Pierce Manufacturing launches High Flow Phase I in Wisconsin

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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.

Pierce Manufacturing outlines $150m US facility investment including Florida expansion

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Pierce Manufacturing facility upgrades in Bradenton

Pierce Manufacturing has announced a new phase of facility enhancements at its Bradenton, Florida location, including adding a nearby 185,000 sq ft facility.

The company said the Bradenton work builds on recently announced investments at its Appleton, Wisconsin manufacturing campus.

It is investing around $150 million across its facilities, including about $70 million invested to date.

the manufacturer has added 800 new US jobs and is still hiring.

The 185,000 sq ft facility is located near Pierce Manufacturing’s Florida campus.

The company described it as part of a previously announced plan for more than 500,000 sq ft of new space to support increased fire apparatus production.

The new space is intended to support expanded material storage and kitting.

It is also intended to support improved production flow and enhanced training capabilities.

The company said the facility is expected to be operational by mid-2026.

Bradenton paint operations and site infrastructure work

Pierce Manufacturing said it is investing in expanded paint operations at the Bradenton campus.

The company said the project includes new booth space and material-handling enhancements intended to streamline workflows and support higher capacity and improved production consistency.

Marty Bass, President, Pierce Manufacturing, said: “Our growing team in Bradenton plays a critical role in delivering the quality and craftsmanship our customers expect.

“Over the past several years, Pierce has significantly expanded its Florida workforce and production capability.

“These investments reflect our continued focus on building high-quality apparatus, supporting our team members, strengthening our operations and positioning Pierce to meet customer demand well into the future.”

The Bradenton campus is also undergoing site infrastructure improvements, including expanded parking capacity, improved traffic flow and enhanced security features.

The company said these changes are intended to support a safe and efficient environment for team members and visitors.

Pierce Manufacturing invests $150m to cut fire apparatus lead times across US

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Pierce invests in Appleton capacity

Pierce Manufacturing has announced a new round of facility upgrades at its manufacturing operations in Appleton, Wisconsin, with work described as part of a modernisation initiative launched in 2022.

The company said the changes are intended to expand production capacity and support faster delivery of fire apparatus to fire departments.

Pierce Manufacturing said the Appleton work sits within more than $150 million it is investing across manufacturing facilities in Wisconsin, Florida and Tennessee.

The manufacturer said around $60 million has already been invested.

Pierce Manufacturing said its recent investments have included expanding manufacturing space by 28% and adding 500,000 square feet of facility space.

The company added that it has hired 800 new American workers over the past several years.

Lead times and production targets

Mike Pack, Executive Vice President and President, Vocational at Oshkosh Corporation, said: “These technologies reflect our dedication to continuous improvement and safety, as well as our commitment to delivering fire apparatus to firehouses faster while maintaining the same exceptional level of quality that defines our products.

“We have already reduced lead times by over three months from their peak.

“With these sustained investments, we are continuing to work to return to pre-pandemic lead times.

“The investments across our operations reflect a unified focus on quality, efficiency, innovation and reducing lead times for critical fire apparatus for communities throughout the United States.

“Every new machine, expansion, and workflow improvement enables us to deliver fire apparatus faster and with the exceptional craftsmanship customers expect from Pierce.”

New fabrication and welding technologies

Pierce Manufacturing said new automation and precision technologies are being introduced across fabrication and assembly processes at its Appleton campus.

The company said each investment is intended to increase production flow, reduce manual touchpoints and improve safety for team members.

Pierce Manufacturing said the newest additions include a Penta 30K laser capable of cutting up to two inches of steel with beveled edges, alongside an automated panel bender designed to complete multiple bends faster than traditional presses.

The manufacturer added that a semi-automated folding machine is intended to allow a single operator to complete complex bends, and that automated rail welding systems are expected to reduce welding time by up to two-thirds.

Pierce Manufacturing said hand-held laser welding technology is also being added, with the company describing it as delivering precise results with minimal material warpage.

Surface preparation and paint expansion

Pierce Manufacturing said buffing robots and an AI-enabled sanding system are being used to prepare metal panels for paint with greater consistency.

The company said a 26,000 square foot paint facility expansion in Appleton is nearing completion.

Pierce Manufacturing said the expansion includes new paint booths and curing ovens, which it said will boost capacity.

Workflow and parts handling changes

Pierce Manufacturing said it has relocated its manufacturing release line to improve production flow and quality control.

The company said it has also modernised its parts facility to centralise warehousing.

Pierce Manufacturing said the cab and chassis lines have been relocated and reformatted within a larger 224,000 square foot space, and that this has freed manufacturing capacity.

What this means for fire apparatus procurement

For procurement teams and fleet managers, the company’s reported reduction of lead times by more than three months from peak levels is a concrete indicator of recent manufacturing throughput changes.

For Fire Chiefs and senior officers planning replacement cycles, the stated aim of returning to pre-pandemic lead times may affect how departments sequence apparatus specifications and delivery windows.

For engineers and equipment specifiers, the described additions, including the Penta 30K laser, automated panel bending, rail welding systems and laser welding, point to changes in how parts are fabricated and assembled within the Appleton operation.

For workshop and maintenance planning, the nearing completion of a 26,000 square foot paint facility expansion and the relocation of production lines and warehousing centralisation indicate updates to finishing capacity and internal workflow.

Oshkosh Corporation Acquires Maxi-Métal Inc

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Oshkosh Corporation, an innovator of mission-critical vehicles and essential equipment and owner of Pierce Manufacturing, announced that it has completed the acquisition of Maxi-Métal Inc. of Saint-Georges de Beauce, Quebec, Canada.

Maxi-Métal is a leader in the design and manufacture of custom fire apparatus and utility vehicles in the Canadian market and will be part of Oshkosh’s Fire & Emergency segment. It has served fire and emergency professionals since 1983 and is a premier fire apparatus manufacturer in Canada. MAXIMETAL will maintain its name, team members, facilities, and branding elements.

John C. Pfeifer, Oshkosh Corporation President and Chief Executive Officer, commented: “Maxi-Métal is an organization known for quality, reliability, and an overriding focus on customer service and support. Their culture and customer focus align exceptionally well with Oshkosh, Pierce Manufacturing and its dealer network.”

“This acquisition will enhance the combined strengths of Pierce and MAXIMETAL by broadening collaboration and expanding sales and distribution capabilities within Pierce’s North American dealer network,” said Jim Johnson, Oshkosh Corporation Executive Vice president and Fire & Emergency segment President. “Oshkosh expects to benefit from MAXIMETAL’s experience and leadership as the company grows its combined presence in the Canadian market.”