There’s something about walking around a brand new building. In many ways, the owner is still breaking it in.
Everything still looks new, and it is equipped with the newest systems available at the point of construction. If the new facility is a manufacturing facility, walking through and observing the product flow is always impressive.
At the end of 2023, Sutphen Corporation, the largest family-owned fire apparatus manufacturer in the United States, closed three facilities in Springfield and Urbana, Ohio, comprising 70,000 square feet and combined them into one 185,000-square-foot facility built from the ground up.
1 Sutphen Urbana is a 185,000-square-foot facility built on a 55-acre parcel. (Photos 1 and 7 courtesy of Sutphen Corporation)
THREE YEARS IN THE MAKING
Drew Sutphen, president of Sutphen, says that the new Urbana facility was a three-year project that began in 2020. As of December 2023, the facility was 95% operational and in March 2024 celebrated its official grand opening.
Known as Sutphen Urbana, it combines Sutphen’s chassis division, the Urbana Pumper Division, and Service and Technical Division. The new complex hosts the Sutphen Monarch chassis line, the Ohio Sutphen heavy duty custom pumper line, and the Sutphen Corporate Service and Technical Center.
Sutphen designed the building from the ground up and had been planning to expand for a while. Four years ago, “We got with all the stockholders and Board of Directors, and we sat down and said, ‘You know our business is better than ever. The backlogs are better than ever,’ ” says Sutphen. “We needed to grow. Our bottleneck was chassis. We couldn’t build enough chassis to build more trucks. With this facility, we can double the line by adding more people. We can do all kinds of things, but it was really to build more chassis because then all the other plants can grow.” The company is headed toward doubling production numbers with the opening of the new facility.
EVT TRAINING
Sutphen Urbana is also the home of Sutphen’s Corporate Service and Technical Center. Its training center accommodates up to 100 students. Sutphen’s Service and Technical Division offers prep classes and proctored exams for the EVT Certification Commission. It also offers its own Technician Program, vendor-specific training (e.g., pump training, generator training, and aerial control training, among others), and Sutphen-specific training on aerial and pumper operations and maintenance. EVT certifications include F1, F2, F3, F4, F5, F6, F7, F8, and FA4. It also offers T1, T2, T3, T4, T5, T6, T7, and T8 National Institute for Automotive Service Excellence (ASE) certifications.
2 A Sutphen emblem above Sutphen Urbana’s main entrance with the American flag hanging behind it inside. (Photos 2-6 by author.)
3 The hand pumper Sutphen sold to the Dearborn (MI) Fire Department in 1907.
4 The training center can seat 100 for various technician classes offered at Sutphen Urbana.
5 Sutphen cabs (shown) are assembled, painted, and placed on chassis at this facility.
6 Pumpers being assembled at Sutphen Urbana.
Sutphen’s Technician Program comprises Tech I, Tech II, and Tech III levels. Tech I is a beginner-level technician who has general knowledge of basic mechanics and certain Sutphen, vendor, ASE, and EVT certifications, all part of the Tech I Foundation Experience. Tech II is an intermediate-level technician who has completed the Tech I Foundation Experience as well as the Tech II Foundation Experience that includes higher level ASE and EVT certifications. Tech III is a master-level technician who holds all Tech 1 and Tech II Foundation Experience certifications as well as additional EVT, vendor, and Sutphen certifications.
POISED FOR THE FUTURE
Sutphen Corporation is led by Drew Sutphen and fellow fourth-generation family member Julie Sutphen Phelps. They were preceded by their fathers, grandfathers, and great-grandfathers going all the way back to the company’s founding in 1890 by C.H. Sutphen. History is important to the company. A hand pumper sold by C.H. Sutphen in 1907 to the Dearborn (MI) Fire Department is a prominent feature of Sutphen Urbana’s lobby, as well as a timeline wall featuring the Sutphen family business from 1890 to the present. According to Sutphen, fifth-generation family members work at the company now, and sixth-generation family members—his grandchildren—are starting to work there as well. Sutphen Urbana is a huge part of ensuring the company will continue to grow for generations to come. “Responsible growth is important,” says Sutphen. “We knew we needed to build more chassis, and combining all three facilities is allowing us to do that.”
7 Finished Sutphen units will go through final inspection here at the Sutphen Delivery Center section of Sutphen Urbana.
The 185,000-square-foot plant is only taking up part of the land purchased. It sits on 55 acres, only 25 of which have been developed. There is plenty of room for growth. “We were landlocked at the other three rental properties,” says Sutphen. “And, we knew we didn’t want that to happen again. So, we bought 55 acres so we can grow a lot over years. Maybe not my generation, but the fifth generation is here, and their name is on the note. We’re passing that to them and the people who work in the business.”
There are many things Sutphen is excited about regarding the new facility, but the customer experience probably tops all of them. “When I pull up in the lot and sit back and look at how well we thought this building out for the customer, I’m really happy how it finished out,” he says. There are five conference rooms for customers during inspections, two outdoor patios for customers and team members, customer lounges, and the Sutphen Gear Store. “Five conference rooms—I know it might sound like a lot,” says Sutphen. But, he explains that with that many rooms, equipped with smart boards, etc., you can have that many more preconstruction meetings and final inspections. “That is huge for the customer experience,” he says.
“We always say that the Sutphen experience is the best in the industry, and that’s something we really pride ourselves on,” says Josh Plichta, marketing and communications manager. “And to be able to have this shining piece to really bring that to customers is something we’re really excited for and to go from 70,000 square feet to 185,000 square feet, to increase capacity, to increase manufacturing, and to increase jobs.”
And, Sutphen Corporation hasn’t forgotten about its employees. “We’re thrilled for our employees,” says B.J. Laney, general manager. “I can come into work every single day and be proud because every single thing about this facility is better than the three facilities we just left. Whether it’s the amenities, the facilities, or the lighting—every single thing about this building is better.”
The office areas of the new facility are arranged in an open concept for the chassis leadership team and training and technical team to engage. For times when these teams need to break out, there are nine huddle rooms. There are four large break rooms for employees as well as the two outdoor patios. And, the Sutphens know their employees. “Julie knows and I know the majority of the people on the floor,” says Sutphen. “I know their kids. We have a lot of employees who have three generations here who aren’t Sutphens. One of the best compliments to me as a family business is to have other families in the business.”
LOOKING AHEAD
Sutphen Corporation will be 134 years old this year, and it remains 100% family-owned. Zach Rudy, director of sales and marketing, notes, “Less than 1% of family-owned groups will go into the fourth or even fifth generation. So, it’s really something what the Sutphen family has done.” So what’s in store to keep it going?
“Our main focus is to maximize our facilities to decrease our backlog—our focus and responsibilities to our current customers,” says Sutphen. “We’re always innovating, but right now our focus is to get our investment here up and running smoothly, reducing our backlog, and building more trucks.”
CHRIS Mc LOONE, editor in chief of Fire Apparatus & Emergency Equipment, is a 30-year veteran of the fire service currently serving as a safety officer and is a former assistant chief with Weldon Fire Company (Glenside, PA). He has served on past apparatus and equipment purchasing committees. He has also held engineering officer positions, where he was responsible for apparatus maintenance and inspection. He has been a writer and an editor for more than 30 years.
