How a Smart Consumer Product Was Launched at Scale with Karkhana.io
A homegrown innovation backed by a skilled R&D team, the Smart Mop was more than just another household device.
Overview
When a fast-growing hardware brand set out to enter the consumer electronics market with an innovative Smart Mop, they knew the challenge wouldn’t just be designing a great product — it would be executing manufacturing at scale, speed, and quality.
A homegrown innovation backed by a skilled R&D team, the Smart Mop was more than just another household device. It was the company’s flagship entry into the smart home segment and they needed a partner who could match their ambition with high-accuracy manufacturing, end-to-end coordination, and rapid scalability.
That’s where Karkhana.io stepped in.
Project at a Glance
Industry:
Consumer Electronics / Smart Home
Product:
Smart Mop – Flagship Entry into the Smart Home Segment
Services Offered
End-to-end manufacturing from component sourcing to ready-to-ship units, vendor qualification, prototyping, DFM feedback, quality control, and mass production management
Capabilities Leveraged
Electromechanical assembly, electronics integration,wire harnessing
Core Customer Challenges
Upliance needed a manufacturing partner who could take full ownership of the product journey:
Fragmented vendor network
Scaling without quality loss
No single-point ownership
Inflexible manufacturing partners
Primary Execution Priorities
As the company ramped up production for their lithium-ion battery packs for 3-wheeler EVs, they faced a familiar set of hurdles:
- Sourcing a wide range of components, from metal enclosures and thermal materials to PCBs and custom wire harnesses
- Executing a flawless box-build process, integrating mechanical, electrical, and electronic subsystems seamlessly
- Managing the end-to-end supply chain without locking up capital in excess inventory
- Ensuring every finished unit was tested, validated, and integration-ready
For a team focused on innovation and product development, getting pulled into operational firefighting was neither scalable nor strategic.
A Complex Supply Chain for a Complex Consumer Product
The company had already invested in strong in-house R&D capabilities. They had a working product design and a clear vision. But turning that vision into a high-quality, consumer-ready product proved harder than expected.
They struggled to find a manufacturing partner who could take ownership of the full box build — not just assembling parts, but managing the sourcing, vendor approvals, prototyping, DFM feedback, and delivery of ready-to-ship units. The process was fragmented. Each component of the mop — from injection-moulded plastic parts to wire harnesses, PCBs, and electrical sub-assemblies — needed different vendors, timelines, and coordination.
Most partners were either too small to scale or too rigid to adapt.
What they needed was a single partner who could stitch all of this together and take full accountability — from prototype to mass production.
Solutions Delivered
Karkhana.io built a customized supply chain for over 50 diverse components, mapping each process from incoming quality checks to final packaging and creating standard operating procedures to ensure consistency. Rapid prototyping cycles enabled real-time testing and product improvements, while active DFM feedback simplified assembly and reduced costs. Rigorous QA checkpoints were embedded at every stage, ensuring defect-free, integration-ready units, backed by full traceability and documentation for compliance and warranty needs. Costs were optimized through strategic multi-vendor negotiations, and the customer had complete visibility via real-time production dashboards and milestone tracking.
Key Outcome
From project kickoff to production readiness
For end-to-end sourcing, production, and delivery
Scalable production capacity, ready to ramp
Achieved through multi-vendor cost optimization
The Karkhana.io Advantage: Integrated, Scalable, Transparent
When they partnered with Karkhana.io, the conversation shifted from “Can this be built?” to “How soon can we ship?”
We took full ownership of the Smart Mop’s manufacturing journey. Within just 60 days of project kickoff, we had built a customized supply chain for over 50 components, including complex injection-moulded parts. All coordination, quality checks, vendor management, and documentation were routed through us — giving the customer a single point of contact and full visibility without the headache.
Our approach wasn’t just about assembling a product. It was about engineering the process behind it.
We mapped every operation — from incoming component QC to final packaging — and developed standard operating procedures to ensure consistency and efficiency. This not only improved quality but also doubled the team’s daily productivity, enabling smooth scale-up.
Outcome Overview
The Smart Mop was launched in record time meeting aggressive quality and delivery expectations while freeing the customer’s internal team to focus on branding, customer acquisition, and growth.
It entered the market not as a prototype or limited release, but as a confidently engineered, fully manufacturable product ready for scale.
Testimonials
Frequently Asked Questions
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