What makes a manufacturing partner truly end-to-end? How does ODM capability give brands a market edge? In a conversation with EFY’s Nitisha, Robin Bunker from Mefron Technologies explains how the company’s integrated EMS infrastructure, strong R&D, and design-led approach enable white-label product delivery across sectors like consumer electronics, EVs, and medical devices, driving speed, innovation, and cost efficiency.
Q. How does Mefron’s end-to-end EMS and ODM expertise enable white-label product delivery?
A. At Mefron, our in-house R&D team focuses on customising and developing products that are ready for our customers to launch under their own brand. Our entire production process, covering design, PCB assembly, tooling, moulding, wire harness, and box build, is carried out under a single roof. This streamlined setup allows us to deliver products quickly, with high quality and at lower costs. We also handle warranty and end-of-life support to ensure lasting customer satisfaction.
Q. Which industries does Mefron focus on?
A. At present, our focus is on four core segments: Consumer Electronics, Automotive & EV, Medical, and Defence & Aerospace—because they are high-growth industries with increasing demand for innovative and reliable electronic solutions. These sectors often require advanced technology, strict quality standards, and tailored manufacturing capabilities, aligning perfectly with our expertise. By concentrating on these key segments, we aim to leverage our strengths, drive sustainable growth, and fulfil the evolving needs of our customers.
Q. What types of products do you specialise in?
A. With an in-house product design and development team, we specialise in the manufacturing of high-tech biometric-based security products. Additionally, we provide PCBAs and charging solutions to our EV clients. Our manufacturing capabilities also extend to a wide range of grooming and personal care products, mobile accessories, and home and kitchen appliances.
Q. Do you provide box build services?
A. Yes, Mefron provides box build assembly services. While box build is considered relatively simple compared to design services, it remains an integral part of our offerings. Mefron adds more value through design services, which allow for greater control over the supply chain and opportunities for cost optimisation through value engineering.
Q. Can you describe your product development lifecycle?
A. The hardware product development lifecycle begins with defining requirements, system architecture, and selecting components. Engineers develop schematics, design PCB layouts, and create mechanical enclosures. Prototypes are built to test functionality, thermal performance, and mechanical fit. The product undergoes rigorous electrical, functional, and regulatory compliance testing (EMI/EMC, BIS, CE, FCC). Based on test feedback, designs are refined for performance, manufacturability, and cost. A pilot run validates production processes and quality controls. Once approved, mass production starts with strict quality checks. Post-production support includes warranty handling, field issue resolution, and managing component lifecycle for sustained reliability and customer satisfaction.
Q. What is Mefron’s production capacity?
A. We have a monthly capacity of producing approximately one million PCBs via our SMT lines and around 300,000 to 400,000 assembled units through box build processes. It currently operates with around 600 employees and can scale up as needed.
Q. Where is your manufacturing facility located?
A. Our manufacturing facility is located near Ahmedabad, Gujarat, with a setup spanning 150,000 square feet (approx. 13935.456 square metres). Mefron distinguishes itself as one of the few EMS companies operating in Western India, drawing customers not only from Gujarat but also from Maharashtra and Rajasthan.
Q. Are all manufacturing activities conducted in-house?
A. Most of the manufacturing activities, including SKD assembly, injection moulding, SMT, and wire harnessing, are conducted in-house. However, for critical components like microprocessors, ICs, displays, camera modules, and batteries, we source from external vendors, predominantly from China.
Q. Do you customise existing reference designs?
A. Yes, we offer high levels of customisation on existing reference designs. Since we are adept at building products from scratch, modifying existing designs is a relatively straightforward task. An example would be changing the power circuitry to accommodate different input voltages, power sources, or battery types, or substituting components for cost optimisation.
Q. What type of equipment is used in manufacturing?
A. We utilise new, high-quality equipment, including Shiborah injection moulding machines (up to 300 tons), Mitsubishi VMC and EDC machines, and Fuji NXT 3 SMT lines capable of 0201 precision. AOI systems, in-circuit testing, and custom jigs are also part of the setup.
Q. Do you use new or second-hand machinery?
A. All machines at Mefron are new. We believe in maintaining high-quality output and operational uptime, which is why we avoid second-hand equipment that may lead to frequent breakdowns and quality issues.
