The HVAC Project

Every day, ATC seeks to provide innovative solutions to our customers' projects. With years of experience in HVAC climate control assembly and test systems, we're positioned as leaders in the industry.

Our customers count on us to provide solutions that can achieve very short delivery schedules and flexible solutions to accommodate their diversity of design. On a recent project, ATC designed and built three separate but identical pallet lines where HVAC units were assembled and tested.

The Challenge

As we worked with our customer, we targeted their need to ensure that workflow was maintained and that defective parts and faulty processes were kept to a minimum. Our ultimate goal was helping our customer reduce costs by providing a quality solution. In this case, it meant ensuring the HVAC units were thoroughly e-tested and function tested after assembly. For our customer, these vital tests could prevent outrageous warranty costs or shortened product lifecycles.

The Solution


By incorporating three identical palletized assembly lines and using lean cells adjacent to the assembly loop, we provided our customer with a large system designed to meet high production volumes with an economical solution.

The system was designed with an outer loop accommodating all assembly operations, and an inner loop designed to facilitate all the testing operations. The assembly operations were done entirely by hand with the use of powered nut-runners and staking devices. Operators pushed or pulled pallets from one assembly station to another, while powered rollers were used to drive the pallets around the four 90-degree turns of the loop.

Following assembly, pallets entered the inner loop for automatic e-testing and function testing. Units which passed the test were marked with a barcode and label identifying the part number, assembly date and other pertinent information. After being labeled to identify reasons for failure, faulty units were isolated onto a pallet repair loop where they would await a technician's attention. This valuable testing ensured that parts were assembled correctly and defective units did not reach the assembly plant.