From Global to Local: How Karkhana.io Localized Ball Valve Manufacturing for Hydraulic Lifts
This case study shows how Karkhana.io delivered a seamless transition through coordinated supplier management, engineering support, and end-to-end execution.
Overview
To serve the growing demand for hydraulic lifts in India’s construction sector, a leading OEM sought to localize its ball valve production—previously handled in Germany and Turkey. The goal: build a fully Indian supply chain without compromising on technical standards, cost efficiency, or product quality. This case study shows how Karkhana.io delivered a seamless transition through coordinated supplier management, engineering support, and end-to-end execution.
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:
Construction
Product:
Ball Valve Assembly for Hydraulic Lifts
Services Offered
Heavy fabrication, material procurement with traceability, complete project and logistics management
Capabilities Leveraged
CNC machining, sheet metal stamping
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:
Multiple Supplier Coordination
Inadequate Technical Specifications
Higher Cost of Logistics & Import Duties
Quality Standards with Interchangeability
Primary Execution Priorities
Managing multiple suppliers for a precision assembly like a ball valve posed significant risks. Clear ownership, coordinated timelines, and traceable updates were essential to avoid delays.
The lack of detailed technical specifications, especially post-anodizing dimensions, made consistent manufacturing difficult. The client needed engineering support to standardize the design for production readiness.
Importing parts from Europe added substantial logistics costs and attracted heavy duties. To remain cost-competitive in the Indian market, the customer needed a domestic manufacturing base with equivalent standards.
Finally, quality control and interchangeability were non-negotiable. The customer required rigorous checks and uniform compatibility across all parts—regardless of supplier or batch.
Solutions Delivered: A Comprehensive Approach
To overcome these challenges, our team designed and executed a tailored solution that addressed each critical area:
Multiple Supplier Coordination
We implemented regular updates and check-ins with each supplier to ensure alignment on delivery timelines and expectations. Our digital platform was used to:
- Manage progress
- Share schedules
- Enhance cross-supplier visibility
Responsibilities across all stakeholders were clearly mapped to streamline communication and avoid overlaps, ensuring smooth coordination throughout the production process.
Inadequate Technical Specifications
We developed detailed technical drawings for all components, factoring in post-processing tolerances (e.g. after anodizing). Collaborating closely with the client’s engineering team, we refined designs and ensured production feasibility from the start.
Higher Cost of Logistics & Import Duties
We designed a full logistics strategy that included:
- Defined roles
- Timelines
- Fallback options for transport
All production was shifted to India while maintaining German engineering standards, enabling the Indian market to be served more efficiently. By localizing the entire product lifecycle, from raw material to final assembly, we eliminated import duties and reduced overall costs.
Quality Standards with Interchangeability
We established stringent quality checks at every manufacturing stage, ensuring consistency across batches. Interchangeability tests were performed to confirm compatibility between parts from different runs or suppliers.
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 demonstrated that complex, high-precision manufacturing can be successfully localized without sacrificing global quality standards. Through a mix of engineering support, digital coordination, and deep supply chain control, Karkhana.io enabled the customer to transition away from Europe-based sourcing—and unlock faster, more cost-effective production in India.
By aligning capabilities with client expectations, we delivered a 15% reduction in product cost, 20% shorter lead times, and 10% savings on logistics and duties. The result: a fully localized, globally competitive ball valve manufacturing solution built for scale.
Testimonials
Frequently Asked Questions
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