From Germany to India: How Karkhana.io Delivered Custom Maritime Components
Deliver a cost-effective, high-quality, and on-time solution by managing every stage from material procurement to supplier management
Overview
When a leading name in the German maritime industry needed a reliable sourcing partner in India, the stakes were high. The project involved manufacturing 28 custom SKUs for maritime applications, each with stringent quality requirements, critical tolerances, and a mix of manufacturing processes.
The goal: deliver a cost-effective, high-quality, and on-time solution by managing every stage from material procurement to supplier management, third-party certifications, and logistics, entirely from India.
Project at a Glance
When the world sets its sights on clean energy, the scale of ambition is immense. One such project—undisputedly the largest solar park on the planet—demanded not just vision, but also robust execution on the ground. Among the critical enablers of this execution were the humble but essential purlin plates—structural components that support and stabilize solar panels across thousands of acres.
While the engineering challenges of a solar park are well-documented, what often gets overlooked is the manufacturing muscle required to bring these structures to life. From precision fabrication to high-volume procurement and coordinated logistics, the behind-the-scenes work can make or break such a project.
With end-to-end manufacturing control, Karkhana.io ensured this clean energy project was delivered without compromise.
Industry:
Maritime
Product:
Custom Components for Maritime Applications (28 SKUs)
Services Offered
Complete customized component manufacturing in India, including material procurement, supplier management, third-party test,inspection certification, and logistics
Capabilities Leveraged
CNC machining, welding, laser cutting, bending, angular milling, ultrasonic cleaning
These capabilities allowed us to deliver a one-stop sourcing solution for a diverse, low-volume, high-mix production requirement — under a single, coordinated project framework.
Post-processing
Anodizing, zinc plating, hard chrome plating, galvanizing
Materials
- Housing: Aluminium (Al 6082)
- Handle: E250 Steel
- Ball: EN1A (Free Cutting Steel)
- Sealing & Sliding Ring: POM (Polyoxymethylene)
- Support Ring: EN19 Steel
- Shift Shaft: EN19
These capabilities enabled us to engineer and deliver a complete localization solution—from component machining to post-processing and final assembly.
Core Customer Challenges
The customer faced four significant challenges in this project:
Diverse Product Portfolio
Multiple Supplier Coordination
Stringent Quality Requirements
High Production and Quality Costs
Primary Execution Priorities
The project faced several core challenges. The diverse product portfolio involved low-volume, high-mix manufacturing requirements, which demanded suppliers with flexible capabilities and the ability to maintain consistent quality across different processes. Multiple supplier coordination was another hurdle, as the components required different manufacturing specializations, making it essential to align all suppliers without losing visibility. Stringent quality requirements added further pressure, with maritime applications demanding tight tolerances and strict compliance, leaving no margin for error. Lastly, high production and quality costs were a concern, as European manufacturing expenses and complex supply chain structures were adversely affecting both margins and delivery timelines
Solutions Delivered: A Comprehensive Approach
To overcome these challenges, our team designed and executed a tailored solution that addressed each critical area:
Diverse Product Portfolio
For low-volume and high-mix products, we leveraged production capabilities from multiple suppliers to meet complex manufacturing requirements without compromising on timelines or quality.
Strategic Partners – Managing Multiple Suppliers
We assessed and identified potential suppliers with diverse in-house capabilities to match the project’s varied needs. A dedicated project management team oversaw and coordinated activities across all suppliers, ensuring seamless collaboration. Real-time digital tracking and monitoring were implemented to keep progress and deliveries transparent at every stage.
Quality – Stringent Manufacturing Tolerances
We ensured Material Test Certification for all high-quality raw material procurement, guaranteeing compliance and traceability. To meet stringent requirements, specialized fixtures were developed for achieving tight H6 tolerance in both angular welding and angular milling.
Cost – High Production and Quality Cost
By providing a one-stop outsourcing solution in India through Karkhana.io’s vetted supplier network, we significantly reduced production and quality costs while maintaining international standards.
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:
Rapid Sampling
Supply Chain Transparency
Diverse Product Portfolio Under One Roof
Customer Service
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 collaboration proved that complex maritime components can be sourced and produced in India to match global quality standards, even under low-volume, high-mix constraints. By combining a diversified supplier base, rigorous quality control, and centralized project management, Karkhana.io delivered a solution that was cost-effective, resilient, and built for repeatability.
Testimonials
Frequently Asked Questions
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