Serial Production

AIC combines advanced technologies and innovative techniques to create high-quality products efficiently and cost-effectively.

With robotics, computer-controlled equipment, advanced materials, 3D printing, and data analytics, we succeed in delivering exceptional products to our clients.

Overview

AIC can manufacture large quantities of customized products. With automated assembly lines and manufacturing processes, we ensure repeatability and high quality of our products.

Serial production at AIC is set up with quality & quantity in mind – it is used to manufacture a series of products made in the same way. As in the case of mass production, products are in constant motion between successive production stations during the manufacturing process. The main difference between serial and mass production is the continuity of work. Mass production is carried out continuously, while serial production is characterized by the manufacture of a batch of products, after which production can be stopped.

AIC is able to design a production line to manufacture a number of different variations of the same product. We design heat exchangers in such a way that part of the product, called the "core", is the same but has a lot of possibilities to customize the external elements to meet the needs of the client. As an experienced manufacturer, we are able to design a well-organized production system with the key role of refined production processes and appropriate procedures that ensure the smooth functioning of each production phase.

Advantages

The main advantage of serial production is that it allows for a large number of products to be manufactured quickly and efficiently while maintaining a focus on high quality.

Serial production offers the following advantages:

The serial production process aims at the manufacture of the products in the same way, which often involves automated production lines. There is less time spent on changing machinery and learning new processes, making the production more efficient.

The serial production process is organized with a view to manufacturing large quantities of products in the same way, ensuring that all products are made to meet quality requirements. It is done with a tracking system, automation, and quality control monitoring.

Serial production allows for standardization, which ensures that all products are made to the same specifications and quality standards. This means a reduced risk of defects and consistency in the product.

The primary focus of the logistic process in serial production is the delivery of products to the client and the decommissioning of serial numbers once the products leave the production chain.

Serial production can quickly and easily respond to changing requirements, which means it can be adapted for the production of larger numbers of products in a shorter amount of time.

Serial production consists of multiple stages, and the products are processed in the order of the stages to complete the manufacturing process. This is essential for the prediction of product completion time, scheduling, and quality control.

As products are made in the same way and automation is involved, this type of production allows for the most efficient use of materials and labor, resulting in cost savings.

AIC Serial Production

With years of experience in implementing serial production process, AIC is able to manufacture large quantities of customized heat exchangers. Automated assembly lines and efficiently optimized production processes ensure repeatability and exceptional quality of our products.

The ability to produce a large number of products with a quick production volume ramp-up while ensuring no compromise on quality is essential for our business. With a constantly changing market environment, our focus is on delivering products to clients on time.

AIC’s production lines are designed for specific product families. The possibility of quick and effective adjusting and retooling of the required production cells enables each production line to manufacture products tailored to the individual client’s requirements.

Our products are entirely manufactured in-house. Every stage of fabrication—from incoming material control through machining and forming of the components to final welding, brazing, assembly, and quality control—is performed using our own resources. We have a separate plant for manufacturing components, which consists of production halls and a warehouse. The halls are divided into zones by a particular metal-forming process.

We have an advanced CNC machine park equipped with wire electrical discharge machines, band saws, milling machines, lathes, press brakes, punching machines, notch forming machines, and plate rolling machines.

We also have in-house tube manufacturing lines. It gives us the possibility of producing dedicated, standard and non-standard tubing solutions for heat transfer purposes.

Key advantages
of our serial production

Automation
and robotization
of production

In order to achieve a high level of quality in our products, we focus on the automation and robotization of serial production processes, which constitute a significant part of our series production lines.

To ensure the highest quality, we prepare the most efficient processes, which are selected taking into account individual needs and requirements.

We have our own automation department within RMA, our subsidiary company, which is a leading provider of comprehensive solutions in the fields of welding automation and laser processing. Owing to the RMA expertise, our production lines have modern stands and tailor-made machines.

IMES production
process tracking
system

We use an electronic system to track every stage of production. Each product has its own history, material, operation, or process that must be performed in the right order.

For this purpose, we use the IMES system, which has been tailored to the requirements of our organization. Each production station is equipped with a scanner that is used to read an individual barcode and a tablet on which all details about the product are displayed.

Thanks to this system, we keep the entire history of the product's creation, including information such as:

  • The type of material
  • Previous and subsequent processes
  • Individual number of the production employee performing the operation
  • Date and time of execution of individual operations
  • Workplace, quality, and welding instructions

At the same time, the system ensures that a given operation can only be performed by a trained and authorized operator.

The system also ensures the sequence of operations, which means that no step of the process can be skipped and the product will not leave the factory without performing all operations required by the technological route, including quality control and packaging.

In-house welding
training program

AIC also has its own welding school, where the most experienced welders in our company train future specialists in TIG and MIG welding technologies, which are used in our production processes. Thanks to this, we are able to prepare and check employees as best as possible before they start working at the production.

High manufacturing
capabilities

From raw material to final product under one roof - in-house manufacturing means self-containment and the highest quality.

