Shumaker Industries, located in Northumberland, Pennsylvania, is a leading manufacturer of concrete mixer drums, replacement parts, and Load and Go (LnG) washing systems. Known for quality and innovation, the company continues to invest in its operations to support growing customer demand and long-term business growth.
Challenge: Capacity Limitations and Inefficient Flow
As production demand increased, Shumaker identified opportunities to improve facility utilization, streamline material flow, and prepare for the planned replacement of its blast and paint booth systems. The existing layout limited efficiency, required significant material movement, and created constraints on future expansion.
At the time of the assessment, production averaged 8–10 drums per week, with materials traveling approximately 2,000 feet throughout the manufacturing process. These conditions increased cycle times, labor requirements, and operational complexity.
Solution: IMC Partnership and Facility Layout Redesign
Shumaker partnered with IMC to evaluate operations and develop a future-state facility layout. Through onsite assessments, process analysis, and collaborative design sessions, the team created a plant layout and implementation roadmap focused on increasing capacity, improving flow, and supporting future growth. The plan included facility expansion, dedicated blast and paint booths operating in parallel, additional crane capacity, improved work cell organization, and enhanced space for both drum manufacturing and the LnG product line.
Results and Business Impact
The recommended improvements are expected to deliver significant operational benefits, including:
- Doubling production capacity from 8–10 drums to 16–20 drums per week.
- Improving throughput and lowering labor costs by cutting material travel distances in half.
- Shortening cycle times through parallel blast and paint operations and improved workflow.
- Improving workplace safety by reducing overhead crane travel and eliminating multi-level material handling.
- Creating additional capacity and growth opportunities within the LnG product line.
- Improving customer responsiveness through reduced lead times and greater production flexibility.
Testimonial
“The IMC team provided valuable insight throughout the assessment process and helped us develop a clear roadmap for future growth. Their expertise enabled us to identify opportunities to improve efficiency, increase capacity, and make informed decisions about our facility investments. It was particularly helpful to soundboard with experienced manufacturing professionals from outside of our organization to help identify blind spots and highlight opportunities for improvement that we might otherwise have overlooked.”
Mike Sellers, General Manager, Shumaker Industries, Inc.
