Just within six years, an Indian component distributor grew into an EMS firm, and then went on to develop R&D capabilities, resulting in the filing of patents. What motivated this transition? From challenges to strategies, Chittaranjan Behera of JC Eletronica shares their journey with EFY’s Akanksha Gaur and Nitisha Dubey.
Q. Can you provide details about JC Eletronica and its business operations?
A. The company was founded in 2018 as a distributor of electronic components. Later, we established our research centre and entered product manufacturing in 2022. With India’s growing electronics industry, we aim to contribute to its progress. This is a first-generation company founded solely by me, with my wife Jageeta also serving as a director.
Q. What specific ODM services do you offer?
A. Our original design manufacturing (ODM) services encompass design, component procurement based on the customer’s Bill of Materials (BoM), and comprehensive printed circuit board (PCB) assembly, including surface mount technology (SMT), through-hole, and mixed-level assembly. We support prototyping, low-volume production, and high-volume manufacturing, ensuring flexibility across all project scales. Quality assurance is maintained through rigorous functional, in-circuit, and environmental testing. We also offer end-to-end logistics and supply chain management, enabling seamless delivery. Catering to businesses at all stages of growth, we manufacture PCBA and ECU components, serving both small and large enterprises with equal commitment.
Q. What Industries do you serve with your PCBA services?
A. We serve any sector using PCBAs, such as automotive and non-automotive.
Q. Which industry offers better opportunities in terms of volume and long-term business?
A. In terms of volume, the home appliance sector is more favourable. However, the automotive industry is more beneficial for long-term business and quality. Once a product is developed for the automotive industry, it can be sold throughout the vehicle’s lifespan, typically lasting 10 to 15 years, depending on the product category. For components like headlamps or taillamps, designs frequently change. However, changes are not as frequent for critical automotive parts such as engine components or powertrain systems. These products generally have a minimum sales cycle of around five years after production begins.
Q. Who are your key automotive clients, and what components do you supply to them?
A. That is our specialisation. We partner with Tier 1 suppliers and original equipment manufacturers (OEMs). Our top clients include leading companies such as Fiem, Foxconn, PV Clean, Aptive, and Minda. At the same time, on the OEM side, we collaborate with Mahindra, Escorts, Hero Electric, TVS, and several Indian electric vehicle (EV) manufacturers. We supply essential components like motors, PCBs, and car key parts, ensuring our products meet stringent quality standards verified by vehicle manufacturers before approval.
Q. What is your automotive component development cycle and collaboration process?
A. The development cycle for automotive components ranges from six months to a year, whereas a new vehicle launch typically takes around three years. We engage early with Tier 1 suppliers to ensure PCB quality for vehicles, as our PCBs are integrated into final OEM products such as sensors, keys, and fuel pumps. Our development process follows a tripartite collaboration model involving OEMs, Tier 1 suppliers, and manufacturers. While we supply motors and PCBs, other suppliers assemble the complete components.
Q. How is your product line contributing to energy efficiency and the evolving motor industry?
A. Our product line is closely related to power-efficient designs. In the automotive sector, we are developing fuel pumps and water pumps. Additionally, for home appliances, we are working on products such as exhaust fans, blower motors, AC motors, and water coolers—all designed with energy efficiency in mind. By 2026, the government is mandating further power reduction, similar to the transition from traditional bulbs to CFLs and now LEDs. The motor industry is following a similar path, evolving from induction motors to DC motors and now BLDC motors, which offer superior energy savings.
Q. What makes your BLDC motors cost-effective, high-quality, and different from others?
A. We maintain all essential standards, including International Organization for Standardization (ISO) certifications, manufacturing safety protocols, and environmental controls such as air and humidity management—features often lacking in other manufacturing units. Our strength lies in our in-house electronic design and manufacturing capabilities, which eliminate third-party involvement. We are also involved in electronic component distribution, allowing us to use 90 per cent of components distributed by us, hence reducing costs.
Q. How does your R&D team ensure product development, testing, and certification compliance in electronics and mechanics?
A. For research and development (R&D), there is a team of highly qualified engineers specialising in both mechanical and electronics domains. The electronics division is further divided into software and hardware. On the software side, we develop code using open-source platforms and integrate software from NXP microcontrollers. On the hardware side, we utilise simulation and design software to develop and design PCBs in-house. Our team designs products for mechanical components based on specific requirements, which are then integrated and delivered to customers. Testing is conducted according to customer guidelines, following the development validation planning (DVP) process, which includes 30 to 35 different tests. Some tests are performed in-house, while others are conducted through third-party certified labs such as ICAT and ARAI. These labs validate our products and provide certifications to meet the required standards and parameters.
