an empty factory floor

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Air-Care improves Manufacturing with Lean

"Manufacture Nevada’s training and expertise in lean manufacturing provided the right tools at the right time to help grow our new product line and fit it into our existing facility.  Our new Bio Cart is now a standardized product that is ready to dominate the market!"  
Wayne Trace, VP of Operations, Air-Care

The Client

Air-Care has grown from a small start-up to the international authority on air duct cleaning equipment and services with about 45 employees on-site at the 30,000 square foot facility in Las Vegas, Nevada. Air Care produces electrostatic air filters, air duct cleaning equipment and Bio-Carts, the world’s most innovative mobile dust containment unit.

The Situation

Air-Care previously used Manufacture Nevada's resources to assist in developing a lean line for electrostatic air filters.  Air-Care wanted to use the same techniques to streamline production on Bio Carts.  

The Solution

Manufacture Nevada met with Air-Care to discuss their needs.  After an assessment of the manufacturing operations, Manufacture Nevada provided Lean, 5S, and Quick Changeover (SMED) training to key supervisors and line staff.  The implementation phase consisted of coaching on the principles. Manufacture Nevada worked with Air-Care’s schedule and implemented lean in short visits over 3 months with very minimal disruption to their schedule.

The Results

  • Reduced Bio-Cart production time by 35%
  • Improved factory-wide working conditions with 5S  
  • Increased Heap filter line throughput by 20%  
  • Completed project at 75% of the original budget
  • Over $50,000 in cost savings per year

Take the First Step

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