Q. What certifications and compliance standards does your facility adhere to?
A. Mefron’s manufacturing facility is certified to ISO 9001, ISO 14001, and 13485 standards. We are also undergoing certifications for IATF (Automotive)-LOC received, AS9100 (Aircraft, Space, and Defense. We strictly ensure RoHS compliance and adhere to rigorous environmental and ethical standards in all our operations. Additionally, we actively support our customers in obtaining essential certifications such as BIS, UL, and CE, helping them access global markets confidently and sustainably.
Q. How do you handle high-mix, low-volume versus high-volume production?
A. We prefer high-volume, low-mix production due to our current growth phase and scalable infrastructure. The focus is on achieving efficiency and cost-effectiveness through mass production.
Q. What is your typical lead time?
A. Lead times vary depending on product complexity. For a new product, it typically takes around three months from order to delivery. For existing products, delivery timelines are usually within a month.
Q. How do you manage peak season demand?
A. Peak demand is anticipated and planned well in advance. Our experience in the industry enables us to accurately forecast seasonal spikes, particularly during the festive season. The facility can scale from two to three shifts, and additional rented space is available for overflow production.
Q. How do you handle supply chain disruptions?
A. We mitigate supply chain risks through long-standing relationships with global suppliers, particularly in China. An office in China helps maintain close contact with suppliers. Strategic stocking and demand forecasting also help minimise disruptions.
Q. What in-house testing capabilities are available?
A. We conduct AOI for SMT, in-circuit testing, and functional testing for PCB and box builds. Environmental stress tests, including salt spray, humidity, and heat testing, are also conducted. Custom jigs and software are developed for specific customer needs.
Q. Do you support third-party testing?
A. Yes, we support third-party validation. We have previously sent products to overseas laboratories, such as SGS in Hong Kong, for validation on behalf of international clients.
Q. How do you handle quality complaints?
A. Quality issues are rare due to our strict adherence to ISO 9001 processes. If a problem arises, Mefron identifies the root cause through techniques such as DFMEA, fishbone analysis, and the 5 Whys.
Q. How do you maintain cost competitiveness?
A. We emphasise design optimisation, process automation, strategic sourcing, and proximity to suppliers through our China office. We also source locally whenever possible to reduce costs and lead times.
Q. What are your sustainability practices?
A. We follow ISO 14001 environmental standards and emphasise ethical e-waste disposal and recycling. Packaging materials are disposed of in an eco-friendly manner.
Q. How big is your R&D team, and how much is invested in R&D?
A. The R&D team, housed within our group company, includes over 200 professionals. Approximately 25–30% of staff remuneration is allocated to R&D, reflecting a significant investment in innovation.
Q. How do you ensure customer IP protection?
A. Customer IP is protected through strict NDAs, cybersecurity policies, and controlled access systems. Employees are trained regularly on data security and confidentiality.
Q. Are your customers mostly domestic or international?
A. Currently, approximately 15% of our clients are international, but this percentage is expected to increase. The company collaborates with clients in the US, Europe, and Australia, and is actively expanding its global presence through exhibitions and targeted marketing efforts.
Q. What is your current headcount, and how has it changed?
A. We currently employ over 600 people, a number that has steadily increased since the company’s inception. Approximately 20% are white-collar professionals, while the remaining 80% are blue-collar workers.
Q. How is your workforce distributed functionally?
A. Most blue-collar workers are in production. Among white-collar staff, approximately 5% are in sales and delivery, 7–8% are in production and quality, and the remainder are in support roles, such as HR and administration.
Q. What was your recent turnover, and what are your growth plans?
A. We had our group company turnover of approximately $70 million in the last financial year. Our company aims to surpass $115 million in the next two years.
Q. What are your future investment and expansion plans?
A. We plan to expand both vertically and horizontally. New facilities are being considered in Delhi NCR and Bengaluru. We are also exploring further presence in Taiwan, Korea, Japan, and the US. Plans are underway to establish a new subsidiary specialising in component manufacturing, potentially supported by the Indian government’s incentive schemes.
