Case Study: How nexTrack Transformed Operations for a Leading Manufacturer

Southern Steel Manufacturing* faced mounting challenges with their industrial gas supply chain. With three facilities across Tennessee processing over 50,000 tons of steel annually, their manual tracking systems couldn’t keep pace with production demands. Frequent supply disruptions and inventory miscalculations were impacting their bottom line.

Initial Challenges

Before implementing nexTrack, Southern Steel’s operations team spent hours each week:

• Manually checking gas levels across multiple storage locations
• Coordinating deliveries through phone calls and emails
• Reconciling inventory disparities between facilities
• Managing emergency orders due to unexpected shortages
• Tracking cylinder locations and maintenance schedules

Production delays occurred weekly due to supply chain inconsistencies, costing an average of $25,000 per incident in lost productivity. The company needed a solution that could scale with their growing operations while eliminating supply chain uncertainties.

Implementation Process

Working with nexAir, Southern Steel began their digital transformation in January 2023. Rather than disrupting all operations simultaneously, they chose a staged implementation approach, starting with their largest facility in Memphis.

The initial focus centered on establishing automated inventory monitoring. nexTrack’s sensors were installed across all gas storage locations, providing real-time visibility into supply levels. Team members received comprehensive training on the new system, with designated champions selected from each shift to support the transition.

Immediate Impact

Within the first month of implementation, Southern Steel experienced measurable improvements:

• Emergency orders decreased by 85%
• Staff hours spent on inventory management reduced from 25 to 4 hours weekly
• Real-time monitoring eliminated manual level checks
• Automated reordering prevented stockouts
• Production delays from gas supply issues dropped to zero

Expanding Success

Following the successful implementation at their Memphis facility, Southern Steel rolled out nexTrack across their remaining locations. As industries Forge Forward with digital solutions, the company found itself ahead of the curve. The system’s centralized dashboard enabled management to:

• Monitor gas consumption patterns across all facilities
• Optimize delivery schedules based on actual usage
• Standardize ordering processes
• Track costs with greater accuracy
• Improve forecasting for future needs

Streamlined Communication

Perhaps the most significant transformation occurred in daily communications. Instead of countless emails and phone calls, nexTrack’s automated notifications kept all stakeholders informed. Facility managers received instant alerts about approaching reorder points. Production supervisors gained visibility into upcoming deliveries. Maintenance teams accessed real-time data about cylinder conditions and locations.

Financial Returns

The numbers tell a compelling story. Within six months of full implementation, Southern Steel documented:

• 30% reduction in gas supply costs through optimized ordering
• 92% decrease in emergency delivery fees
• 15% improvement in overall production efficiency
• 40% reduction in cylinder rental costs through better tracking
• Zero lost production time due to gas supply issues

Environmental and Safety Benefits

Beyond operational improvements, nexTrack’s implementation yielded unexpected environmental and safety advantages. Optimized delivery routes reduced carbon emissions from transport. Real-time monitoring helped identify potential leaks before they became safety hazards. Improved maintenance tracking extended equipment life spans.

Looking Forward

Today, Southern Steel serves as a model for modern industrial gas management. Their success with nexTrack has attracted attention from other manufacturers facing similar challenges. The company continues to discover new ways to leverage the system’s capabilities, recently beginning to use predictive analytics for long-term capacity planning.

Are you ready to transform your operations with nexTrack? Let us show you how your facility can achieve similar results. Schedule a consultation with nexAir to discover your potential savings and efficiency gains. Our team will develop a customized implementation plan based on your specific operational needs, backed by our expert KnowHow™.

*Company name changed to protect privacy. Results based on actual customer data.