Pierce Manufacturing Launches Phase I of High Flow Production Line

Phase I of Pierce Manufacturing Inc.'s new High Flow production line, which modernizes the personalized chassis assembly process, was successfully launched at the company's Appleton, Wisconsin manufacturing facility. In order to increase production capacity, enhance quality, and shorten lead times for fire equipment, Pierce has been investing $150 million in manufacturing sites in Wisconsin, Florida, and Tennessee. The High Flow Line is another significant milestone in this multi-year modernization project.

The High Flow Line presents a revised manufacturing model that emphasizes balanced workloads, improved production line quality controls, and integrated technologies to support consistency, efficiency, and safety. Pierce's dedication to providing firehouses with high-quality bespoke fire apparatus more quickly is reinforced by the quantifiable gains that Phase I implementation is already bringing about throughout the custom chassis production process. In the second half of 2026, subsequent stages will change the remaining final assembly activities.

“These investments reflect our continued focus on transforming how custom fire apparatus are built to meet the needs of modern firefighting,” said Marty Bass, president of Pierce 
Manufacturing. “By integrating High Flow production principles with advanced technology and expanded facilities, we’re creating safer, more efficient work environments for our team members while accelerating lead time reductions for our customers. We’ve already reduced lead times by more than three months from their peak, and we expect this next phase will build on that momentum.”

Pierce continues to reduce backlogs more quickly while upholding its high levels of performance, personalization, and workmanship thanks to better process design and closer labor and resource alignment.

In order to promote safe operations and consistent output, Phase I also includes increased use of computerized work instructions, enhanced tooling, ergonomic workstations and cutting-edge inspection technology. These improvements go well in hand with other recent investments made at the Appleton, WI, location, such as increased paint capacity, sophisticated automation, robotics, and fabrication technologies, all of which are intended to improve production flow, quality and efficiency.

One part of Pierce's larger manufacturing change is the High Flow Line. The company has invested over $70 million, expanded its operations by more than 500,000 square feet, and added almost 800 new team members. When taken as a whole, these programs support Pierce's long-term dedication to workforce expansion, innovation, and providing top-notch fire equipment to communities and first responders nationwide.

Bass added, “With High Flow, we’re embedding continuous improvement into every stage of production. This approach helps eliminate waste, simplify work and elevate customer quality while creating a more consistent, predictable manufacturing process that supports our teams and our customers.”

As Pierce continues to apply its updated production model throughout operations, more stages of the High Flow Line are anticipated.

Visit www.piercemfg.com/expansion for additional details on Pierce fire equipment and manufacturing investments.