Vertical integration expediates Weyland Europe’s turnaround for essential NHS PPE visor production
European thermoforming packaging company Weyland Europe has joined forces with longstanding customer and partner Ricoh 3D to bolster the national manufacturing and supply chain effort to provide personal protective equipment for the NHS.
In a bid to help meet urgent demand caused by the coronavirus pandemic, 3D printing specialist Ricoh 3D was first approached on Monday, 23rd March by The Royal London Hospital. Since then, countless NHS trusts and medical establishments have come forward, with Ricoh entering mass production of 40,000 face shields per week.
Following a swift response to source and produce the plastic visor component of the face shield, Waddington Europe was primed to go into full production by Wednesday, 8th April, only 16 days after the initial request was made.
Weyland Europe, Managing Director Eduardo Gomes said, “The coronavirus outbreak requires support and collaboration from all manufacturing and supply chain companies, and we are pleased to be working in solidarity to support the increased production of PPE and medical supplies to the NHS.”
Weyland Europe’s Bridgwater-based in-house design and development team produced and laser-cut two initial design options, with amendments to the position of the visor holes, so that the visors could be thermoformed on their thermoform machines. Samples were dispatched within 12 hours of receiving the request, enabling Ricoh to assemble and present the prototype visor to the NHS for approval within 24 hours.
Feedback from Ricoh required sourcing extra clear material, which was immediately used to re-sample the visor, while working with Weyland’s manufacturing site in Arklow, Ireland, to begin mass production of the super-clear extruded material within a week.
Eduardo continued, “We were also able to ensure our tool makers delivered the new cutter, required for production, to the same tight timescale, and I’m pleased to say, also free of charge to the customer.”
“As a truly vertically integrated thermoforming business, we have the agility, flexibility and in-house skill to respond to our customers’ needs at short notice in this way, and I’m delighted we could pivot and provide for such an essential need at this unprecedented time”
Mark Dickin, Additive Manufacturing & Moulding Lead at Ricoh, said, “We were very impressed at the speed and efficiency that our packaging supplier, Waddington Europe, was able to work with us to turn this critical project around.”
The government has recognised anyone involved in food production, processing, distribution, sale, and delivery as an essential key worker. As one of the largest thermoformed food-packaging suppliers in Europe, Waddington Europe has already ramped up production to ensure an uninterrupted supply to all its customers.
They are reviewing all government guidelines, as well as CDC guidelines, in conjunction with their USA-based parent company, Novolex, on a daily basis across the group, with changes implemented immediately as new requirements and best practices are identified.
Secondary-tier support staff are working from home, and clear procedures for self-isolation or quarantine are in place. Hygiene and cleaning procedures have been re-evaluated, and frequency has been increased. External visitors and sub-contractors are no longer permitted on any of the sites, and staff cannot move between sites. Contacts have been established with COVID-19-certified cleaning companies, and preparations for a quick-response action plan have been put in place in the event of a COVID-19-positive test.
Eduardo finished “I am personally committed to ensuring a seamless and reliable service to all our customers at all times, but now more than ever, we will be going the extra mile to help our colleagues and customers, friends, families and local communities.”
