Operational Excellence in Action: Glen Copack’s Journey to Scalable Manufacturing Growth

In the heart of Watkins Glen, New York, Glen Copack Food Manufacturing—a small but ambitious non-profit food packaging company—faced a critical inflection point. Rapid growth, driven by new equipment and facility upgrades, had outpaced the company’s operational infrastructure. Amid bottlenecks and inefficiencies, Glen Copack turned to Rochester Institute of Technology’s Center of Excellence in Advanced and Sustainable Manufacturing (COE-ASM) for guidance. What followed was a collaborative transformation that not only optimized production but also empowered a mission-driven enterprise to scale sustainably.

-Wendy Shutter, Director of Business Services @ Arc of Chemung-Schuyler

Understanding the Challenge

Glen Copack, a subsidiary of The Arc Chemung-Schuyler, employs individuals of all abilities, including those with intellectual and developmental disabilities. The organization enables supported individuals to gain experience, and develop vocational skills and work habits.

After receiving grants from FuzeHub and the Appalachian Regional Commission, the company invested in new equipment and facility renovations. These upgrades significantly boosted production capacity, enabling Glen Copack to attract larger clients and expand its offerings. However, this growth revealed critical inefficiencies in the shop-floor layout and inventory management systems, leading to production delays and logistical challenges.

COE-ASM’s Strategic Approach

Recognizing the complexity of Glen Copack’s situation, COE-ASM deployed a team of experienced engineers to conduct an on-site assessment in the fall of 2022. Their approach was rooted in collaboration, empathy, and technical precision. Rather than prescribing generic solutions, the COE-ASM team engaged in active dialogue with Glen Copack’s leadership, particularly Wendy Shutter, Director of Business Services. This participatory method allowed the engineers to tailor their recommendations to the company’s unique operational and social mission.

-Gerry Hurley, COE-ASM Technical Program Manager

Data-Driven Diagnostics

The COE-ASM team began by mapping Glen Copack’s existing production workflows, identifying pain points such as double-handling of materials, inefficient storage practices, and uncoordinated delivery schedules. Using lean manufacturing principles and simulation tools, they analyzed throughput, space utilization, and labor allocation. This diagnostic phase was not just technical—it was deeply human-centered, taking into account the needs of employees with varying abilities and the company’s inclusive culture.

Collaborative Redesign

One of the most impactful outcomes of the engagement was a reimagined shop-floor layout. COE-ASM proposed a streamlined configuration that reduced unnecessary movement, improved material flow, and minimized cross-traffic. These changes enabled Glen Copack to streamline 75% of its production footprint, significantly easing operational management. Importantly, the redesign also enhanced safety and accessibility for all employees, aligning with the company’s inclusive values.

Real-Time Problem Solving

Throughout the project, COE-ASM engineers demonstrated remarkable adaptability. During meetings, they engaged in real-time problem-solving, incorporating feedback from Glen Copack staff and adjusting their models on the fly. This iterative process fostered trust and ensured that the final recommendations were both practical and embraced by the team. As Shutter noted, “Working with COE-ASM was a major help. They adjusted to our needs quickly and provided in depth insights into how we could make immediate actions.”

Outcomes and Impact

The collaboration yielded measurable improvements. Glen Copack experienced smoother production flows, reduced lead times, and enhanced capacity to handle larger and more diverse orders. The operational clarity also empowered the leadership team to make informed decisions about future investments and staffing. Perhaps most importantly, the project reinforced Glen Copack’s mission by creating a more supportive and efficient environment for its workforce.

Conclusion

The Glen Copack case exemplifies the transformative potential of university-industry partnerships. COE-ASM’s approach—grounded in technical expertise, empathy, and collaboration—enabled a small manufacturer to overcome growing pains and emerge stronger. For mission-driven enterprises navigating complex operational landscapes, this case offers a compelling blueprint for sustainable growth through strategic innovation.

Learn more about our project with Glen Copack and how our engineers assisted.