Boxed controller product for HVAC-R equipment
From a Nordic HVAC-R manufacturer’s validated prototype to a boxed, tested controller — molding, PCBA and final assembly coordinated through GANI-owned and GANI-managed qualified processes.
- Delivery geography
- Nordics & Benelux
- Annual volume
- ~8,000 units/year
- Batch size
- 600–900 per release
- Variants in scope
- 5 variants
- Program duration
- Third program year
- Responsibility level
- Product
- Standards applied
- IPC-A-610 Class 2 as practice · CE declared by the customer
What the delivered system actually does.
This is the controller that sits inside HVAC-R equipment and runs it: reading sensors, driving compressors, fans and valves, holding the setpoint and reporting state. The customer designed it and validated a prototype. What they did not have was a way to produce it.
GANI took it to a boxed product. The plastic housing is molded, the PCBA is produced and tested, final assembly brings them together, and the finished unit is functionally tested and packed — coordinated through GANI-owned and GANI-managed qualified processes rather than being brokered across unconnected suppliers.
What the customer buys is a finished product in a box, to their design and their brand, arriving to a schedule. Everything between their prototype and that box — the tooling, the process, the test, the yield — is our responsibility rather than theirs.
The manufacturer had a validated controller prototype but no route to production: enclosure tooling, PCBA sourcing, assembly and test were all open, and their team wanted one accountable partner instead of coordinating four vendors.
STARTING CONDITIONWorking prototypes, schematics and a preliminary BOM existed; nothing was industrialized and no tooling had been cut.
- Validated prototypes with schematics and firmware image
- Preliminary BOM and approved-vendor constraints
- Enclosure CAD and appearance requirements
- Three-year volume forecast by variant
- DFM review across board, enclosure and assembly
- Injection molding tooling through a GANI-managed qualified toolmaker
- PCBA coordination with a qualified partner, assembly and test at GANI
- Design and build of the end-of-line functional test fixture
- Final assembly, labelling and boxed packaging
- Golden sample process with the customer’s engineering team
What the program delivers.
- Golden sample approved after joint review
- Series deliveries running at roughly 8,000 units/year across variants
- Every unit serialized with a stored test record
- Engineering changes handled through an agreed ECO process
