Befor Rajnikanth was confirmed, Aamir Khan, Shah Rukh Khan and Ajith Kumar were all approached.


The film was originally planned in 2001 starring Kamal Haasan and Preity Zinta titled as ''Robo''.


This was director Shankar's dream project. After the completion of Indian (1996) with Kamal Hassan, Shankar approached Kamal Hassan to do the role. At that time, the project was to commence once he completed the Hindi version of Mudhalvan, Nayak in 2001. Then actress Preity Zinta was also cast opposite to Kamal Hassan but later during the year, the project got shelved. The project then was resurfaced when Shankar casted Vikram for a film in 2005, which was then later known as "Anniyan." In 2007, the project came up as Shankar's next film after completing Sivaji the Boss. Bollywood actor, Shah Rukh Khan was to approached by Shankar to do the film as well as produce it. However, due to creative differences, SRK declined the offer and the role ultimately went to Rajnikanth. At the same time, Shankar roped in Aishwarya Rai to play opposite to Rajni with a whopping 60 crore. This is her second time working with Shankar after Jeans (1998).


Shooting of the seeming climax fight happened at SIPCOT IT Park, Siruseri, Chennai from the 23rd August onwards till 27th August. There were more than 30 people dressed and made-up to look like the honorable thalaivar, Rajnikanth.