Brad Cairns switches from doors to face shields
April 1, 2020 | 4:05 pm UTC
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Canadian lean manufacturing expert Brad Cairns has switched full production at his Best Damn Doors factory to making anti-virus protective gear.

ONTARIO, Canada – Popular FDMC lean manufacturing columnist Brad Cairns announced he has switched all production at his Best Damn Doors factory from making doors to making coronavirus-related protective equipment.

“We have gone ALL-IN on this fight,” Cairns said in an email. “The entire plant is dedicated to making PPE Face Shields, and we have ramped up from the prototype phase to 5,000 units per day capacity in under a week. WE NEED TO BEAT THIS THING so we can all get back to work.”

All 14 people in Cairns’ 8,000-square-foot plant are involved in the project, making plastic face shields of their own design that can be washed and reused and adjust to fit all wearers, including with glasses or wearing other protective gear such as face masks.

“We have capacity to make 50,000 kits per day if people want to put them together themselves,” said Cairns. “They come in packs of two and cases of 64, and we can ship globally. With volume we are continuing to lower to price so we can keep getting these in the hands of the people that need them.”

Cairns talks about the project and even demonstrates the face shields in a video he posted (see below).

 

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William Sampson

William Sampson is a lifelong woodworker, and he has been an advocate for small-scale entrepreneurs and lean manufacturing since the 1980s. He was the editor of Fine Woodworking magazine in the early 1990s and founded WoodshopBusiness magazine, which he eventually sold and merged with CabinetMaker magazine. He helped found the Cabinet Makers Association in 1998 and was its first executive director. Today, as editor of FDMC magazine he has more than 20 years experience covering the professional woodworking industry. His popular "In the Shop" tool reviews and videos appear monthly in FDMC.