi, Managing Director and CEO of Maruti Suzuki India Limited, highlighted the strategic importance of this expansion. He stated that Gujarat has become a key manufacturing and export hub for the company, supported by strong infrastructure and a progressive industrial environment.
Takeuchi added that the new production line will strengthen Maruti Suzuki's ability to meet increasing demand from customers both in India and abroad. It also advances the company's "Make in India, Make for the World" vision and expands its global presence. He further noted that the Hansalpur facility, along with an upcoming plant in Sanand, Gujarat, will be vital in achieving Maruti Suzuki's long-term goal of producing 4 million vehicles annually in India.[angelone+13]
Sustainable Manufacturing Practices
Maruti Suzuki has also integrated sustainable logistics into its Hansalpur operations. In March 2024, the company commissioned India's first automobile in-plant railway siding at the Hansalpur facility. This initiative falls under the Prime Minister's GatiShakti programme.
This railway siding has helped reduce CO2 emissions and fuel consumption in vehicle transportation. It has also eased road congestion. In February 2026, this in-plant railway siding achieved global recognition by becoming the world's first Modal Shift Transportation Project registered under Verra's Verified Carbon Standard (VCS) program. Since March 2023, the facility has dispatched over 750,000 vehicles by rail.[angelone+9]
Meeting Rising Market Demand
This capacity expansion comes at a critical time as Maruti Suzuki aims to capitalize on strong market demand. The company saw its market share increase to 42% in April 2026, up from 39% in the previous fiscal year. In May 2026, Maruti Suzuki successfully reclaimed and strengthened its domestic passenger vehicle market share to approximately 41%–43%.[m+1]
The company has observed significant growth in sales, especially in rural areas, where its market share reached 52% in May 2026. This growth is driven by increasing demand for both traditional passenger cars and SUVs. The new production capabilities will help the automaker reduce waiting periods for popular models and support the rollout of new launches, including electric vehicles.[auto+1]
Future Expansion Plans
Looking ahead, Maruti Suzuki has outlined ambitious plans to further expand its manufacturing footprint in Gujarat. The company is developing another large manufacturing complex at Sanand. This new facility is expected to have an annual capacity of 1 million units and is planned to be operational by 2029.
Maruti Suzuki has approved an investment of ₹10,189 crore for the first phase of this new greenfield facility at the Khoraj Industrial Estate in Sanand. The total planned investment for this plant is around ₹35,000 crore. Once operational, Maruti Suzuki's total manufacturing capacity in Gujarat alone will reach 2 million vehicles annually. This highlights the state's growing importance for both domestic production and exports. These strategic investments align with Suzuki Motor Corporation's long-term goal of making India its largest global manufacturing and export base, targeting approximately 4 million units annually by FY2030.[autopunditz+15]
The commencement of production at Hansalpur's Plant D marks a significant step in Maruti Suzuki's strategy to bolster its manufacturing capabilities, meet evolving consumer demands, and reinforce its leadership in the Indian and global automotive markets.[autopunditz+8]
