Clicarity › Hvac Manufacturing
❄️ Industry · HVAC Manufacturing

When a unit fails leak test, do you know which joint it was?

Which joint keeps failing, and on whose shift. How many units are sitting half assembled. How many commissioning teams had to go back a second time.

One manufacturer logged sixty-five leak failures in a quarter. Thirty-four were the same joint location. Each had been repaired individually.
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HVAC manufacturers — unit assembly and testing visibility live
As featured in PrintWeek India, April 2026 ↗

Three manufacturers. Each one repaired every failure and fixed none of the causes.

01 The unit that failed leak test

Every unit is leak tested. Failures are repaired and retested, and the unit ships.

The failure is recorded as a failure. Which joint, which brazier, which shift is not, so the same joint fails every week and is repaired every week.

Leak test failures by joint location
Suction line joints34 units
Discharge joints15 units
Coil connections10 units
Service valves6 units

The failure location and the person who made the joint are recorded, so a pattern replaces a repair.

65 failures → 22per quarter
Find out howBring last quarter. Fifteen minutes.
02 Coils, sheet metal and the assembly that waited

A unit needs a coil, a cabinet, a compressor, controls and refrigerant. They come from different lines and different vendors.

Assembly starts when it looks ready. One item short and a bay is occupied by a half-built unit that cannot be finished or moved.

Units held mid-assembly, one month — why
Component short13 units
Coil not ready7 units
Controls awaited5 units
Drawing query3 units

Kit completeness is a checked stage before a bay is occupied.

28 units → 8held mid-assembly
Show me howFifteen minutes. We look at one unit.
03 The commissioning that needed a second visit

The unit reaches site. The team arrives to commission it. The power is not ready, the ducting is incomplete, or the wrong capacity was sent.

A second visit costs a day and a vehicle. Site readiness was never confirmed as a step, only assumed from a phone call.

Commissioning visits needing a return, one quarter
Site not ready12 visits
Wrong specification supplied4 visits
Missing accessories5 visits

Site readiness and the despatch checklist are both confirmed stages before the team is scheduled.

21 return visits → 6per quarter
Show me howFifteen minutes. We add the site stage.

Repairing a failure closes a job. Recording it closes a cause.

Your Production Flow

Every unit. Every component. Every test tracked.

This is how a print job moves through your business. Clicarity gives you live visibility at every phase — and flags delays before they become client calls.

01
Order & Engineering
3 stages
Order Received
Customer order confirmed — unit type, capacity, configuration, site conditions.
✓ Clicarity: Job ID created, BOM generated, procurement initiated
Engineering & Drawings
Unit design finalised, drawings issued to floor.
⚠ ⚠ Common delay: design changes after BOM — procurement rework required
BOM & Procurement
All components — coils, casings, fans, compressors, controls — procured.
⚠ ⚠ Common delay: one component late — entire assembly held
02
Coil Fabrication
4 stages
Copper Tube Cutting
Copper tubes cut to required lengths for coil headers and circuits.
Fin Pressing
Aluminium fins pressed to required pattern and spacing.
✓ Clicarity: Fin count per coil tracked — specification verified
Coil Assembly & Brazing
Tubes and headers assembled and brazed.
⚠ ⚠ Common delay: brazing leak — coil reworked before pressure test
Coil Pressure Test
Coil pressure tested with nitrogen before fitting.
✓ Clicarity: Test result logged — failed coils tracked for rework
03
Unit Assembly
4 stages
Casing Fabrication
Sheet metal casing fabricated, powder coated, and assembled.
✓ Clicarity: Casing completion logged — unit assembly can begin
Mechanical Assembly
Fans, motors, coils, and drainage components assembled in casing.
✓ Clicarity: Assembly checklist logged per unit — no step skipped
Refrigeration Assembly
Compressor, condenser, expansion valve, and refrigerant piping assembled.
⚠ ⚠ Common delay: refrigeration component shortage — unit held
Electrical Wiring
All electrical connections, controls, and safety devices wired and labelled.
✓ Clicarity: Wiring completion logged — testing cannot start without sign-off
04
Testing & Dispatch
3 stages
Leak Test & Evacuation
System leak tested and evacuated before gas charging.
✓ Clicarity: Leak test result logged — gas charging blocked until pass
Performance Testing
Unit run-tested at rated conditions — capacity, current, noise.
✓ Clicarity: Test data logged per unit — non-conformances tracked
Dispatch
Unit dispatched with test report, data sheets, and warranty card.
✓ Clicarity: Full unit history from BOM to dispatch preserved
Real Printing Business. Real Results.
""Testing used to reveal problems with refrigerant charge that should have been caught at assembly. Now leak testing is a stage before gas charging. We eliminated rework at the most expensive point in the process.""
PR
Production Head
HVAC Manufacturer — Pune, Maharashtra
As featured in PrintWeek India, April 2026 — Vol 18, Issue 12 ↗ Also in Print Bulletin, May 2026 — Pages 20–21 ↗

What improves in HVAC businesses using Clicarity

↓ 55%
Rework from late-stage test failure
↑ 40%
On-time dispatch improvement
↓ 45%
Component shortfall delays
5 days
To go live — full setup included

Questions from hvac manufacturing businesses

How does Clicarity work for a printing business specifically?
Clicarity is configured around your specific print workflow — pre-press, printing, finishing, dispatch — in your terminology. Every job gets a unique ID and moves through your defined stages. You see live status, timestamps, and alerts when a job sits too long at every stage. The Clicarity team builds everything for you. You go live in 5 days.
Does it work for both offset and digital printing?
Yes. Clicarity works for any print process — offset, digital, wide format, screen printing, or a combination. The stages are configured around your actual workflow. If offset jobs go through plate making and digital jobs skip that stage, both can be tracked correctly under the same system.
Can it track material wastage at each stage?
Yes — with the Multi Licence. At every stage, your team logs quantity in and quantity out. Clicarity calculates the loss automatically. You see wastage by stage, by job, live — not at month-end when nothing can be done about it.
Will my press operators actually use it?
Yes. The update screen has two fields — Job ID and status. Under a minute. No training needed. GP Offset's entire team was using it from day one, including floor workers who had never used a software system before.

See every unit. Every stage. Before the test fails.

Book a free demo. We'll map your HVAC assembly workflow live on the call.

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