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Debar

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Case Study

Debar is a leading manufacturer and supplier of high-quality bifold doors and hardware components.

The Challenge

  • The ability to rapidly adapt to customer needs is a priority for Debar
  • Productivity was hindered through excessive finished goods on hand. This was adopted to protect against variation in demand.
  • The overall goal was to achieve the above whilst increasing productivity and efficiency.

The Solution

To pilot a manufacturing cell for Debar’s cleats within assembly. Focusing on implementing 4 lean improvement techniques:

  • Single piece flow
  • Bottleneck management
  • Cellular manufacturing
  • Set-up reduction

The Outcomes

The Debar team and the pilot ‘proof of concept’ achieved some outstanding results by working smarter, NOT harder. The before and after graphs shown are not exaggerated in any way!

Testimony

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. Well done guy’s and keep up the great work.

Richard Glasbey, Production Manager, Debar