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The battery is the heart of electric vehicles. Therefore, when it comes to buying an electric vehicle, everyone is interested in knowing about its range. But how the battery of an electric vehicle is manufactured, have you ever thought about this? In this blog, we will talk about all this, and what the manufacturing plant of electric batteries looks like. Visiting JSW MG Motor’s battery assembly plant is like entering a different world. The environment inside the plant is like a factory, but every activity performed there is precise. You will feel the odour of plastic and metal, machines working at a constant speed. Every activity performed by the experts is deliberate, almost surgical in nature.

 

 

The plant we are talking about is the Halol plant in Gujarat, where JSW Group and MG Motor—now owned by Chinese state conglomerate SAIC—have invested heavily to create an electric future. With the capacity of manufacturing 100,000 vehicles annually, the plant is developed for compact electric cars. 

 

A Workforce with a Difference

The first thing which you notice inside the campus is the presence of the workforce. MG has tried to maintain diversity in its production teams, and it shows. It would be interesting to know that the entire battery assembly plant is managed by women. Women constitute up to 85–90% of the workforce. Importantly, women hold not only assembly roles but also supervisory and managerial positions.

 

Kanupriya Khandwal, one of the production managers, will make you understand the working process of multiple modules across stations, including how each test is enforced, and how quality is treated as a discipline, not just a slogan.  Moving ahead, aiming to empower the women workforce, MG has constructed substantial women’s hostels, dedicated buses, and strict security protocols. They also collaborate with local colleges to recruit a technically skilled workforce to ensure the appointment of talented staff into the plant.

 

Anatomy of a Battery

The assembly floor is categorised into four sections: the module line, the pack line, the final line, and the end-of-line process. Each has its own rhythm, precision checks, and culture of accountability.

 

Module Line: Cells, prequalified by overseas vendors, arrive sorted by capacity and internal resistance. The Windsor pack uses 98 cells, while the Comet runs on 36. Each one is managed with precise care, tested for voltage, insulation, and polarity multiple times. Modules are then stacked, fitted with coolant circulation hardware (for the Windsor and Windsor Pro), and tagged for traceability. Every cell, every module, is accounted for.

 

Pack Line: Modules are combined into larger assemblies. Bus bars are welded, torque tools fasten connections under strict monitoring, and gaskets and covers are applied. Housing is sealed to IP67 standards, and leak tests ensure integrity. From this stage onward, batteries are treated as high voltage, with operators wearing protective equipment and performing double-checked actions.

 

Final Line: Here, packs undergo charging and discharging cycles, simulating real-world conditions. Internal resistance is rechecked, and any anomaly in balance or capacity is flagged. Packs are pushed to verify they can handle both regular use and stress scenarios.

End-of-Line Process: This is the final verification stage. Traceability codes, voltage, insulation, and torque logs are matched to batch records. Even a single deviation sends the pack back for rework. Nothing leaves the floor without a complete data-backed certification.

 

Conclusion

 

JSW MG Motor’s Halol plant is the best illustration of precise engineering, workforce diversity, and the growing importance of electric vehicles in India. From a structured assembly line to the rigorous quality checks and inclusive workforce policies, the facility embodies a forward-looking approach to automotive manufacturing. It’s not just about building batteries—it’s about crafting a sustainable and equitable electric future.