Maruti Suzuki starts production at fourth Gujarat plant, lifting Hansalpur capacity to 1 million units
Maruti Suzuki has commenced commercial production at Plant D in Hansalpur, Gujarat. The Rs 3,900 crore facility adds 250,000 units of annual capacity and will initially manufacture the e VITARA EV, supporting domestic demand, exports and the company’s 4-million-unit India production ambition.
What happened
Maruti Suzuki began commercial production at its fourth Hansalpur, Gujarat plant, adding 250,000 annual units and taking the site to 1 million. The Rs 3,900
Key facts
- 250,000 units annual capacity for Plant D
- Hansalpur total capacity increased from 750,000 to 1 million units annually
- Rs 25,288.7 crore cumulative investment at Hansalpur
- Rs 3,900 crore estimated investment for Plant D
- Maruti Suzuki total manufacturing capacity: 2.9 million units annually
- Hansalpur accounted for nearly 47% of overseas shipments in FY26
- 4 million units annual India production ambition
Why this matters
Hansalpur’s new EV-capable capacity reinforces Maruti Suzuki’s strategic manufacturing foothold in Gujarat and expands its ability to serve export markets from India.
What to watch
- Monthly e VITARA production and dispatch volumes after commercial launch.
- Export allocation, destination markets and port-throughput growth from Gujarat.
- Plant D utilization rate relative to its 250,000-unit annual capacity.
- Battery sourcing announcements, localization percentages and new supplier investments.
- Domestic EV bookings, dealer inventory days and discounting versus Tata, Mahindra and Hyundai.
- Further Suzuki-Maruti announcements on new Gujarat plants or revised 4-million-unit production timelines.
- Increase supplier localization for EV drivetrains, battery packs, thermal systems and electronics around Gujarat.
- Use e VITARA exports to build volume utilization before relying on broad domestic EV penetration.
- Expand dealer EV readiness, financing offers, service training and charging partnerships in major urban markets.
- Sequence additional India capacity investments toward the 4-million-unit production ambition, contingent on Plant D ramp performance.
- Leverage higher Hansalpur scale to improve procurement economics and reduce per-unit manufacturing costs across ICE, hybrid and EV production.