Toyota Production System key to ramping up production in warp speed, providing critical items to healthcare workers
Toyota-Bullard team applied TPS to produce faceshields, respirators, hoods
Eliminated backlog of faceshield orders; 700-percent increase in output from March to April
Doubled production capacity for respirators; 85-percent faster deliveries
Created new hood line and doubled production capacity
Cross-trained employees for a more flexible workforce
'With every single unit we make, I imagine my doctors, nurses and others on the frontline needing them to do their job,' Barnett said. 'We know we are doing our part to save lives and protect families, communities and people around the world in this battle against COVID.'
With demand of its healthcare-related products skyrocketing, Bullard teamed up with
'We are very grateful for the partnership with
'It's in Bullard's DNA to protect people and save lives - we've been doing it for more than 120 years, starting with our invention of the hard hat.'
'Considering the urgent need to supply medical gear to caregivers on the frontlines of the fight against COVID, we were very eager to share our know-how to help increase output as fast as possible,' said
'TSSC has been sharing TPS outside
For all three products (faceshields, respirators and hoods), work was broken down from one person making units in batches, to multiple people each having a small part of creating the product. Units are now made one-by-one, in a continuous flow. In other words, completed products come off the line every couple minutes, versus not having a completed product until the middle of a shift. This means Bullard is getting the necessary products to healthcare workers quicker and in higher quantities.
Faceshields
There was a huge increase in demand for faceshields and the previous batch method just wasn't producing enough to meet the growing demands. To increase production, Bullard added employees to the area and created two new continuous flow lines, quadrupling production in just a few days. This new method led to a 700-percent increase in production between March and April.
Respirators
Creating the continuous flow line in respirators led to quick results.
Bullard doubled production capacity for respirators and significantly reduced the time from when a customer placed the order to when that order was shipped. Initial improvements cut that time in half; the addition of the automated calibration machine made deliveries 85-percent faster.
Hoods
Bullard mobilized workers to create a new sewing line for its hoods - which are used in conjunction with a respirator. While it's difficult to find experienced sewers to build a hood from start to finish, breaking the process down into multiple steps meant these new employees could learn and master the process faster. These new sewers doubled production capacity for hoods, and they didn't need to have any sewing experience.
'It's our responsibility to respond to and support all the brave men and women on the frontlines of this pandemic,' Bullard said. 'I'm proud of our team, not just for changing the way we do things to protect more workers, but for doing it while also putting in strict COVID-19 prevention protocols, including social distancing and mandatory face masks, to ensure their own health and safety.'
For Barnett, the partnership has been a blessing. 'We know there's a PPE shortage and we want healthcare workers to know we hear you and we're working as fast as we can to get you more supplies.'
About
The Toyota Production System Support Center (TSSC), based in
Through the Start Your Impossible campaign,
About Bullard
Bullard is a global leader in personal protective equipment and systems designed to help save lives. Founded in 1898, Bullard protects workers in the
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