For years, “data is king” has been a key phrase in manufacturing. But while most manufacturers have recognised the importance of data, the real challenge lies in transforming raw numbers into meaningful, real-time insights that drive smarter decision-making.

Ideal Heating have embraced Artificial Intelligence (AI) and Machine Learning not just as industry buzzwords, but as fundamental tools that are shaping their business.

As the UK’s leading heating specialist and a key brand within Groupe Atlantic’s global thermal comfort portfolio, they’re leveraging these technologies to drive innovation in their manufacturing processes and maintain market leadership.

Moving from data collection to intelligent insights

Four years ago, Ideal Heating found themselves facing a common manufacturing challenge – collecting vast amounts of data without truly leveraging its potential. They were gathering information across their production lines, but weren’t using it to laser-focus on efficiency and performance improvements.

The company’s transformation began with a strategic approach to digitisation. They implemented advanced vision systems with high-definition cameras, six-axis robots, and cloud-based data analysis that allowed them to anticipate challenges before they arose.

This isn’t just about collecting data – it’s about creating a navigation system for their entire manufacturing operation.

Driving continuous improvement

Ideal Heating’s approach to AI and Machine Learning boils down to a simple yet profound principle: What gets measured, gets managed. But it goes far beyond traditional measurement. The real power lies in the ability to identify variations in a system, anticipate potential issues, and take proactive action before problems escalate.

It’s about how they achieve consistent, repeatable operations that generate significant value for the business and their customers. By adopting technologies that allow them to see issues before they happen, the business can focus their manufacturing and human resources teams on driving continuous improvement that further enhances manufacturing processes and ultimately helps assure that they continue to delight their customers.

This isn’t just about implementing technology – it’s about creating a system of sustained, verifiable progress. Each improvement is tracked, measured and validated to ensure it delivers lasting value. The goal is not a one-time fix, but a continuous cycle of refinement that keeps operations stable, predictable and cost effective.

AI-powered quality control

Their approach to quality control represents a quantum leap in manufacturing technology. Take their boiler production operation, for instance. They now use intelligent systems that conduct over 210 quality checks in just 200 seconds.

The technology is remarkable. A six-axis robot with high-resolution cameras compares each boiler against a library of “perfect” images. If something is even slightly off – be it a misaligned wire or a potential structural issue – the system doesn’t just flag the problem, it precisely identifies the exact location and nature of the deviation, allowing for immediate correction.

Empowering their people

Ideal Heating’s AI implementation is also helping to empower their workforce. By handling complex data analysis and repetitive quality checks, the AI systems free their team to focus on innovation, problem-solving and continuous improvement.

They’ve embedded this approach across product lines – from traditional gas boilers to evolving technologies such as air source heat pumps. Their dedicated improvement and engineering teams, working closely with operational IT, ensures they’re constantly extracting insights and driving efficiency.

Measuring impact

The results are clear. In recent years, the Hull-based company has grown from being one of the largest boiler manufacturers in the UK to becoming the market leader. Their production capabilities have expanded significantly, enabling them to increase the output of boilers in a single shift.

More importantly, they now consistently achieve exceptional quality, with near-perfect results on full functional tests. With changeover time between different boiler variants being drastically reduced, all supported by cloud-based, AI-driven systems.

A blueprint for innovation

For other manufacturers looking to harness AI, the key lesson from Ideal Heating’s experience is clear: Implementation must be purposeful. It’s not about adopting technology for its own sake, but about using AI to amplify what makes your business unique.

In John Cook’s own words (Production Designer at Ideal Heating): “AI isn’t just another tool – it’s an extension of our expertise, helping us to anticipate change, drive efficiency and maintain our competitive edge. 

“The future of manufacturing will be shaped by those who embrace innovation, with AI playing a central role in that transformation. By embedding intelligent systems into our operations, we’re not just responding to change – we’re defining it.”

John (below, right) presented at Make UK’s recent National Manufacturing Conference 2025 on the use of AI in manufacturing. You can watch the session back here.

Ideal Heating's John Cook speaks at Make UK's 2025 Conference