Engineering Structural Excellence: How Karkhana.io Delivered High-Volume Facade Brackets for a Landmark Construction Project
This case study highlights how our integrated approach to fabrication, procurement, and logistics made it possible.
Overview
In today’s fast-moving construction landscape, delivering high-quality components at scale is critical. For a landmark corporate project, Karkhana.io was tasked with manufacturing and supplying facade brackets in large volumes—while ensuring accuracy, traceability, and on-time delivery. This case study highlights how our integrated approach to fabrication, procurement, and logistics made it possible.
Project at a Glance
Industry:
Construction
Product:
Facade Brackets
Services Offered
Heavy fabrication, material procurement with traceability, complete project and logistics management
Capabilities Leveraged
Laser cutting, fabrication, DP testing, hot dip galvanizing
These capabilities formed the foundation of a solution designed to address every phase of the supply chain, from raw material sourcing to final delivery.
Core Customer Challenges
The customer faced four significant challenges in this project:
High-Volume Fabrication
Material Procurement
Material Test Certificates with Traceability
Logistics Management
Primary Execution Priorities
In high-volume fabrication, customers expect production processes that can handle large quantities without sacrificing precision or consistency. The ability to scale efficiently while maintaining quality is a core expectation.
Material procurement is another key requirement. Clients look for partners who can source high-quality materials in bulk and manage inventory reliably to avoid delays or disruptions during execution.
Traceability across the supply chain is critical. Customers expect proper documentation and material test certificates (MTCs) to ensure full compliance and accountability at every stage.
Finally, logistics must be seamless. Coordinating the transport and delivery of heavy fabricated components needs to be both cost-effective and tightly aligned with project schedules — minimizing delays and ensuring smooth handoffs.
Solutions Delivered: A Comprehensive Approach
To overcome these challenges, our team designed and executed a tailored solution that addressed each critical area:
High-Volume Fabrication
Developed and executed a robust production process plan for high-volume fabrication. Implemented efficient warehouse management practices to maintain order and inventory control. Enabled real-time project tracking, ensuring full traceability and visibility into production progress.
Material Procurement
- Designed and implemented a procurement process plan optimized for bulk purchasing.
- Established strong supplier coordination to guarantee timely and accurate material delivery.
- Managed inventory dynamically to support uninterrupted large-scale production.
Material Test Certificates (MTC) and Traceability
- Established standard operating procedures (SOPs) for issuing material test certificates.
- Implemented a centralized system to maintain and manage all test certificate documentation, ensuring complete traceability across the supply chain.
Logistics Management
- Managed logistics for over 50 tons of various component sets with precision.
- Coordinated transportation and delivery schedules to align seamlessly with project milestones.
- Optimized logistics workflows to handle large-scale quantities cost-effectively, reducing both lead times and costs.
Key Outcomes
With a combination of integrated execution, robust QA, and smart coordination, the project achieved results that would be hard to replicate in a fragmented setup:
Improved Efficiency and Timeliness
By streamlining procurement, production, and logistics processes, we ensured material availability and smooth project management, minimizing delays and bottlenecks.
Cost Optimization
Efficient inventory management and logistics planning reduced excess stock and transportation costs, delivering significant savings across operations.
Enhanced Quality Control
Standardized SOPs for MTC issuance and traceability maintained consistent product quality, reduced rework, and ensured full regulatory compliance.
Supplier Coordination and Risk Mitigation
Proactive supply chain coordination eliminated bottlenecks and mitigated risks of delay, keeping the project firmly on schedule.
More than just numbers, the outcome was a smooth, scalable supply chain that allowed Pi Green to focus on product innovation while Karkhana.io took care of execution.
Outcome Overview
This project is a testament to what’s possible when engineering expertise, advanced manufacturing capabilities, and thoughtful logistics management come together. From laser cutting and fabrication to final delivery, every step was optimized to deliver structural excellence at scale.
By combining heavy fabrication, rigorous quality control, and integrated supply chain solutions, we empowered our client to complete a high-profile corporate project with confidence—and set a new standard for efficiency, quality, and reliability in construction component manufacturing.
Testimonials
Frequently Asked Questions
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