Pierce Manufacturing launches High Flow Phase I in Wisconsin
Iain Hoey
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Pierce Manufacturing launches High Flow Phase I
Phase I of the new High Flow production line has launched at Pierce Manufacturing’s Appleton, Wisconsin manufacturing campus, changing the custom chassis assembly process as part of a wider manufacturing update.
Pierce Manufacturing, an Oshkosh Corporation business, announced the launch as part of its multi-year modernisation programme and ongoing $150 million investment across manufacturing facilities in Wisconsin, Florida and Tennessee.
The company said the High Flow Line introduces a redesigned manufacturing model centred on balanced workloads, enhanced quality controls within the production line and integrated technology.
Pierce said Phase I is already delivering measurable improvements across the custom chassis production process.
The company linked the line to plans to expand production capacity and improve quality, with the aim of reducing fire apparatus lead times.
According to Marty Bass, president of Pierce Manufacturing: “These investments reflect our continued focus on transforming how custom fire apparatus are built to meet the needs of modern firefighting.
“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 Manufacturing outlines further production changes
Pierce said later phases of the High Flow Line will change the remaining final assembly operations in the second half of 2026.
The company said improved workflow design and closer alignment of labour and resources are supporting faster backlog reduction while maintaining customisation, craftsmanship and performance standards.
Phase I also includes expanded use of digital work instructions, improved tooling, ergonomic workstations and advanced inspection technologies.
Pierce said these changes add to other recent Appleton campus investments, including advanced automation, robotics, fabrication technologies and expanded paint capacity.
Across its operations, the company said it has added more than 500,000 square feet of facility space, invested over $70 million to date and hired about 800 new team members.
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.”
Additional phases of the High Flow Line are planned as Pierce continues applying its modernised production model across operations.