Increasing Response to Pandemic, Toyota Partners with American Safety Company Bullard

Increasing Response to Pandemic, Toyota Partners with American Safety Company Bullard

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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

Plano, Texas (August 10, 2020) – Producing high-quality personal protective equipment (PPE) is a point of pride and passion to the team at Bullard – a fifth-generation safety equipment manufacturer located in Kentucky. Now, in the face of the COVID-19 pandemic – it’s downright personal. From team leader and cancer survivor Danny Barnett whose daughter has lung issues, to 33-year employee Brenda Hall whose daughter is a nurse caring for patients with coronavirus – every team member knows their work is impacting the world in a very serious way.

“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 Toyota to increase production in warp speed. Shortages of faceshields, respirators and hoods – all critical to caring for patients with COVID-19 – led to increases in demand for Bullard’s products reaching as much as 30-times normal orders. Doing nothing to meet the high demand was not an option.

“We are very grateful for the partnership with Toyota and proud of what we have accomplished together,” said Wells Bullard, CEO of Bullard, who is the great-great granddaughter of the founder, Edward Dickinson Bullard. “We are driven every single day to advance human safety and it was incredible to see that Toyota shares that same mission.”

“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.”

Toyota reached out, offering help to Bullard in whatever way it could – free of charge. That offer turned into Toyota Production System Support Center (TSSC) working with Bullard team members to apply the Toyota Production System (TPS) in those areas of greatest need.

“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 Jamie Bonini, vice president, TSSC.

“TSSC has been sharing TPS outside Toyota since 1992. This is a natural extension and speaks right to our mission of making a positive impact on society.”

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.


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.


Creating the continuous flow line in respirators led to quick results. Toyota engineers from the Production Engineering Headquarters just down the road in Georgetown, Ky., stepped in to help with the bottleneck – a calibration machine. The machine cuts the time in half needed for calibration and automates the process so employees can work on another step while the respirator calibrates. The result was more respirators being made in April than in all of 2019.

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.


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 Toyota

The Toyota Production System Support Center (TSSC), based in Plano, TX, helps American businesses and nonprofit groups learn more about the Toyota Production System to optimize the way they work. For more information about TSSC, visit 

Toyota (NYSE:TM) has been a part of the cultural fabric in the U.S. and North America for more than 60 years, and is committed to advancing sustainable, next-generation mobility through our Toyota and Lexus brands. During that time, Toyota has created a tremendous value chain as our teams have contributed to world-class design, engineering, and assembly of more than 38 million cars and trucks in North America, where we have 14 manufacturing plants, 15 including our joint venture in Alabama (10 in the U.S.), and directly employ more than 47,000 people (over 36,000 in the U.S.). Our 1,800 North American dealerships (nearly 1,500 in the U.S.) sold 2.8 million cars and trucks (2.4 million in the U.S.) in 2019.

Through the Start Your Impossible campaign, Toyota highlights the way it partners with community, civic, academic and governmental organizations to address our society’s most pressing mobility challenges. We believe that when people are free to move, anything is possible. For more information about Toyota, visit

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 Industrial Health & Safety and Emergency Responder markets. Headquartered in Kentucky, Bullard is a fifth-generation family-owned global company with offices and facilities in the U.S., Germany and Singapore. For more information, visit Bullard’s website at or call Bullard Customer Service at 877-BULLARD or +1-859-234-6616.


Carley Hummel
[email protected]

Ashley Brauer
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Bullard team members utilize Toyota Production System (TPS) elements to make face shields. The partnership between Bullard and Toyota led to a 700-percent increase in face shield production between March and April 2020. (Cynthiana, Ky.)

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A Bullard team member packs a respirator and hood to ship to workers on the frontlines of the pandemic. Toyota helped Bullard make changes with the Toyota Production System (TPS) that resulted in respirators being delivered 85-percent faster. (Cynthiana, Ky.)

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Tom Jones, Toyota Production System Support Center (TSSC), discusses the Toyota Production System (TPS) with American safety company Bullard. The companies partnered in March 2020 to ramp up production of personal protective equipment (PPE) in the face of the COVID-19 pandemic. In a four-week period, Bullard increased production capacity by 10-times previous capacity. (Cynthiana, Ky.)

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Brenda Hall, a 33-year Bullard team member, sends a respirator down a chute to the next team member who stands 6-feet away on the line. Hall said integrating Toyota Production System (TPS) principles resulted in a smoother, faster process. Following the partnership with Toyota, Bullard doubled production capacity of respirators and is delivering customer orders 85-percent faster. (Cynthiana, Ky.)

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In the face of the COVID-19 pandemic and skyrocketing demand for personal protective equipment (PPE) for frontline workers, Bullard team member Abby Cooper sews a hood on a new sewing line. Bullard and Toyota worked together to implement the Toyota Production System (TPS) for critical PPE items. The changes resulted in doubled production capacity of hoods. (Cynthiana, Ky.)

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