How white goods manufacturers can achieve agility in manufacturing processes

In an interaction with Industry Outlook, Sukrit Bharati, MD, Virtuoso Optoelectronics shares his views on how the current market for white goods manufacturing is witnessing steady growth driven by rising consumer demand for energy-efficient and technologically advanced appliances and more.

The current market for white goods manufacturing is witnessing steady growth driven by rising consumer demand for energy-efficient and technologically advanced appliances. Manufacturers are focusing on product innovation, customization, and sustainability to stay competitive. How do you see the current evolution of this industry? 

The current evolution of the white goods manufacturing industry is characterized by a shift towards energy efficiency, technological advancements, customization, and sustainability. Manufacturers are adapting to changing consumer preferences and market dynamics, focusing on innovation, and striving to create products that meet the needs of a more conscious and demanding consumer base.  This demand is driving manufacturers to invest in research and development to create innovative and eco-friendly appliances.

To stay competitive, manufacturers are heavily focusing on backward integration, localization, and product innovation. India as a country was importing a significant portion of its white goods requirement till very recently. Now with the government policies, increasing demand, and cost pressure companies started focusing on local manufacturing. Which is further adding to the entire ecosystem locally. This will help not only develop the local market but also to start laying the foundation for making India a prominent exporter of white goods.

Sustainability and environmental considerations are other key focuses for manufacturers. They are incorporating eco-friendly materials, optimizing energy consumption, and reducing water usage in their appliances. Recycling initiatives, extended producer responsibility programs, and product life cycle assessments are becoming more common, reflecting a commitment to reducing the environmental impact of white goods.

The evolution of the industry extends beyond the final product. Manufacturers are also focusing on improving supply chain efficiencies and manufacturing processes. This includes adopting lean manufacturing principles and optimizing logistics to reduce costs, enhance productivity, and shorten lead times. The white goods manufacturing industry is expanding globally, with emerging markets experiencing substantial growth. Rapid urbanization, rising disposable incomes, and an increasing middle-class population in developing countries are driving demand. Manufacturers are capitalizing on these opportunities by expanding their presence in these markets through partnerships, joint ventures, or establishing local manufacturing facilities.

Keeping up with rapid technological advancements is a significant challenge for white goods manufacturers. How should research and development be approached to keep incorporating new features, improving energy efficiency, and integrating smart technologies?

White goods manufacturers should approach research and development by leveraging market insights, fostering collaborations, adopting agile development processes, investing in internal R&D capabilities, prioritizing key areas, continuously learning and adapting, and ensuring regulatory compliance. By embracing these strategies, manufacturers can effectively incorporate new features, improve energy efficiency, and integrate smart technologies to meet the demands of a rapidly evolving industry.

Manufacturers should allocate dedicated resources and budgets for internal R&D activities. This includes establishing R&D teams with diverse expertise, investing in research facilities and equipment, and fostering a culture of innovation. By nurturing an environment that encourages experimentation and exploration, manufacturers can stay at the forefront of technological advancements. Given the multitude of technological advancements, it is crucial for manufacturers to prioritize their R&D efforts. This involves identifying key areas where technology integration and energy efficiency improvements can have the most significant impact. By focusing resources on critical areas, manufacturers can maximize the value and relevance of their R&D investments.

R&D is an ongoing process, and manufacturers should foster a culture of continuous learning and adaptation. This includes staying updated on the latest technological developments, attending industry conferences and seminars, and encouraging cross-functional knowledge sharing within the organization. Regularly evaluating and adjusting R&D strategies based on market feedback and emerging trends is essential to remain competitive and relevant in the market.

R&D strength is going to play a significant role for the industry in the next 10 years and for us to develop this capability we have to start small with the ambition of finishing big.

Manufacturers face the challenge of meeting stringent energy efficiency standards and complying with environmental regulations. How can they design appliances that consume less energy while maintaining performance and durability?

Designing energy-efficient appliances while ensuring performance and durability is indeed a significant challenge for manufacturers to meet stringent energy efficiency standards and comply with environmental regulations. Achieving improved product efficiency requires a combination of factors including process efficiency, component efficiency, design efficiency/optimization, and the evolution of technology.

Process efficiency involves optimizing manufacturing processes to minimize energy waste and enhance overall efficiency. Manufacturers can streamline production techniques, reduce material waste, and implement energy-efficient practices throughout the manufacturing cycle. Component efficiency focuses on selecting energy-efficient components and materials for appliances. Manufacturers can prioritize components with low energy consumption and high energy conversion efficiency, such as advanced motors, efficient compressors, and insulation materials with excellent thermal properties.

