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Efficiency and innovation at Flokk: the Turek transformation story

Discover how Flokk transformed its Turek site into an advanced, lean manufacturing hub, driving efficiency, innovation, and sustainable growth.

How can businesses turn setbacks into opportunities for growth?

 

At Flokk, we faced such a challenge with the transformation of our Turek site. After acquiring Profim in 2018, we saw an opportunity to reimagine the Turek facility with a focus on efficiency and innovation. This is our story of turning adversity into a strategic advantage, using M&A and production excellence to create lasting impact.

 

Lean manufacturing for efficient growth 

Lean manufacturing is about maximizing value by optimizing processes and eliminating waste. At Flokk, we apply these principles across our operations to streamline workflows, improve product quality, and control costs. This approach enhances production speed and consistency, delivering value for our customers, employees, and owners.

 

When we acquired Profim, our goal was to transform its Turek site into one of Europe’s most advanced seating production facilities. However, a fire in 2019 disrupted our plans. Rather than seeing this as a setback, we viewed it as an opportunity to accelerate our "Future Production Setup" project. By fast-tracking this initiative, we embedded lean principles fully into Turek, creating a streamlined 27,000-square-meter production hub producing 100 product families with greater efficiency and agility.

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Old Setup: The previous assembly line in G8 consisted of separate work centers for swivel chairs, resulting in longer cycle times and unnecessary movement. This layout relied heavily on manual tasks, limiting overall efficiency and productivity.
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New Setup: The new integrated Flex swivel line in G8 features a product-family-focused layout that streamlines assembly and reduces transition times between stations. This reorganisation minimises waste, shortens cycle times, and enhances productivity, allowing us to respond more effectively to customer demands.
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Old Setup: Fabrics were manually transported after cutting, leading to extended handling times and limited workflow flexibility.

 

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New Setup: Automated fabric transportation has been introduced, improving both efficiency and flexibility in the sewing process. By reducing manual handling, this enhancement enables faster turnaround times and greater adaptability to production needs.
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Old Setup: The previous paint line had lower capacity and slower throughput, which impacted production efficiency and consistency in finish quality.
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New Setup: The new high-capacity paint line offers increased throughput and delivers a consistently high-quality finish. This upgrade boosts production speed and reliability, ensuring a more efficient process and a superior final product.

M&A as a tool for operational efficiency 

Strategic acquisitions like Profim allow us to introduce lean principles to new facilities, driving greater efficiency across our organization. By centralizing production for brands like Offecct and Giroflex at Turek, we have streamlined operations, reduced complexity, and lowered costs—all while maintaining high standards.

 

This consolidation strategy enhances our ability to adapt to market demands while positioning M&A as a path to sustainable, efficient operations that strengthen our offering. With Turek as a centralized hub, we can integrate newly acquired brands seamlessly, achieving scalable growth without sacrificing quality.

 

Building a platform for long-term success 

The transformation of Turek marks a pivotal step in Flokk’s growth strategy. Through strategic investments in technology, automation, and continuous improvement, we’ve positioned Turek as a core asset that supports future growth and acquisitions. With this strong foundation in efficient manufacturing practices, Flokk is well-prepared to integrate new brands seamlessly and maintain our competitive advantage and customer offering.   

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