Industrial and HVAC equipment: Lean manufacturing software for industrial and HVAC equipment makers
LeanSuite gives makers of industrial machinery and HVAC equipment one system for complex assembly: work instructions drafted from video, skills tracked by job, supplier defects sent back as SCARs and near misses closed out.
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The problem
What slows industrial and HVAC equipment plants down
Industrial machinery and HVAC equipment are built in many configurations, from many bought-in parts, by skilled people. Here is where that slows them down.
High-mix, low-volume production
Many models, options and small batches mean operators rarely build the same unit twice in a row. Standard work is hard to keep current, and changeovers between models add up.
Work instructions for complex assembly
A single unit can take hundreds of steps, torque values and wiring checks. The real method often lives in a few experienced assemblers' heads, and writing it down takes an engineer hours.
Skills held by a few experienced people
Skilled assemblers, welders and test technicians take years to develop. When one retires or calls out, a critical station can stand idle.
Quality of bought-in parts
Castings, motors, compressors, controls and sheet metal come from many suppliers. A bad lot found at final test costs far more than one caught at receiving.
Rework after final test
Leaks, electrical faults and failed run tests at the end of the line send units back for rework, and the same failures repeat when the cause is never fixed.
Near misses and lockout
Heavy lifts, welding, pressure testing and machine servicing all carry serious risk. Near misses go unreported when reporting is a hassle, and paper lockout binders go out of date.
How LeanSuite helps
How LeanSuite helps industrial and HVAC equipment plants
Each problem maps to a LeanSuite module you can start with on its own, then connect to the rest.
High-mix, low-volume production
In LeanSuite: Build checklists and work instructions per model or option in Lean Creator, with conditional logic that changes the required checks based on the part number entered. Changeovers run as visual checklists, and step timings show where each one loses time.
Work instructions for complex assembly
In LeanSuite: Film the job once and LeanSuite drafts the work instruction with numbered steps, photos, safety notes and torque values. Engineers can edit every step before it is published, and drafts can be routed to engineering, EHS and quality for sign-off.
Skills held by a few experienced people
In LeanSuite: The skills matrix shows jobs only one person can do, so you can schedule cross-training before that person is out. Training and on-the-job sign-offs update skill levels automatically, and One-Point Lessons that AI builds from your experts' before-and-after photos capture their know-how.
Quality of bought-in parts
In LeanSuite: Lean Creator runs inbound inspections with photos and pass/fail logic at the dock. Issue Management routes each defect to the supplier as a SCAR, the days the supplier takes to respond with an 8D or containment plan are tracked, and KPI dashboards build supplier scores and defect trends from the data.
Rework after final test
In LeanSuite: Each non-conformance is captured with photos and routed to quality and engineering. Containment tasks, such as quarantining a batch, are assigned and time-stamped before root cause analysis starts. Systemic issues run through 8D or DMAIC in Kaizen & Projects, and the fix goes to every affected operator as a One-Point Lesson before the NCR closes.
Near misses and lockout
In LeanSuite: Anyone can report a near miss by scanning a station QR code with their phone, anonymously if you allow it, and each hazard becomes a corrective action with a due date. Lean Creator turns lockout procedures into photo-verified isolation steps, and only trained, authorized people can start a lockout.
Customers
Companies that use LeanSuite
What getting started looks like
Under a week
Until your first module is live; our team does the setup
$3,000
90-day pilot per facility, credited in full to the annual plan
One flat price per facility
Unlimited users, so adding people does not change the price
99.5%
Monthly uptime commitment in the service agreement
SOC 2 Type 1 audited, hosted on secure cloud infrastructure, with single sign-on through Microsoft Entra ID or Okta and employee-ID sign-in for operators without email. Details on the security page.
Free tools
Related free calculators
Work out the numbers behind these problems. Each calculator shows its formula and a worked example, with no sign-up.
First pass yield (FPY) calculator
First pass yield at each step and rolled throughput yield (RTY) across the whole process.
Open calculatorCycle time calculator
Cycle time against takt, units per hour, capacity per shift and the gap to daily demand.
Open calculatorSMED changeover calculator
Time saved by moving changeover steps from internal to external, capacity freed per week and the smaller batch it allows.
Open calculatorCost of poor quality (COPQ) calculator
Total COPQ and cost of quality, and each as a share of revenue, from the four quality cost categories.
Open calculator
FAQ
Questions from industrial and HVAC equipment plants
See LeanSuite on your assembly floor
Bring the routine you want to fix first. We will show you how LeanSuite handles it and what a 90-day pilot would cover.