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  • nexAir’s Expertise: Forged by Deep Industry Experience

    nexAir’s Expertise: Forged by Deep Industry Experience

    nexAir’s success and longevity can be attributed to its dedication to exceeding client expectations and deep industry experience. While we could have merely focused on delivering gases and nothing more, our commitment to our clients has cemented our legacy. This customer-centric approach has been a key factor in nexAir’s 83 years of business success.

    Today, nexAir’s clients span a wide range of industries that include healthcare, automotive, chemical, manufacturing, and medicine, to name a few. They all rely on our KnowHow as well as our reliable and precise gas supplies. 

    Let’s take a look at a few case studies where our knowledge and experience made a pivotal difference for our valued clients.

    Helping a Client Navigate a Nationwide Helium Shortage

    In the midst of a nationwide helium shortage, nexAir worked closely with a client and assisted them in identifying and fixing leaks in their pipelines. This resulted in a 33% reduction in their helium usage and allowed them to continue operations despite challenging conditions. nexAir also advised a 10% reduction in the customer’s helium mixture which led them to enjoy significant savings without compromising quality. 

    Aiding Welding Efficiency

    DeShazo Crane, a global crane manufacturer, approached nexAir with a challenging welding request from one of its aerospace customers: They needed help with a specific welding process. Despite the fact that it was outside our usual scope, nexAir quickly analyzed the need, collaborated with DeShazo, and developed a workable approach that encompassed specific products, techniques, and employee training. This enabled DeShazo to identify and bring a critical part of the job in-house, turning their project into a success.

    Enabling Automation and Maximizing Employee Efficiency

    Taylor Manufacturing, a metalworking shop in Stevenson, Alabama, sought a solution to meet the demands of a new customer. They approached a nexAir Territory Manager who recommended integrating the Vectis Cobot welding tool into their operations. This programmable and efficient welding tool enabled Taylor to increase its production from one part per day with two welders to four complete parts per day with just one welder. By embracing automation and upgrading its technology, Taylor Machine & Welding was able to Forge Forward, meet deadlines, and fulfill their new customer’s requirements.

    Upgrading Welding Set-up to Drive Efficiency

    LMC, a leading manufacturer of separation and shelling equipment in Georgia, experienced a surge in demand for its food-grade machinery. However, their TIG welding thin gauge stainless parts required more time and skilled labor.  nexAir identified the IPG LightWELD handheld laser welding system as a suitable option for higher quality and faster production. The IPG LightWELD enabled LMC to improve quality and speed without hiring additional skilled welders.

    Unlocking Signification Cost Reductions In Operations

    NAK Kiln Services, a long-term customer of nexAir based in Georgia, specializes in kiln installation, repairs, and maintenance. They faced challenges with grinding and resurfacing work due to the cost and performance of their current grinding wheels. nexAir suggested sampling PFERD’s wheels as an alternative in their process. Despite initial skepticism, NAK agreed to try the PFERD Ceramic Oxide Grinding Wheel. The difference was immediately noticeable with PFERD’s wheels outperforming the previous product. NAK experienced a 30% cost reduction per wheel while maintaining high quality.

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    Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.

    The Hidden Costs of Gas-Related Downtime

    When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:

    • Production rescheduling that disrupts carefully optimized sequences
    • Rush shipping fees to meet customer deadlines despite delays
    • Quality inconsistencies when processes restart after interruptions
    • Overtime costs to catch up after unplanned stoppages
    • Reputation damage when delivery commitments are missed

    For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.

    From Reactive to Proactive: The Supply Continuum

    Most facilities follow a predictable pattern in their gas management evolution:

    Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.

    Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.

    Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory. 

    Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.

    Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.

    Customizing Solutions for Maximum Uptime

    Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:

    • For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
    • For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
    • For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
    • For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.

    This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.

    Beyond Traditional Supply: Integrated Services for Total Reliability

    Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:

    Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions

    These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.

    Measuring Success: The Results That Matter

    The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:

    Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability

    These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.

    Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.

    Looking out for your future

    Get your career going on the right track with nexAir

    Industry Knowledge and Expertise

    Find out how nexAir KnowHow has impacted businesses all over the Southeast

    nexAir in the news

    Our expertise makes us more than a valuable partner, it makes us headlines

    nexAir is always open!