A focused lean pilot inside Debar's cleat assembly cell, designed to free up cash tied up in finished goods while lifting throughput.
The challenge
The ability to react quickly to customer demand is a competitive priority for Debar. To protect against that variation, the business was carrying excess finished-goods stock, and it was quietly capping productivity and tying up working capital.
- Rapid response to customer needs is a priority Debar can't compromise on
- Excess finished-goods stock was being held to protect against demand variation
- The goal: lift productivity and efficiency without losing that responsiveness
The approach
Fluere piloted a dedicated manufacturing cell for Debar's cleats within assembly, built around four core lean improvement techniques.
- Single-piece flow
- Bottleneck management
- Cellular manufacturing
- Set-up reduction
See how Fluere works on the shop floor
The same hands-on, on-the-floor approach used at Debar runs through every Fluere engagement.
The result
- A working single-piece-flow cell live in assembly within months
- A repeatable lean model the team can extend to other product lines
- Closer, day-to-day partnership between Fluere and the Debar shop floor
“Well what can I say apart from…..FANTASTIC. These guys have been with us here at Debar for only a few months, and what a transformation. The team of Paul, Jake and Barney have been magnificent throughout our whole process. The improvements made have been really significant and our staff here at Debar have ALL welcomed the Fluere team and worked really well together.”Richard Glasbey, Production Manager, Debar
Typical impact across Fluere engagements
These ranges are aggregate figures from across Fluere's project history, not specific to Debar alone, and give a sense of what's typical once a project like this is underway.