Exclusive Interview with Mr. Rupak Jha, Founder & COO, E-Fill Electric
E-Fill Electric, a leading name in the EV charging sector, has made significant strides since its inception in 2019. The company, founded by Mayank Jain and Rupak Jha, has been at the forefront of providing reliable and innovative EV charging solutions in India. In this exclusive interview, Mr. Rupak Jha shares the journey of E-Fill Electric, the challenges faced, the state-of-the-art technologies employed, and the future trends in the EV charging infrastructure.
- Can you walk us through the journey of E-Fill Electric from its inception in 2019 to becoming a leader in the EV charging sector?
E-Fill Electric was founded by Mayank Jain and Rupak in 2019. Our initiative was driven by our collective expertise in automotive research and development and a shared passion for sustainable mobility solutions. While researching the EV industry, we recognized India’s pressing need for reliable charging infrastructure and localized e-mobility solutions. The initial foray into the EV space focused on charging solutions. We soon discovered that the existing charging infrastructure was unreliable and underutilized. When we started back in 2019, the charger market was new, and the utilization at that time was low.
Moving forward into 2023 and beyond, E-Fill Electric remains committed to pushing the boundaries of EV charging technology. We continue to innovate with next-generation charging solutions that support ultra-fast charging, bidirectional energy flow, and vehicle-to-grid connectivity, laying the foundation for a smarter and more interconnected electric mobility ecosystem.
Our vision extends beyond borders, as we explore opportunities to replicate our success in international markets and contribute to the global transition towards sustainable transportation solutions. Through relentless innovation and unwavering dedication, E-Fill Electric is shaping the future of electric mobility, driving us toward a cleaner, greener tomorrow
- What specific challenges did you face during the initial stages of establishing E-Fill Electric, and how did you overcome them?
During the initial stages of establishing E-Fill Electric, we encountered significant challenges that reshaped our approach in the EV sector. Initially focusing on developing reliable charging solutions for the Indian market, we found that the existing infrastructure was inadequate and underutilized when we began in 2019, hindering widespread electric vehicle adoption.
This setback prompted E-Fill Electric to pivot towards the Indian e-rickshaw market. Despite being in existence for nearly a decade, this sector was largely served by unorganized players heavily reliant on imported components. This dependence often led to quality control issues and parts availability concerns, impacting safety and operational efficiency.
As a result, we re-evaluated our strategy and explored alternative segments within the EV market. This shift compelled us to innovate our product offerings, not only enhancing charging infrastructure but also focusing on improving the reliability and safety of systems tailored EVs. Collaborating closely with local manufacturers and regulatory bodies, we prioritized developing indigenous solutions that could meet the unique operational demands of e-rickshaw fleets across India.
Implementing stringent quality control measures and forging partnerships with reliable suppliers became integral to ensuring the consistent availability of high-quality components. This proactive approach not only mitigated risks associated with imported parts but also built trust among customers.
- E-Fill Electric is known for its state-of-the-art manufacturing facilities. Can you describe the technologies and processes that set your facilities apart?
E-Fill Electric takes pride in its cutting-edge manufacturing facilities, Over nearly four years, we have dedicated resources to enhance our design, development, infrastructure, and plant facilities. Our technological prowess is evident through a suite of advanced equipment including 3D printers, prototype testing machines, EB simulators, LCR meters, oscilloscopes, and current probes, ensuring precise development and testing processes.
In addition to our robust hardware capabilities, we leverage sophisticated software tools such as SolidWorks, Catia, and Altair for PCB and firmware design, enabling us to stay at the forefront of technological innovation. Our manufacturing operations encompass dedicated assembly lines for three-wheelers and chargers, batch production setups for chargers, and streamlined line production for three-wheelers. Each product undergoes rigorous quality assurance protocols, conducted using in-house EV simulators and various load tests, ensuring that only the highest standards of quality are met before dispatch.
- With ARAI-approved AC and DC EV chargers spanning various power outputs, how do you ensure the quality and reliability of your products?
With ARAI-approved AC and DC EV chargers offering a range of power outputs, ensuring the quality and reliability of our products is paramount. Our AC chargers for charging stations are already 95% localized, with only display ICs imported. We are actively advancing towards greater localization, targeting 60% to 70% for critical components in both AC and DC chargers. This commitment, coupled with controlled production processes and a dedicated in-house R&D team, underpins the high standards of quality and reliability we uphold in our products.
- E-Fill Electric has a franchise network spanning over 25 states and districts in India. What strategies have you implemented to achieve such extensive coverage?
