Manufactured Capital

Our best-in-class manufacturing facilities utilise advanced technologies to aid the development of products that offer the assurance of quality, customer convenience and cost-efficiency. The strength of our manufactured capital, therefore, creates customer confidence and contributes towards sustained business growth.

Material topic linkage

  • Quality and service delivery
  • UN SDG linkage:

    In the fiscal year, we have undertaken initiatives to enhance our in-house production capabilities and promote premiumisation for our Fans portfolio. By diligently pursuing capacity debottlenecking initiatives, we have ensured that our manufacturing processes operate at optimal levels, enabling us to meet the growing demand for our premium products. Moreover, our commitment to sustainable manufacturing practices has been unwavering, as we have embraced Total Productive Maintenance (TPM) and focused on enhancing Overall Equipment Effectiveness (OEE). These strategic steps have not only strengthened our operational efficiency but have also reinforced our dedication to environmental stewardship.

    Bajaj Electricals is known for introducing an extensive array of consumer electrical products, focused on enriching customer convenience. With rapid deployment of advanced technology in our manufacturing facilities, we continue to undertake significant design improvements that help in the production of the finest products and enable us to adhere to rigorous quality parameters.

    Our plants too implement sustainable manufacturing practices that are directed to minimise our impact on the environment. We also continue to undertake efforts to enhance operational efficiency while ensuring optimum resource utilisation. These steps have also helped us to achieve significant cost efficiencies across the manufacturing process.

    Improved operations

    At Bajaj Electricals, we remain committed to ensuring manufacturing excellence through operational efficiency. We have strengthened our operations through Total Productive Maintenance (TPM) and effective cost management. We have an effective system of resolving challenges through revised and new business models and restructuring of cross functional activities and improving Overall Equipment Effectiveness (OEE).

    Inspection at manufacturing plants

    To ensure product quality and durability we have strengthened process inspection at every stage with

    Our manufacturing facilities

    Ranjangaon plant



    EPC products

    36,200 MT

    Installed capacity

    28,007 MT

    Annual production

    Capacity utilisation
    Chakan plant




    units per annum

    Installed capacity


    Installed capacity


    units per annum

    Installed capacity


    Installed capacity

    Capacity utilisation
    • In January 2023, the Chakan facility reached a record breaking production level of 273,000 fans, marking its highest output for the month.
    • The Chakan Fan Factory has introduced a cutting-edge paint shop capable of handling up to 325,000 fans each month.
    • The fan factory has also established a state-of-the-art assembly line with an impressive total capacity of 400,000 fans each month.
    Nashik Plant

    Water Heaters





    units per annum

    Installed capacity


    units per annum

    Annual production

    Capacity utilisation
    • The plant produced 60,000 LED bulbs in a single day in February 2023
    • It recorded the highest number of storage water heater production of 60,000 units, in September 2022
    Aurangabad Plant

    Non-stick cookware

    Pressure Cooker


    units per annum

    Installed capacity


    units per annum

    Annual production

    Capacity utilisation
    • The plant achieved the milestone of manufacturing 78,000 Pressure Cookers in September 2022

    Focus on Total Productive Maintenance (TPM)

    We have incorporated Total Productive Maintenance (TPM) across our operations to inculcate a comprehensive approach to equipment maintenance. It aims to maximise the overall effectiveness and efficiency of manufacturing plants. TPM helps to regulate maintenance activities efficiently, reduces downtime and optimises productivity. It has resulted in considerable cost savings by minimising repair costs, extending the life of equipment and reducing energy consumption.

    Digital adaptation

    The implementation of Manufacturing Execution Systems (MES) and digitisation of the production process has improved efficiency, productivity, and overall performance of our plants. The integration of sophisticated technology and automated systems across our operations is also expected to optimise our production workflow,

    increase real-time monitoring of systems and enable seamless data exchange across the manufacturing ecosystem. With rapid adoption of digital capabilities at our manufacturing plants, we aim to create a connected and intelligent factory environment, capable of quickly adapting to changes in market dynamics, reducing downtime, improving product quality and streamlining operations.


    Minor accidents at Chakan

    278.6 mg/l

    ETP TDS Value at Chakan

    60.5 mg/l

    STP-COD at Chakan


    First Aid Injury at Chakan

    19.5 mg/l

    STP-BOD at Chakan

    21.3 mg/l

    ETP BOD at Chakan

    64.4 mg/l

    ETP COD at Chakan

    15.2 mg/l

    STP- TSS at Chakan

    Embedding sustainability in our operations

    We are making significant strides to reduce environmental impact and enhance efficiency as part of our ongoing efforts to integrate sustainability into our operations. Through responsible resource management, utilisation of renewable energy sources and a sharp focus on employee health and safety, we are setting new industry benchmarks for sustainable practices.

    Initiatives implemented during FY23:

    Built a Zero Liquid Discharge (ZLD) plant to recycle effluent within the manufacturing process. We are also reusing the paint shop wastewater after recycling.

    All our plants comply with the Pollution Control Board’s (PCB) guidelines for e-waste disposal and overall waste management.

    Installed Variable Frequency Drives on two robotic cranes for energy optimisation, currently under monitoring and evaluation.

    Changed water taps in washrooms and reused water for plantations to optimise water usage.

    Installed new solar panels to lower greenhouse gas emissions. At our plants, we also focus on the effective surveillance and upkeep of existing panels.

    Launched awareness campaigns via emails and verbal announcements to encourage our personnel to adopt sustainable practices.

    Way forward

    • In the upcoming year, we plan on scaling up our digitalisation initiatives and the implementation of the Manufacturing Execution System (MES) at the Chakan factory.
    • Through advanced machine learning algorithms and predictive analytics, we aim to improve our capacity utilisation.
    • To lower our carbon footprint and enhance product efficiency, we intend to revamp our manufacturing processes by incorporating green technology and sustainable practices.