SMC: How was the manufacturing facility set up to produce these products?
KT: Fortunately, we already had the equipment in place to produce these products. We have a CNC router that we use to cut polycarbonate and acrylic while the HP Latex 115 printer and cutter helps us produce vinyl labels and large-format signage.

SMC: How did the materials supply chain differ from the traditional products you used earlier? With many companies/industries manufacturing PPE, was it difficult to find suppliers?
KT: Much to my surprise, our regular supply of plexiglass and polycarbonate was completely run dry. The lead times for plastic supply were between four and eight weeks, which was certainly not going to work for us. We scoured the internet to find possible sources and, finally, found what we needed. Suppliers did not have sufficient stock, often selling out of products the same day they became available. I remember being placed on hold while the sales representative negotiated with a buyer on another line who was ready to buy their entire stock. With the help of Tribe Medical Group, a Canadian distributor of Arthrex and LifeNet products, we were able to secure enough polycarbonate to produce thousands of face shields.

SMC: Are you currently producing traditional signage? If yes, how do you balance the workload?
KT: Yes, we are also producing traditional signage. It has been difficult to balance the workload indeed. At first, we were relying on volunteers to produce face shields. With sales at an all-time low, we could not justify any new hires and were forced to lay off a few staff members. Slowly, things started to turn around and, by May, we were able to employ those volunteers, creating more part-time opportunities within the company. That said, we often find ourselves working longer hours, but we are very grateful to come out of this crisis on a positive upswing.

SMC: What were some of the challenges involved and how did you overcome them?
KT: Developing a face shield that is comfortable and functional while conforming to the Government of Canada’s material recommendations was the real challenge. We overcame this by launching a feedback campaign, which encouraged all end-users to submit their comments, complaints, and recommendations. This data along with a few healthcare practitioners’ napkin sketches helped us further refine our design, making it a true one-size-fits-all, useful, and practical product.

SMC: Do you see PPE as a part of your product offerings going forward?
KT: Definitely! Our intentions with this product line go long term. What started out as an initiative to give back has evolved into a new business venture. We have started selling our PPE products on the North Medical Group website. These items offer a reliable revenue stream. We now have the opportunity to get creative and produce new, functional products in Canada.