Creating a Multi-Domain Training Environment at Johnson Controls, Inc.

When Johnson Controls (JCI) announced the sale of its historic Milwaukee headquarters in 2021, it sparked the opportunity to reimagine the future of technical training across all business domains. As the organization began consolidating training for HVAC, Fire Detection, Security, and Building Efficiency into a unified model, it became clear that traditional training infrastructure would no longer meet evolving needs.

Johnson Controls needed a scalable, space-conscious, and visually impressive solution to support its new flagship learning center in Glendale, Wisconsin. The goal was to deliver a world-class, multi-domain training experience in a limited physical footprint—without compromising on flexibility, functionality, or instructional quality.

To realize this ambitious vision, JCI partnered with McIver Engineering & Controls, an industry leader in custom control panels and industrial training workstations.

Johnson Controls provides highly specialized training across over 100 technical courses spanning multiple business areas. Historically, each domain operated independently, with dedicated training equipment and setups. As the company shifted toward a more integrated model, its Learning & Development (L&D) team needed to combine these efforts into a central training environment.

The relocation from the Milwaukee site to the new headquarters in Glendale presented several key challenges:

• No Shipping/Receiving Access: Equipment could not be transported in and out for different classes.
• Space Constraints: The training space was limited, requiring a compact yet adaptable solution.
• Course Diversity: Equipment needed to support diverse training across HVAC, Security, and Fire Detection systems.
• Functional Aesthetics: As a high-visibility site, the facility needed to be both attractive and cutting-edge.
• Lack of Internal Resources: JCI L&D lacked the in-house capability to design and manufacture training equipment at scale or to required safety standards.

The project required a trusted, innovative manufacturing partner who could engineer custom workstations and training panels to solve all these issues cohesively.

McIver Engineering & Controls took a collaborative, engineering-first approach to designing a modular training system that met all of JCI’s unique requirements.

1. Custom Industrial Workstations: McIver Engineering & Controls engineers designed custom-built, sleek, durable workstations that served as the physical and functional foundation for each classroom. Designed for flexibility, mobility, and ease of use, these stations feature:
   • Flip-Down Panel Mounts: Enabling rapid swaps between HVAC, Security, and Fire Detection training modules.
   • Integrated Wiring & Connectivity: All electrical and data connections were pre-wired by McIver to meet UL and NEC standards — ensuring safety, functionality, and quick, easy plug-and-play transitions.
   • Color & Material Customization: Matching JCI’s branding while withstanding heavy classroom use.
   • Compact Storage Capabilities: Unused panels could be stored vertically in minimal floor space.
2. Multi-Protocol HVAC Training Panels: For the HVAC controls domain, McIver Engineering & Controls designed and manufactured three specialized training panels simulating real-world system configurations:
   • MS/TP (BACnet)
   • IP (BACnet/IP or Ethernet)
   • Wireless Communication Protocols

   Each panel was designed to replicate the exact communication paths used in the field, giving trainees real-time, hands-on exposure to the technology they would deploy and support in live environments.

3. Seamless Integration Across Domains: McIver Engineering & Controls worked closely with JCI’s L&D team to convert existing Fire Detection and Security training modules into flip-down panel formats that could slot into the new workstations. The resulting system offered:
   • Domain Agnostic Infrastructure: One classroom could now host multiple classes from different divisions without reconfiguring the entire space.
   • Rapid Setup Time: Trainers could switch between panels in minutes, cutting setup time by over 80%.
   • Elevated Learner Experience: Clean, modern aesthetics and robust engineering elevated the perception of JCI’s technical training programs to a premium level.

Leveraging McIver Engineering & Controls’ expertise and collaborative approach, Johnson Controls successfully launched its new multi-domain training center—now a flagship facility that supports efficient, scalable, and immersive learning experiences for internal teams and customers alike.

Key Outcomes:

• Maximized Space Efficiency: Custom-designed panels with vertical storage capabilities dramatically increase available classroom space. This space optimization supports a cleaner, more organized, and efficient training environment.
• Rapid Setup and Increased Instructor Productivity: McIver’s mobile workstations reduce classroom setup time from days to just hours. This streamlined configuration process minimizes setup costs and allows instructors to focus their time and energy on delivering high-quality training instead of managing equipment.
• Substantial Footprint Reduction and Cost Savings: With McIver’s tailored solution, Johnson Controls reduced their training facility footprint to just 25% of its original size. This compact, modular design delivers significant savings in real estate, utilities, and facility maintenance.
• Seamless Multi-Disciplinary Training: The flexible system supports HVAC, Security, and Fire Detection training within a single room. Instructors can transition between disciplines effortlessly, maximizing resource utilization and minimizing downtime.
• Showcase Learning Environment: The upgraded Glendale classroom has become a high-visibility flagship site, serving as a global benchmark for integrated, technical training across Johnson Controls locations worldwide.