 The Art of Production |
|
|
|
The Art of Production:
A host of experienced technicians apply their specialized skills (totaling 540 years of combined
experience), to fabricate your patient's orthotics. From the moment your casts are received,
they are handled by people who fully understand their professional significance. Your
reputation, and your patient's healthcare, is dependent upon the precise transformation of your
casts and prescription into effective orthotic devices.
Throughout each phase of production, the devices are subjected to the rigors of some
34 no compromise quality control checks necessary for maintaining the highest level of
craftsmanship and standards. No detail is too minor. In most cases, the fabrication process takes |
|
|
|
| |
5-6 working days from the date of receipt.
Expedite your order to a 3 day "walk through" for an additional charge.
|
| |
Our Lab tour highlights the quality checkpoints within each department.
|
| |
| 1. Shipping, Receiving and Technical |
|
|
|
Receiving, Technical and Shipping:
This department receives, unpacks all shipments and matches negative casts to the correct prescription. The prescription is read and "booked in" to our computer system. A work order
is then generated detailing each departments process for the next 5 five days. The work order and negative casts are given a unique tracking number and date, and then placed into production.
Receiving checks:
1. Completed information. Any discrepancies are forwarded to the Technical Department for a phone call to the prescribing doctor.
2. Condition of the casts, i.e. low borders, weak casts or damage to the casts.
3. After creation of the work order, information is double-checked to the original Rx.
: |
| 2. Cast Pouring |
|
|
|
Cast Pouring
This section prepares the casts for plaster pouring as necessary (such as low borders, weak casts) and marks anatomical landmarks. All casts are poured perpendicular unless otherwise
specified. Casts may be poured inverted or everted to the transverse plane if so specified on the prescription.
Pouring checks:
1. Work order accuracy.
2. The integrity of the finished cast.
3. Lab Manager or Dr. Smith checks that all positives are poured vertical.
|
| 3. Cast Grinding |
|
 |
|
Cast Grinding
This section trims the positive cast to the width and length, balances the forefoot as prescribed, marks dimensions for distal trim and marks areas for expansion plaster.
Cast Grinding checks:
1. Second check for vertical heel.
2. Difference in the stated shoe size.
3. Verifies the doctor's findings on the forefoot values and records on the work order.
4. The Lab Manager or Dr. Smith evaluates the corrected cast. |
| 4. Plaster Additions |
|
| |
|
Plaster Additions:
This section adds expansions (medial, lateral & heel), and adds plaster to the platform as necessary. Evaluates casts for doctor's personal preference.
Plaster Additions check:
1. Quality of cast grinding and balancing.
2. Quality of finished plaster additions.
|
| 5. Orthotic Fabrication |
|
|
|
Orthotic Fabrication
This section arranges the various laminates necessary to comply with the prescribed orthotic type and desired flex of the device. The devices are labeled to indicate the prescribing medical professional, the patient and the identification number. The devices are then processed and re-established with the work orders.
Orthotic fabrication checks:
1. The positive casts for any imperfections.
2. Correct calibration on all equipment.
3. The quality of the finished device, i.e. no wrinkles in the shell of the device or labels, correct internal structure, pattern and flex.
|
| 6. Posting Section |
|
|
|
Posting Section
This department adds extrinsic rearfoot and forefoot posts accordingly. The posting section is also responsible for the complete manufacturing of the Prescription Comfort product line. Cutting, grinding, gluing and latex are the components completed in this section before final top cover assembly and finishing.
Posting check:
1. Correct placement of the post.
2. Quality of the posting material.
3. Correct posting values.
4. Correct location of accomodations for excrescencies.
|
| 7. Orthotic Grinding |
 |
|
|
Orthotic Grinding
The grinding section removes excess material and
finishes the edges of the device.
Orthotic Grinding checks:
1. Work orders timeliness and expedites if necessary.
2. Quality of the posting.
3. Correct flex.
4. Components of the device, i.e. deep heel cups are present, the correct functional shape.
5. Correct labels on device.
6. Lengths and widths of the device.
7. Any accommodations in devices.
|
| 8. Top Cover |
|
|
|
Top Cover
This department adds the accommodations necessary and adds a final top cover.
Top Covers check:
1. Quality of grinding of device.
2. Doctor's personal preferences for top covers and accommodations.
3. Final quality of accommodation and top cover placement.
|
| 9. Finishing Section |
|
|
|
Finishing Section
The finishing section bevels the superior edge of the top covers
and touches up the orthotics as necessary. This department is
also responsible for silk screen printing the logos on the
top cover material.
Finishing checks:
1. Completeness of top covers and accommodations.
2. Makes sure that the edges are glued down properly and that no air pockets are present.
|
| 10. ShippingTop^ |
|
|
|
Shipping
The shipping department verifies compliance of the device
to the work order. This department cleans, packages and ships
the device.
Shipping checks:
1. The final quality of the device.
2. Multiple orders going to one office. By combining orders this saves on the shipping charges.
3. The doctor's shipping preference.
|
