Localizing Smart Hardware for India’s First AI Cooking Assistant
A complete manufacturing journey that turned an AI-powered kitchen idea into a market-ready product—at scale and under budget.
Localized Box Build Solution for India’s First AI-Powered Cooking Assistant
When you’re building a category-defining product like India’s first AI cooking assistant, every decision—from sourcing components to optimizing assembly—can influence your speed to market, scalability, and competitiveness.
The challenge wasn’t just to manufacture a smart home appliance. It was to localize and scale production for a device that combines software intelligence with hardware complexity, while delivering a premium user experience.
The Ask: Go Local. Stay Smart.
Upliance needed a manufacturing partner who could take full ownership of the product journey:
Establish a robust China supply chain with competitive QCD (Quality, Cost, Delivery)
Drive SKD localization (Semi Knocked Down kits) to reduce import dependency
Optimize costs without compromising quality or performance
Customize parts, tools, and packaging to align with branding
Standardize manufacturing and assembly processes for long-term scale
What did we do?
To build a reliable, scalable, and cost-efficient supply chain for Upliance’s AI cooking assistant, we broke the problem down into four distinct phases, from SKD-based assembly to near-complete localization.
Phase 1: SKD Import & Initial Assembly Setup
Timeframe: ~ 4 Weeks
Localization: ~ 20%
We began by importing over 30 components from China, including plastics, jars, harnesses, and accessories, while localizing core operations like assembly, painting, packaging, and hardware integration.
Key wins:
- Identified local suppliers for PCBA and tablets
- Established a lean assembly line with standard tools and station-wise processes
- Managed end-to-end procurement and BIS certifications
- Delivered a 100% increase in throughput from Day 1
Phase 2: Component Localization & Process Optimization
Timeframe: ~ 8-10 weeks
Localization: ~ 30-40%
Next, we dove deep into each imported component to evaluate its potential for localization based on cost, volume, and technical feasibility.
What we did:
- Identified and onboarded local vendors for critical electrical parts (PCBA, control boards, harnesses)
- Transitioned 3D-printed parts to full tooling (mould design, material selection)
- Replaced off-the-shelf tablets with custom solutions (including BIS-certified assembly in India)
- Developed process flows for IQC, in-line testing, and PDI to standardize quality control
Phase 3: Scaling Plastics & Accessory Localization
Timeframe: ~ 10-14 weeks
Localization: ~ 70-80%
With the core electronics localized, we moved on to plastics and accessories.
Our focus:
- Expanded vendor network to include high-quality plastics and localized accessories
- Modified the assembly workflow to accommodate more localized SKUs without disrupting product performance
- Conducted functional validation and stress testing to ensure product premiumness
Phase 4: Production Ramp-Up & Final Optimization
Timeframe: ~ 16 weeks
Localization: ~ 80%+
This phase marked the transition from prototype to pilot to full production scale.
Key wins:
- Real-time production monitoring and performance tracking
- AOI (Automated Optical Inspection), functional testing, and reliability checks on every unit
- Design and implementation of new packaging (transitioning from PP to cardboard for cost and quality gains)
- Localization of all branding elements—stickers, manuals, decals—to meet both brand and compliance standards
Key Outcome
From batch 1 to batch 5, we optimized sourcing and processes to bring down per-unit costs significantly.
In just 6 months, we scaled production from 1,000 to 3,000 units/month, without sacrificing quality.
Faster localization and production cycles enabled quicker market launches and restocks.
More vendor options meant more resilience and flexibility for future product iterations
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Beyond Manufacturing: Strategic Partnership
Upliance didn’t just need a factory. They needed a thinking partner, someone who could help them navigate the make-vs-buy dilemma, build local capabilities, and create a repeatable, scalable manufacturing playbook.
At Karkhana.io, we approached the engagement not just as manufacturers but as co-builders of their product journey.
From China to India, from import to localization, from pilot to production—this is how next-gen hardware gets built today.
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