zen industries

ZEN Industries eNewsletter:
October 2021

Zero Defects in HVAC Fabrication

Eliminating the Cost of Failure for Everyone

HVAC Duct OrderIs it truly possible to have zero defects in any manufacturing operation? Can production be so well organized as to produce flawless results? To paraphrase the poet Robert Browning, “a man’s reach should exceed his grasp, or what’s [perfection] for?”

Zero defects is a production philosophy focused on continuously identifying flaws in systems that cause non-conformance errors. It’s about recognizing that no production error is acceptable when it affects you personally, so why should you allow any defects to make it off the production floor and into the hands of your customers? In your personal life:

  • If it doesn’t fit, you take it back.
  • If it’s the wrong item, you take it back.
  • If it arrives too late and is no longer needed…

In each of these cases, frustration and dissatisfaction precede the practical steps of solving the problem. Indeed, whether the problem was solved or not, you come away with a bad feeling about the transaction.

On the other hand, receiving what you need, when you need it, along with good customer service and high-quality workmanship, always makes your day. But it’s more than feelings. A zero-defects approach makes the project go faster, with less trouble shooting, less aggravation, and more profit all down the line.

In the world of HVAC duct, zero defects can lead to longer equipment lifespan, lower energy costs, and less frequent maintenance.

The ZEN Way to Zero Defects

At ZEN Industries, we’ve developed our own zero defect methodologies, a series of checks that start in estimating, flow through computer aided design, and go from coil line data entry and Vulcan plasma tables all the way to delivery.

Using Smartsheets, we keep a comprehensive non-conformance log so that no problem goes unchallenged. We work to understand the source of errors and revise workflows to address the issue. Making the same mistake over and over is not an option.

Non-Conformance Log

As soon as newly fabricated pieces come off the coil line, there is a quality check in the middle of the shop, with a QA foreman trained to make sure production is on track.

Field Check inFinally, there is a quality, quantity, and accuracy check in the shipping department. The same Field Check In table is used to check shipments leaving our facilities and arriving on site.

This double-check using the same instrument helps identify the smallest variances quickly.

How the ZEN Way Benefits Our Customers

By investing in The ZEN Way, our customers benefit from:

  • Elimination of field measuring and field layout costs.
  • Optimized field labor (your least experienced crew can handle the job).
  • Your PM, Superintendent, or Foreman gain time to manage additional projects.
  • The ZEN Way delivers real cost savings between 25% and 35%.

We take tedious and expensive onsite work like FMSL and deal with it in 3D. Using our advanced Coordination Drawing and Shop Drawing capability, we build out the entire duct installation in a highly precise virtual model.

When duct arrives on site everything is numbered, like a perfectly engineered puzzle piece. But unlike puzzles, we clearly number where everything goes!

Because our coordination and building information models are so precise, The ZEN Way also means up to 15% lower fabrication costs for duct over the initial bid price. We optimize the number of standard lengths of duct and minimize the total number of joints and fittings.

We’ve pioneered a variety of ways to save on duct acquisition. If you’d like to learn more about them, give us a call at 877-600-0274 or visit our website today.

New Upgrades and Rebuilds

Part of The ZEN Way is keeping our production floor up-to-date. Recently, ZEN Industries has installed and upgraded a variety of pieces on our production floor for even more efficient fabrication.

Over the last year, ZEN Industries has installed and upgraded a variety of pieces on our production floor for even more efficient fabrication.

New Equipment Upgrades

Upgrade on Lockformer 5x20 plasma table; new Vicon dual head corner machine; new MG 8’ x ¼” CNC 4 roll - plate rolls; and an IPI coil line rebuild.

Plasma upgrade: A Lockformer 5’ x 20’ plasma upgraded with new Hypertherm Controls, ATH (automatic torch height adjustment) system and Hypertherm PowerMAX 45 power supply.

Brand new MG 4-roll, 8’ x ¼” CNC plate roll.

IPI Coil Line Rebuild: Over a 5-week period of time in our facility, Mestek (IPI) technicians upgraded/ rebuilt an existing IPI line to 2021 standards.

  • New electric drive package replaces the old hydraulic system.
  • New tie rod punching system installed.
  • Each component in the line was updated with new controls.
  • Main drive rolls replaced to accommodate new electric drive system, including new encoders.
  • Entire control system was replaced / upgraded to 2021 vintage. New wiring, PLC’s, touch screen and all encoders on the machine were replaced with new.
  • New glue system installed.

Coil Line Capabilities:

  • 16 ga capacity shear
  • Tie rod punching
  • TDC/snaplock
  • 75 FPM operating speed
  • Liner capable
  • Wrap brake

Interested in learning more about how ZEN Industries can fulfill your project needs for HVAC duct and fittings? Call us at 877-600-0274 or complete our Contact Us form today.

Partner with ZEN to Do More and Earn More

Our goal is to partner with our customers in ways that make the entire workflow from order to installation a seamless exercise in time and cost savings.

As an experienced fabricator of HVAC duct for over 22 years, ZEN Industries supplies traditional Rectangular Ductwork as well as Spiral Ductwork, Double Wall Spiral, , PCD Ductwork, and Specialty Ductwork.


Success is All About Great Service

Founded in 1999 on a set of unbreakable core principles, ZEN strives to provide top-quality fabrication, advice, and planning for our customers.

The quality of our HVAC duct work is of the highest caliber and our price is competitive with the best in the industry. Of course, ZEN Industries Inc. gains its edge with unbeatable service, and service means people - it's about our experienced personnel and the relationships we build with each and every customer.

At ZEN Industries, we believe success is all about great service. Our affordable HVAC shop drawings, estimating services, and duct fabrication can be reached at 877-600-0274, or visit our Contact Us page today!

Learn more at www.ZENindustries.com

Return to Top