Design efficiency/optimization plays a vital role in maximizing energy efficiency. Manufacturers can explore innovative designs that optimize airflow, minimize heat loss, and incorporate smart controls and sensors to regulate energy usage based on actual needs. Additionally, improving overall ergonomics and user experience can encourage energy-saving behaviors. Keeping up with the evolution of technology is crucial for manufacturers. Investing in research and development enables the integration of the latest energy-saving technologies into appliances. Advancements in materials science, electronics, and software can be leveraged to create more efficient and intelligent appliances that consume less energy without compromising performance or durability.

By considering and implementing improvements in process efficiency, component efficiency, design efficiency/optimization, and embracing evolving technologies, manufacturers can successfully design appliances that meet stringent energy efficiency standards, comply with environmental regulations, and offer optimal performance and durability.

White goods manufacturers need to adapt to changing consumer preferences, which can pose challenges in terms of product design and functionality. How can they achieve the required agility in manufacturing processes and efficiency of product lifecycle management?

Agility to meet customer requirements comes from having a strong collaborative component/supplier ecosystem available locally. It also involves being able to design and optimize product designs in-house. Also process dynamism in terms of manufacturing, sourcing, and SCM plays an important role.

Finally, product designs that differentiate themselves and appeal aesthetically to the customer should be designed in a manner that can be produced without adding manufacturing complexity to ensure smooth delivery.

By implementing these strategies, white goods manufacturers can achieve the required agility in manufacturing processes and efficiency in product lifecycle management. Adapting to changing consumer preferences becomes more manageable, enabling manufacturers to stay competitive in the dynamic market landscape.

Ensuring consistent product quality and reliability throughout the manufacturing process is crucial. What kind of quality control measures must be in place to address any potential issues to minimize product failures, warranty claims, and customer dissatisfaction?

Quality in manufacturing is dependent on 3 major factors: Design, Raw Materials Used & Process. Each of the factors requires meticulous planning and consistent improvement actions. Being an OEM/ODM we at VOEPL take all 3 factors very seriously and try to ensure that every product that we ship out delights our consumers which will help us satisfy the expectation of our customers.

To ensure consistent product quality and reliability throughout the manufacturing process, white goods manufacturers must implement robust quality control measures. Manufacturers should conduct rigorous testing for critical components, functionality, safety standards, and adherence to specifications. Manufacturers should maintain stringent supplier quality management processes. This involves evaluating and selecting reliable suppliers who meet predefined quality standards. Regular audits and inspections of supplier facilities can ensure that the raw materials and components used in the manufacturing process meet the required quality criteria.

Documented quality standards and procedures should be established that encompass all aspects of the manufacturing process. This includes defining quality checkpoints, inspection criteria, and testing methodologies. Documented procedures provide guidelines for employees, ensuring consistency and adherence to quality standards throughout the production process.

They should establish effective channels for collecting customer feedback and managing complaints. This includes setting up customer support systems and feedback mechanisms to promptly address any concerns or issues reported by customers. Analyzing customer feedback helps manufacturers identify recurring problems, implement corrective measures, and continuously improve product quality and reliability. Most importantly, ongoing training and skill development for employees are crucial to ensure consistent quality control. Manufacturers should provide training programs on quality standards, testing techniques, and problem-solving methodologies. Well-trained employees understand the importance of quality control and play a critical role in identifying and addressing potential issues during the manufacturing process. Customer devices are also a vital part, and the companies selling these white goods need to ensure them.

With the integration of smart features and connectivity options in appliances, manufacturers face challenges in ensuring the security and privacy of customer data. How can they ensure data protection, address cybersecurity risks, and comply with data privacy regulations?

Manufacturers integrating smart features and connectivity options in appliances face challenges in ensuring the security and privacy of customer data. To address these concerns, they can adopt specific measures. Firstly, having local hosting of data by storing it within the appliance itself reduces the risk of unauthorized access and data breaches. Secondly, manufacturers should closely adhere to government protocols and guidelines to ensure compliance with data privacy regulations and enhance data protection. Ensuring maximum data anonymity involves collecting and storing customer data in an anonymized or pseudonymized format, minimizing the risk of individual identification. Additionally, processing information on user devices through on-device processing or edge computing reduces the need for data transmission, minimizing the risk of unauthorized access. By implementing these measures, manufacturers can mitigate cybersecurity risks, protect customer data, and comply with data privacy regulations in the context of smart appliances.