Producing a surgical instrument requires a little over 80 steps before the instrument is ready for use and multiple quality checks to ensure consistent results across the whole range of the products. Few of the production processes are mentioned below.
Forging/Filling
This is one of the initial steps that takes the raw material and shape and form the rough shape of the instrument out of a sheet of stainless steel.
Setting
This step ensures that the instruments are all as per the sample requirements, if any instruments requires further filling, grinding or shaping it is all done during this phase of production.
Tempering
Tempering or heat treating makes the instruments hard and enables them to withstand rigorous use. Stainless steel is brought to a very high temperature and then cooled until it has reached the proper hardness. Hardness is measured in units called Rockwell Hardness (HRc). A typical hardness range for needle holders is HRc 40-48. For scissors, the range is HRc 50-58.
Polishing
Polishing is one of the later processes that allows the instrument to be brought to life. Different types of finish give the instruments a different character. Matt Finish or Gloss finish are all done as per client requirements. Various other instrument coatings are also available suiting the need of the client.
Ultrasonic Cleaning
Ultra Sonic Cleaning is the process through which instruments are thoroughly cleaned removing any residue accumulated on the instrument through the various production phases. This process is one of the last few process.
We monitor and verify the accuracy of our manufacturing process through frequent audits. Multiple quality checks are in place to ensure the high standards of quality, that Durrani & Co. proudly delivers, without disrupting the smooth production flow.