Regional Targeting: We meticulously identify states with high growth potential, favorable regulatory environments, and a strong target market for electric vehicle adoption.
Tiered Franchise Structure: Our tiered structure features master franchises overseeing smaller franchise units in specific regions, ensuring localized management and effective market penetration.
Digital Marketing Strategies: Leveraging online platforms, we efficiently connect with potential franchisees nationwide, enhancing outreach and engagement through targeted digital campaigns.
Pan-India Service Network: We maintain a comprehensive service network across the country, supported by remote assistance capabilities, ensuring prompt support and operational continuity for our franchise partners.”
- Being the sole manufacturer of lithium-ion battery-powered electric three-wheelers in India is a significant achievement. What drove your decision to enter this market segment, and what impact has it had?
When we started back in 2019 the charger market was new and the utilization at that time was low. The setback forced us to re-evaluate our approach and explore alternative segments within the EV market. We, then, settled on the Indian e-rickshaw market. Though the industry has been thriving for over a decade, it’s dominated by unorganized players. Also, these players often rely heavily on imported components, leading to issues with quality control and parts availability.
- Innovation is at the heart of E-Fill Electric. Can you elaborate on the R&D initiatives that have led to securing over seven patents?
Our design, development, and testing equipment include 3D printers, prototype testing machines, EB simulators, LCR meters, oscilloscopes, and current probes. Additionally, we utilize software like SolidWorks, Catia, and Altair for PCB and firmware design.
- With a monthly production capacity of 1300 AC chargers, 290 DC chargers, and 300 E-rickshaws, how do you manage and optimize your manufacturing processes?
We do this by following:-
Fostering a Culture of Continuous Improvement (Kaizen):
Encouraging employees to identify and suggest process improvements. Holding regular brainstorming sessions, implementing employee suggestion programs, and rewarding successful improvements.
Building Strong Supplier Relationships: Partnering with reliable suppliers to ensure a steady flow of materials and minimize production disruptions..
Implement Effective Production Planning and Scheduling:
Establishing a Robust Quality Management System
Prioritizing Quality: Implementing quality control procedures at every stage of production, conducting regular inspections, and investing in quality control equipment.
Investing in Employee Training:
Embracing Preventative Maintenance: Schedule regular maintenance for equipment to prevent breakdowns, minimize downtime, and extend equipment lifespan.
Standardizing Processes: Develop standardized procedures for all aspects of production to ensure consistency and efficiency.
- How has your background in mechanical and automation engineering and experience in the oil and gas industry influenced your approach to leading E-Fill Electric?
My background in mechanical and automation engineering, coupled with my experience in the oil and gas industry, has been invaluable in leading E-Fill Electric. Here’s how it translates:
- Engineering Expertise: My engineering knowledge is crucial for product development and other technical aspects. I can understand the intricacies of electric vehicle charging systems, identify potential issues, and work with the engineering team to develop innovative solutions.
- Operational Efficiency: In my previous role within the oil and gas industry, a significant focus was on operation handling. This experience directly translates to managing operations at E-Fill Electric. I understand the importance of efficient workflows, safety protocols, and ensuring smooth day-to-day functioning.
- Business Acumen: My prior experience running a business has been instrumental in setting up and running E-Fill Electric. I understand the challenges and opportunities in the electric vehicle charging market, allowing me to make informed decisions about strategy, resource allocation, and overall business growth.
- What future trends do you foresee in the EV charging infrastructure, and how is E-Fill Electric preparing to adapt to these changes?
Faster Charging and Higher Power:
- Ultra-Fast Charging (UFC): Charging times will continue to plummet, with stations offering megawatt (MW) charging capabilities. This can alleviate range anxiety and encourage long-distance travel with EVs.
- Adaptation: E-Fill Electric is investing in developing UFC-compatible chargers. Upgrading existing infrastructure may be necessary in the long run.
Wireless Charging:
- Convenience and Efficiency: Wireless charging pads could eliminate the need for cables, offering a more user-friendly experience.
- Adaptation: E-Fill Electric can monitor the development of wireless charging technology and consider incorporating it into future charging station designs.
Diversification of Charging Options:
- Home and Workplace Charging: Demand for convenient home and workplace charging solutions will rise.
- Public-Private Partnerships: E-Fill Electric can collaborate with workplaces and residential complexes to install charging stations, expanding their reach beyond traditional public locations.
Focus on Sustainability:
- Renewable Energy Integration: Charging stations powered by solar or wind energy will be increasingly sought after.
- Adaptation: E-Fill Electric can explore integrating renewable energy sources into their charging stations, showcasing their commitment to sustainability.
