MANUFACTURING PROCEDURE OF ZAINSA INSTRUMENTS.

1. Steel
2. Forging
3. Forging Inspection
4. Machining
5. Milling
6. Machining and Milling Inspection
7. Filling
8. Filling Inspection
9. Temper
10. Sand Blasting
11. Plant Treatment
12. Polishing
13. Q.A Inspection 50%
14. Ultrasonic Cleaning
15. Lubrication
16. Tuck Checking
17. Passivation
18. Boil Test
19. Copper Sulphate Test
20. Final Polishing
21. Final Checking
22. Etching
23. Cleaning and Checking
24. F.Q inspection 5%
25. Packing
26. Storage
27. Delivery

• Steel:

The quality of steel is very important in the production of quality instruments. The best you select the best you produce. In order to ensure the finest of quality steel, we have imported best quality local steel as required by valued customers.

• Forging:

Forging is a process of cutting shaped raw instruments with the help of dyes and hammers. Here, the skilled hands give life to the metal and give it the rudimentary shape that will go through series of complicated processes.

• Forging Inspection:

At this stage, forged tools are checked to ensure no piece contains any cracks or reshaped beyond acceptable limits. Checking the quality of raw instruments for: –
a. Shape fault
b. Broken

• Machining:

In this process forging is cut or shaped by machines i.e. cutting sharp edges and raw material in the shape. Here instruments are given their shape through grinding and hammers. For this purpose, extremely skilled labour is required and this process is carried out by instrument specialists only.

• Milling:

Drilling of holes in the instruments where required for screws. Different kinds of screwing machines are used and instruments are made pairs here. Instruments with even the slightest difference in whole positions will suffer otherwise.

• Machining and Milling Inspection:

At this stage, all the instruments are inspected not only for machining and milling, but for every process they’ve been through. It’s the stage where only best instruments are selected and instruments with tiny holes and manufacturing faults are again sorted out.

• Filling:

At this stage the steel is not too hard so filling is used to shape the instruments in the exact shape they are required to be. The workers match the shape exactly with the samples provided at this stage. So the instruments get most of their shapes at this stage.

• Filling Inspection:

After filling the inspection is made and measurements and shapes are checked according to samples.

• Temper:

In this process instruments put them in temper machine, which is filled with a particular material. Here instruments are tempered and its ensured that every instrument get equal heat and treatment so a consistent quality would achieve.

• Sand Blasting:

Sandblasting is a general term used to describe the act of propelling very fine bits of material at high-velocity to clean or etch a surface. Due to the dangers of inhaling dust during the process, sandblasting is carefully controlled, using an alternate air supply, protective wear, and proper ventilation.

• Plant Treatment:

In this process the instruments are dipped in a material by hanging for five minutes to harden the material.

• Polishing:

Instruments are polished at this stage. Till this point at manufacturing stage, all the necessary shaping is done. Polishing makes every millimeter of instrument clear and any instrument with hidden defects are revealed could be sorted out.

• Q.A Inspection 50%:

50% of each lot of instruments is checked quality assurance manager and then go the further processing. In inspection they see each and every part and defective parts are marked with red marker and if rejected send to polishing again.

• Ultrasonic Cleaning:

In this process the instruments are dipped in two materials for cleaning the polish raw thing on it. 1 min. for first material and then for half min. for other material. Ultrasonic cleaning cleans any polishing material stuck and leaves the instrument crystal clear.

• Lubrication:

All the instruments involving screws are lubricated at this step. Lubricating the instruments moveable portions facilitates the instrument movement.

• Tuck Checking:

In this process workers check the cuts and all other things just by viewing the instruments individually.:

• Passivation:

A crucial part of instrument finishing is the Passivation Process, this is a Nitric Acid surface treatment to remove foreign bodies and oxidise the surface of the material to increase corrosion resistance. Passivation is performed by trained technicians, who have suitable protective equipment and knowhow.
The ability of an instrument to re-process through sterile services, without any problems i.e. rusting and corrosion, is a very good sign of its quality. This is particularly important, as most instruments are made from Martensitic Steels, and therefore have more chance of corrosion.

• Boil Test:

The Boil Test is performed to check presence of corrosion in surgical instruments resulting either due to some process faults or due to some material composition problem disturbing the passivation layer of the stainless steel surgical instruments. The boil test is applicable to martensitic, austenitic, and precipitation hardened materials to detect surface imperfections.

• Copper sulphate test:

The copper sulfate test is used to detect chromium depletion at the grain boundaries caused by improper heat treatment or improper cold working of austenitic materials. The copper sulfate test is used to detect improper heat treatment of martensitic materials.

• Final Polishing:

Instruments are finally polished at this process to make sure quality appearance of the goods.

• Final Checking:

Instruments are finally checked at this stage to ensure all the above stages are fully achieved and requirements of the above processes are completely obtained at this stage.

• Etching:

Putting each instrument on stamp pad and burning process to put stamp on each instrument. This stamping procedure is done through electronic etching machines that makes the stamp reliable and even sustainable under high boiling temperatures when instruments are sterilized.

• Cleaning and Checking:

Instruments are cleaned and checked again one by one. Again it’s the checking for operation, measurements, polish and usability.

• F.Q Inspection 5 %:

Final quality inspection of the instruments is done by Chief Executive himself, 5% of each lot. Samples for inspection are taken randomly and are observed to every bit of detail. Even the slightest difference from acceptable standards could result in rejection of whole lot.

• Packing:

Packing in boxes each contains 100 pieces. 10 Boxes in a Carton. Here instruments are packed with respect to sizes and types. Instruments boxes are properly labeled and stored in proper storing environment.

• Storage:

Storage by lot and order number

• Delivery:

Good are delivered to foreign destinations through courier services.
These processes are also included as required.