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Sheet metal stamping, where progressive and stage tools with autoloaders are used to achieve the high precision needed to manage an ethanol flame
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Bespoke processes for a bespoke product
KOKO’s factory was built from the ground-up to produce its highly specialised bioethanol cooker. The highly-capable manufacturing team tailored all the equipment, tools and fixtures used to meet the stringent design requirements of the cooker.
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Even the large-scale manufacturing processes involved were adapted and customised so that high-quality products are delivered in the lowest cycle times. This includes
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Considering the nature of the product, the quality of each part is vital to ensuring that KOKO customers have a positive experience. Each part is therefore subject to rigorous testing, and undergoes a series of in-line quality checks to ensure that it meets the highest quality standards, such as
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Pressurised air leak test, which tests all the fuel joints in metal and plastic parts |
Nugget tests, for pull-load testing in the welding process |
Functional tests, custom-made for sub-assembly functionality |
Performance tests for fully assembled cookers in every batch |
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Specific critical parts are also regularly submitted to accredited labs, where they undergo tests like
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Assessing physical, chemical and thermal material properties |
Assessing performance under longer durations, such as salt-spray tests for powder-coated parts |
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At the heart of the factory is a state-of-the-art toolroom. This toolroom is capable of full-scale development as well as high-quality tool maintenance that can increase tool life and deliver sustained output. The toolroom also supports the design, development and upkeep of fixtures, jigs and gauges across the shop floor.
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Mutually beneficial relationships with suppliers
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KOKO Manufacturing has invested considerable resources in building a robust supply chain that ensures zero disruptions to the manufacturing process and can support higher efficiencies. As the cookers and canisters require over 100 parts, KOKO has established deep relationships with over 60 suppliers, with multiple suppliers being leveraged to source critical parts.
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In an effort to ensure sustainability in our supply chain, most of the parts are sourced from local suppliers, with only a handful being provided by suppliers overseas. By keeping the bulk of our supplier base local, KOKO not only minimises environmental impact but also ensures faster turnarounds of inventory with fewer supply risks.
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Every supplier undergoes a rigorous onsite evaluation before being onboarded, and they must qualify through a detailed PPAP (Production Part Approval Process) before commencement. This helps verify that they clearly understand the design specifications and requirements and that they can consistently meet those requirements during actual production runs.
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KOKO Manufacturing also believes that a fair business relationship based on trust and mutual respect is critical to success. As a result, while suppliers are expected to adhere to KOKO’s stringent quality and supply guidelines, they are also supported in their development. KOKO Manufacturing ensures suppliers get the right kind of guidance and training regularly to improve their operations.
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As the operations grew, KOKO has built considerable expertise in shipping products to various international locations in an optimised and disruption-free manner. The organisation has developed deep relationships with trusted freight partners who have the right knowledge and a strong presence in international markets. All shipments are optimised to reduce delivery time and cost, with finished goods being dispatched every week and being ready for distribution in the market in just 5 weeks.
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Global expansion |
KOKO’s ambitions need to be supported with a suitable global manufacturing footprint. KOKO Manufacturing has developed a highly competent global manufacturing engineering team that can quickly and effectively
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Evaluate multiple business models based on region-specific needs to support setting up a manufacturing facility locally |
Develop and design the right equipment, toolings, fixtures, jigs and processes (whether manual, semi-automated or fully automated), as well as efficient factory layouts |
Conduct field studies to evaluate and implement an optimised supply chain |
Evaluate capable contract manufacturing, component, tooling and equipment suppliers by applying an informed techno-commercial lens |
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Design and implement an end-to-end value stream |
Develop alternative methods and processes to optimise manufacturing |
Provide extensive training through custom modules to build the right skills and capabilities for the new location |
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As a result, KOKO’s global expansion team has developed and racked various models for efficiently setting up optimised facilities across the world. To ensure consistency in the production process and quality levels across all manufacturing sites, KOKO Manufacturing has defined standard equipment and processes that can be quickly deployed.
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Uncompromising quality
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KOKO is determined to ensure we only produce the best quality products for our customers. Through highly capable processes, quality controls and stable toolings, KOKO Manufacturing generates world-class quality yield that consistently exceeds customer expectations. KOKO Manufacturing is also ISO 9001:2015 certified.
Our rigorous quality checking starts before production even begins. Every single part produced in the factory goes through a CTQ (Critical To Quality) dimensional analysis. Before starting a production batch, parts are submitted for CTQ. It is only after the part clears the assessment that batches are produced. KOKO’s expertise and knowledge has resulted in a shift in how quality is approached. KOKO Manufacturing now focuses on quality assurance, where processes and systems are defined that ensure high-quality requirements will be fulfilled. This is a distinct shift from quality control, which focused more on inspection and management of the quality during production. Once our cookers clear our internal assessments, the cookers remain sealed and untouched through their journey through various ports and logistics channels, until it is received by the end customer. |
