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A glove for your feet is goal of McCook orthotics company
by Gene O. Morris

There's a reason foot doctors in all 50 states turn to Burns Lab in McCook, Neb. for individually designed foot braces for their patients.

"We've built a reputation," says Mary Thorson, general manager of the Burns Podiatric Laboratory. "We produce the best quality orthotics in the United States."

Orthotics are orthopedic devices usually fitted into shoes that are designed to treat and support various biomechanical foot disorders. Although some orthotics are simple, commercially-made devices, the most effective orthotics, are custom-made devices crafted to meet the specific needs of a particular individual.

Mary, a member of the Burns Lab team for 30 years, says the company's attainment of excellence is directly traceable to two essential factors: a talented team of technicians, and: modern materials which allow very precise molding of foot appliances.

A devotion to quality

From the start, the formula has worked because of the founding family's devotion to quality control. The late Larry Burns, a Doctor of Podiatric Medicine, needed foot appliances matched to the exacting needs of his patients. Unable to find the quality he craved, Dr. Burns began shaping them in the basement of his clinic on McCook's Main Street. The year was 1969. Larry's children, now the leaders of the company, pitched in to help.

Quickly, Dr. Burns found that other podiatrists also sought precision-molded foot appliances. He and his children started filling special orders and, in ever-increasing numbers, that is what's still happening today.

"The process starts with the podiatrist's examination of the individual foot needs of his patients," Thorson said. "The doctor makes a mold, sends it to us, and we transform the prescription into an orthotic that — pardon the analogy — fits like a glove."

The secret for the exceedingly precise fit of Burns' foot appliances is polypropylene, a revolutionary material in orthotics which gave technicians the ability to shape devices to the exact specifications of the podiatrist yet still have a stable, comfortable, long-lasting device.

Lucky to be born in McCook

Looking back, Thorson says the company was very fortunate to be born and based in McCook, a town of 8,000 in southwestern Nebraska. "The work ethic here is extraordinary," she said. "We have a work force of 35 people, who, all together, have 298 years of employment with the company. What sets them apart is a devotion to quality. They will not quit until the orthotic order is filled to exact specifications."

An average of 3,000 custom foot appliances are produced per month at the McCook plant, a 70,000 square foot building at the intersection of U.S. Highways 6-34 and 83.

Continuing to grow, Burns Podiatric Laboratory is part of a group known as Burns International. Through the worldwide company, Burns serves podiatrists in a number of foreign countries, including Israel, Canada, Australia and several European nations.

The personal touch

“As big as we have become, we remain one-to-one," Thorson said. "It all boils down to the order from the podiatrist. We fill each one individually. We have the luxury of computerized automation, which helps us visualize and customize the prescription, but the personal touch remains the single most important part of the process."

The Burns family continues to provide company leadership. Dr. Michael Burns, who has a podiatric clinic in Fort Collins, Colo., is the president, and Mary Burns O'Dea of Loveland, Colo. is vice president and comptroller. Mike and Mary's brother, Dr. Greg Burns of Kearney, Neb., also shares ownership of the company. Like Mike, Greg is a practicing podiatrist.

At the McCook production facility, three managers fulfill key roles. Tom Kaminski, the production manager, has 22 years of experience; Tim Holthaus, the automated systems manager, has 18 years with the company; and Darren Harpham, the quality control manager, has 13 years of service. "They see that the work gets done," Thorson said.

"They are invaluable members of the team."

That's what it's all about at Burns Lab: the people and their dedication to producing the best foot appliances in the United States.

"There's a sense of pride here," Thorson said. "It stems from a passionate commitment to quality. We turn out lots of foot appliances, but what really counts is that each of them is for the individual needs of a person seeking help for a foot problem. That's our focus. That's our reason for being."

Gene Morris is a freelance writer observing rural life and business from his home in McCook.

Who To Contact...

Burns Podiatric Laboratory
301 N. Hwy 83
McCook, NE 69001
(308) 345-2300

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