A major HVAC manufacturer wanted to improve their quality control process for control board assembly. The manufacturer produces approximately one million units annually. At this production volume, even small changes have a significant impact on operations.
The control board assembly involved multiple harness connections in a continuous production environment. The manufacturer’s main challenge was that they were unable to detect connection mistakes until the units were tested later in the process. When units failed testing, they had to be moved to a different section for rework.
Assembly Copilot was implemented with a multi-camera setup integrated with the PLC system. The solution provided real-time verification of connections to enable immediate detection of errors. The system uses a step propagation method across three stations. The data from the station was passed to a subsequent one to track completed connections at each point. If any misconnection is detected, the system automatically stops the production line to prevent defective units from proceeding further in the assembly process. This verification setup allows the manufacturer to detect errors immediately rather than discovering them during final testing.
Assembly Copilot significantly reduced the rework frequency by enabling real-time detection of connection errors. The system’s integration with the production line ensured immediate response to quality issues. With the manufacturer’s high production volume of one million units annually, even the 1-1.5% improvement achieved through early error detection translated into substantial operational benefits.
A leading HVAC manufacturer focused on quality assurance and efficient production in their high-volume manufacturing operations.
HVAC Manufacturing
Automated verification in control board assembly.
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Brandin is a seasoned manufacturing leader, who has spent more than a decade designing and setting up assembly lines in both the US and China, optimizing them, and working with human operators to maximize productivity and quality.
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Andrey co-founded and successfully exited a startup to immigrate to the US. He spent his next eight years building the core data science infrastructure for Amazon’s supply chain planning team, and the CV/ML infrastructure for Microsoft’s HoloLens organization.
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Zeeshan was a scientific leader at Microsoft’s HoloLens division, where he invented AI technologies to assist frontline workers across industries. Earlier, he shipped IoT platforms and visual defect detection software for manufacturers at Siemens and MVTec GmbH.
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Huy led teams of scientists and engineers at NEC and invented technologies for driver assistance systems that are part of 500,000+ Honda cars. He is an inventor on more than 20 US patents, and his research papers are cited by every lab from MIT, Stanford, and CMU to Apple, Google, and Baidu.