Q. How do you ensure a seamless transition between different phases of R&D efforts?
A. To ensure a smooth transition between R&D phases, we follow a structured AQ-PQ (advanced quality and production quality) Plan, outlining the timeline for development. The process includes four key prototype phases. The A-sample stage validates basic functionality using early prototypes like scratch models or 3D-printed parts. B-samples refine the design with low-volume production using soft tooling. C-samples follow standard manufacturing workflows and undergo validation testing. The D-sample phase represents pre-production under full serial conditions, leading to production release if no major changes are needed. Critical issues are addressed at each stage to ensure design stability, minimise risks, and streamline the transition to mass production.
Q. What rapid prototyping techniques are utilised in your R&D process?
A. We leverage in-house 3D printing for mechanical components, enabling us to create prototypes within 2-3 hours. For bare PCBs, we rely on third-party suppliers who can deliver within 2-3 days, though at a higher cost. This allows us to streamline our prototyping phase while maintaining flexibility.
Q. How do you manage design iterations and engineering changes?
A. We follow the engineering change notification (ECN) and engineering change request (ECR) processes. Changes are initiated based on customer demands or internal requirements. Once a modification is finalised, the ECN is released, and customer approvals are obtained before implementation.
Q. What innovative technologies have you developed and patented?
A. Last year, we secured two patents, and this year, we expect to obtain approximately three more. One of our ongoing projects involves developing a sensor with an integrated EMC/EMI filter for DC motors. Some customers avoid using DC motors due to high noise levels, which often fail lab tests at ARAI and ICAT. To address this, we are designing a PCB incorporating filtration technology to ensure compliance with testing standards. We have applied for a patent for this innovation. The second patent involves a flow sensor designed to prevent corrosion caused by prolonged water exposure. Over time, water can lead to rust buildup, affecting sensor performance. The solution integrates a corrosion-resistant filter and sensor within the flow sensor module. This technology is beneficial for drinking water systems and storage tanks, where contamination can occur. Our light-flow sensor technology ensures reliable operation even in challenging conditions.
Q. How do you handle custom PCB design requests and changes?
A. We offer functionality-based flexibility, ensuring that minor design adjustments can be accommodated. We offer functionality flexibility rather than design modifications. Customers specify functional requirements, and we ensure feasibility. Change requests are accommodated, especially in prototyping (typically five to ten units), which has higher costs due to iterations. Once validated, the design moves to mass production, reducing per-unit costs.
Q. How do you manage complex PCB designs, including multilayer boards?
A. We currently develop up to six-layer PCBs. While 16-layer PCBs exist, we only design them based on customer demand, ensuring a customer-driven approach.
Q. Can you share details about the IATF certification mentioned on your website?
A. Before production can commence, obtaining certifications like the International Automotive Task Force (IATF) is essential in the automotive sector. A third-party agency from Germany certifies suppliers for automotive parts, a process that typically takes between one and one and a half years and involves strict procedures and guidelines. We rigorously follow these guidelines to ensure our product quality and processes align with the required standards, thereby eliminating any risk associated with our product labels. Every stage is thoroughly monitored in accordance with the established procedures.
Q. How do you source, manufacture, and assemble electronic components while ensuring quality and reliability?
A. India has several certified suppliers, including those approved by IATF, with whom we collaborate when needed. We manufacture PCBs in India and, after sourcing all necessary child parts, assemble them in-house at our facility. Maintaining the strength and quality of these components throughout the production process is critical to ensuring the reliability and performance of our PCBs.
Q. Why should a customer choose your PCBA services?
A. We provide a one-stop PCB solution, integrating design, sourcing, and manufacturing while leveraging a robust supplier network to optimise cost and lead time. By conducting competitive benchmarking, we analyse rival products to enhance our designs for greater performance and efficiency. Our PCBs consistently meet high-quality standards while remaining cost-effective. As industry pioneers, we were the first in India to locally manufacture a steamer controller locally, offering a reliable, high-quality alternative to imports. With strong design capabilities, dependable supply chains, and competitive pricing, we deliver high-performance, long-lasting PCB solutions.
Q. How do you manage your supply chain efficiently?
A. We have a dedicated supply chain team and approximately 40 to 45 authorised distributors in our pipeline. We place purchase orders with our suppliers based on customer demand and three-month projections. Our purchase team reviews and finalises orders every month, ensuring smooth procurement and inventory management.
Q. Can JC Eletronica efficiently manage low-volume production runs? What is the minimum order quantity (MOQ) you can accommodate?