At AIC, we believe that having complete control over the heat exchanger production process is the only way to ensure high quality and long-term reliability. For this reason, our products are almost entirely manufactured by utilizing our in-house capabilities. Every single stage of fabrication—starting from incoming material control, through machining and forming the components, final assembly by welding, brazing, and bolting, and ending with pressure tests and leakage detection—is performed using our extensive and broad resources in our factories.

Well-developed
machine park

A well-equipped machine park with CNC devices for turning and drilling, bending machines, press brakes, and cutting lasers allows us to make even the most sophisticated design come true quickly and efficiently and ensures the highest product quality.

In-house
tube production

Developed over many years, our in-house tube manufacturing line gives us almost unlimited possibilities for the production of dedicated tubing solutions for heat transfer purposes. Thanks to highly developed forming techniques, we’ve been able to introduce unique tube designs based on advanced forming technology. The AIC’s pinched and dimpled tubes feature outstanding thermal efficiency and elevate heat transfer technology to the next level.

Tube and profile production:

1

Automatic line for longitudinal laser welding

0.3 – 2.5 mm

Wall thickness

6 – 60 mm

Tube diameters

Several tube production lines:

  • Flat, smooth tubes
  • Flat, dimpled tubes
  • Circular dimpled tubes
  • Diamond-shaped tubes
  • Helical tubes

Material quality
control system

An incoming inspection, also known as a receiving inspection or material inspection, validates the quality of purchased raw materials based on set acceptance criteria. It is performed by well-trained quality assurance personnel in our manufacturing facility to resolve quality issues during pre-production.

Key advantages
of our serial production

In order to achieve a high level of quality in our products, we focus on the automation and robotization of serial production processes, which constitute a significant part of our series production lines.

To ensure the highest quality, we prepare the most efficient processes, which are selected taking into account individual needs and requirements.

We have our own automation department within RMA, our subsidiary company, which is a leading provider of comprehensive solutions in the fields of welding automation and laser processing. Owing to the RMA expertise, our production lines have modern stands and tailor-made machines.

We use an electronic system to track every stage of production. Each product has its own history, material, operation, or process that must be performed in the right order.

For this purpose, we use the IMES system, which has been tailored to the requirements of our organization. Each production station is equipped with a scanner that is used to read an individual barcode and a tablet on which all details about the product are displayed.

Thanks to this system, we keep the entire history of the product's creation, including information such as:

  • The type of material
  • Previous and subsequent processes
  • Individual number of the production employee performing the operation
  • Date and time of execution of individual operations
  • Workplace, quality, and welding instructions

At the same time, the system ensures that a given operation can only be performed by a trained and authorized operator.

The system also ensures the sequence of operations, which means that no step of the process can be skipped and the product will not leave the factory without performing all operations required by the technological route, including quality control and packaging.

AIC also has its own welding school, where the most experienced welders in our company train future specialists in TIG and MIG welding technologies, which are used in our production processes. Thanks to this, we are able to prepare and check employees as best as possible before they start working at the production.

From raw material to final product under one roof - in-house manufacturing means self-containment and the highest quality.

At AIC, we believe that having complete control over the heat exchanger production process is the only way to ensure high quality and long-term reliability. For this reason, our products are almost entirely manufactured by utilizing our in-house capabilities. Every single stage of fabrication—starting from incoming material control, through machining and forming the components, final assembly by welding, brazing, and bolting, and ending with pressure tests and leakage detection—is performed using our extensive and broad resources in our factories.

A well-equipped machine park with CNC devices for turning and drilling, bending machines, press brakes, and cutting lasers allows us to make even the most sophisticated design come true quickly and efficiently and ensures the highest product quality.

Developed over many years, our in-house tube manufacturing line gives us almost unlimited possibilities for the production of dedicated tubing solutions for heat transfer purposes. Thanks to highly developed forming techniques, we’ve been able to introduce unique tube designs based on advanced forming technology. The AIC’s pinched and dimpled tubes feature outstanding thermal efficiency and elevate heat transfer technology to the next level.

Tube and profile production:

1

Automatic line for longitudinal laser welding

0.3 – 2.5 mm

Wall thickness

6 – 60 mm

Tube diameters

Several tube production lines:

  • Flat, smooth tubes
  • Flat, dimpled tubes
  • Circular dimpled tubes
  • Diamond-shaped tubes
  • Helical tubes

An incoming inspection, also known as a receiving inspection or material inspection, validates the quality of purchased raw materials based on set acceptance criteria. It is performed by well-trained quality assurance personnel in our manufacturing facility to resolve quality issues during pre-production.

AIC Automated production processes

We have several dozen production lines, including fully automated ones, dedicated to various types of heat exchangers. Automation of the production is planned at the early implementation stage of each project.

Automated production lines perform the following operations:

Tube packet assembly, combustion chamber and shell welding, including nameplate engraving

Complete unit assembly, welding, testing, geometry measuring, and packaging

Tube feeding, tube bundle mounting, trimming tube edges, expanding tube ends and welding

Complete product assembly, welding, engraving, applying solder paste application and transporting