A. Yes, we can efficiently manage low-volume production runs, and we do not impose strict minimum order quantity requirements. If the order quantity is low, the pricing is adjusted accordingly to account for setup costs. In the case of mass production, the setup time is significantly reduced, which results in lower costs. Our facility is capable of handling orders ranging from as few as 10 pieces to as many as 1,000 pieces, ensuring that we can accommodate various production needs.
Q. What is your current production capacity, and what strategies are you implementing to scale up for larger production volumes?
A. In our SMT line, we measure CPS (components per second) to track how many components are placed on a board per hour. Currently, our production line operates at 48,000 CPS, with 60% of our machine capacity utilised. To prepare for future demand, we are procuring additional machines. We follow a similar approach for other divisions, such as lighting and assembly lines. If our existing machines exceed the 60 per cent threshold, we plan for expansion. Otherwise, we maximise our current production capacity before investing in new equipment.
Q. What sets your SMT line apart, and how do you select your machines?
A. High-precision, efficient equipment, carefully selecting suppliers based on specifications, performance, accuracy, and cost-effectiveness are our priority to ensure optimal production quality. We use advanced Japanese machines like Panasonic for superior accuracy and efficiency, maintaining the highest production standards.
Q. Do you use AOI or X-ray inspection?
A. Currently, we use automated optical inspection (AOI). However, we plan to install offline X-ray inspection, subject to customer requirements.
Q. As an EMS firm, what common issues arise after PCB delivery, and how do you address them?
A. As an EMS provider, we ensure strict quality checks, but occasional PCB issues may occur. To prevent transit damage, we use robust packaging. Our multi-level inspection process includes AOI for visual defects, as I said, in-circuit testing (ICT) for electrical integrity, functional testing for performance, and 100 per cent visual inspection before packaging. These measures minimise post-delivery concerns.
Q. Can you explain your validation lab capabilities?
A. Our validation lab features testing chambers for temperature, humidity, dust, rain, and thermal cycling to simulate real-world conditions and ensure product reliability. We perform two types of validation: Functional testing, which ensures that product fabrication meets customer requirements. And, field validation, where tests are conducted both in-house and via third-party labs, covering tests such as EMC, EMI, vibration, and temperature stress. Additionally, our products comply with different certification standards, ensuring adherence to global quality and environmental regulations.
Q. Are your testing machines purchased domestically or imported?
A. Most of our testing equipment is imported from Japan, Korea, and China.
Q. What is your payment cycle for different customers?
A. Average payment terms are 60 to 90 days.
Q. How many employees do you have? And how is the organisation structured?
A. We have 50 permanent employees and 35 casual/contractual staff. We categorise our operations department-wise, like production, quality, marketing, materials, human resources (HR), each function headed by a departmental head.
Q. Are you planning any investments or government funding?
A. We have not taken any government or external funding. We reinvest our profits into the business annually.
Q. What is your current manufacturing facility setup?
A. We have one setup here in Manesar. A second manufacturing facility is currently under construction nearby and is set to launch in July. The plant is equipped with a Panasonic SMT line, Panasonic placement machines, DEK screen printers, MIRTEC SPI machine, JT reflow ovens, MIRTEC AOI, manual and automatic router/de-paneliser, customised automated test equipment, Hioki in-circuit testers, and an environmental and thermal shock chamber.
Q. Are you planning to manufacture the same products in the new facility?
A. The expansion is to increase our manufacturing capabilities with upgraded SMT lines and Test Equipment.
Q. What are your expansion plans for the next five years?
A. We recently opened an office in Hong Kong to expand our global business. This year, we are setting up a new SMT line and additional manufacturing facilities. Next year, we plan to establish a dedicated motor division, likely in Manesar.
Q. Are you planning to expand beyond Manesar?
A. Yes, we are considering expansion in South India, where major clients like Foxconn, Flextronics, and LG are located. Mahindra is also present in that region, making it a strategic choice for future growth. Although this is subject to business feasibility.
Q. What challenges do you face in the industry?
A. The biggest challenge is supply chain disruptions, including delays in supplier fulfilment and high lead times. To mitigate this, we maintain extra stock for two to three months and plan accordingly to ensure seamless operations.
Q. What is your biggest technical challenge right now?
A. Manpower availability remains our most significant challenge, as access to technology and suppliers is no longer a constraint.
Q. How do you manage waste disposal?
A. We have partnered with an external vendor who collects and processes our waste monthly. Most of our waste is non-harmful materials like copper, fibre, and PCB scraps. Since we primarily use surface-mount device (SMD) components, our waste generation is minimal.
Q. What was your last fiscal growth, and what are your plans for the next two years?
A. Last year (2023-24), our revenue was approximately ₹300 million. We are likely to close 2024-25 at approximately ₹450 million. For the year (2025-26), it is projected to be around ₹600 million.
