Supplemental Instrument Classes and Repairs.docx

Repaired instruments are to include all surgical instruments that are, or could be, used over the course of the following procedure types in the following specialties:

· Micro instruments

· Laparoscopic

· Eye

· ENT

· Orthopedic

· Plastics

· Vascular

· Cardiothoracic

· Genitourinary

· GYN

· Dermatology

· Dental

· Neurology

· Podiatry

· General

· Bariatric

· Scalpels & handles

· Knives (skin, tissue, specialty)

· Osteotomes, chisels, and gouges

· Curettes

· Rongeurs (Kerrison, Leksell, double‑action)

· Bone cutting forceps

· Biopsy punches

· Tissue forceps (Adson, Rat‑tooth, Ferris‑Smith)

· Dressing forceps

· Atraumatic/DeBakey forceps

· Needle holders (Crile‑Wood, Mayo‑Hegar, Olsen‑Hegar)

· Tenaculum forceps

· Towel clamps

· Kocher clamps

· Pean clamps

· Carmalt clamps

· Bulldog clamps (non‑vascular versions in general sets)

· Right angle clamps (Mixter, Lahey)

· Bowel clamps

· Army‑Navy

· Senn

· Volkmann

· Richardson

· Deaver

· Ragnell

· Langenbeck

· Self‑retaining retractors

· Gelpi

· Weitlaner

· Beckman

· Balfour abdominal retractors

· Dilators (male, female urethral style used in general sets depending on specialty)

· Depth gauges

· Calipers

· Rulers

· Suture ties and guides

· Knot pushers (laparoscopic, if included in “general” sets)

· Frazier suctions

· Poole suctions

· Suction adapters and tips

· Cannulas and obturators

· Suction tubes (Frazier/Poole)

· Laparoscopic mechanical cannulated instruments (if included without power components)

· Graspers

· Dissectors

· Atraumatic laparoscopic forceps

· Knot pushers

· Trocarr

· Spatulas

· Elevators (e.g., Freer elevator)

· Mallets (non‑powered orthopedic mallets sometimes included in general trays)

· Hooks (single‑end, double‑end)

· Punches

· Bone rongeurs (manual)

· Specula (nasal, vaginal—depending on set)

· Kerrison Rongeurs (All Types)

· Double‑Action Rongeurs

· Osteotomes, Gouges & Chisels

· Biopsy Punches

· Specula With Moving Parts

· Towel Clip & Tenaculum Variations

· Manual Dermatome Blades & Carriers (NOT powered handpieces)

· Meshgrafter

· Bone reduction clamps

· Plate bending instruments

· Bone holding forceps

Dental Handpieces

· High Speed Handpieces

· Low Speed Handpieces

· Latch Angles

· Prophy Angles

· Motors

· Torque Multipliers

· Auto chuck angles

· Adapters

· Electrosurgical (ESU) Cable

· Light,& Accessory Cable

Repair and Preventive Maintenance

Repair/Maintenance Type An instrument may require multiple “types” of repairs

Specifics Each repair type requires all corresponding “specifics” to be performed for each possible type

Cutting Instrument Repair

· Sharpening of all surgical scissors (Mayo, Metzenbaum, Iris, Potts, Tenotomy, Bandage, Lister, Operating scissors)

· Restoration of cutting angles and bevel geometry

· Honing of rongeurs, bone cutters, and similar cutting surfaces

· Edge restoration for chisels, curettes, osteotomes, gouges

· Bite sharpening and jaw resurfacing for rongeurs & punches

· Correcting rolled, burred, or mushroomed edges

· Re‑polishing cutting edges after sharpening

· Recreating the “set” on scissors (lateral curvature for proper cut)

· Creating micro‑serrations (if OEM design requires)

· Rebuilding broken or chipped tips

· Reshaping pointed tips (Iris, tenotomy, micro scissors)

· Correcting blunt or rounded tips to restore precision

· Re-aligning tips to meet perfectly at the distal end

· Fixing tip overlap or tip gap issues

· Correcting tip twist caused by torsional damage

· Realigning scissor blades (horizontal and vertical alignment)

· Correcting blade ride height

· Adjusting blade crossing point for proper cut action

· Restoring “riding angle” between blades

· Straightening bent blades or bent shafts

· Ensuring rongeur/punch jaws close evenly and without rocking

· Restoring parallel closure to cutting jaws

· Micro‑welding missing metal on cutting edges

· Rebuilding rongeur cups or bite edges

· Restoring gouges and deep nicks with metal overlay

· Rebuilding chipped osteotome or chisel tips

· Reconstructing broken Kerrison punch footplates

· Filling pits or cracks on cutting surfaces prior to sharpening

· Replacing hinge screws on scissors

· Tightening or reseating pivot screws

· Replacing broken rivets or pins

· Correcting hinge stiffness or looseness

· Removing corrosion inside hinge

· Aligning blades via pivot pressure adjustment

· Restoring proper opening/closing pressure

· Adjusting screw torque to correct blade engagement

· Setting proper tension for smooth scissor glide

· Correcting weak or excessively tight action

· Restoring worn serrations on biting instruments

· Recutting worn teeth

· Removing damaged or rolled serrations

· Rebuilding serrations using welding when needed

· Ensuring serrations align correctly on both jaws

· Re‑establishing correct angle for osteotomes, chisels, gouges

· Correcting bevel asymmetry

· Repairing hollow‑ground scissor edges

· Restoring OEM‑specific profiles (e.g., curved, micro‑curved, angled)

· Correcting bevel to prevent edge folding or dulling quickly

· Replacing or rebuilding footplates

· Rebuilding bite edges

· Restoring bite action and clearance

· Cleaning and resurfacing the throat

· Correcting shaft alignment

· Reconditioning internal surfaces to prevent sticking

· Replacing or repairing springs (on certain models)

· Sharpening inner and outer edges

· Restoring curvature and profile

· Rebuilding worn or flattened curette rings

· Reconditioning orthopedic curette cups

· Sharpening osteotomes and chisels

· Smoothing burrs on bone files

· Regrinding bone rongeur edges

· Rebuilding chipped bone-cutting tips

· Removing burrs left from sharpening

· Smoothing unintended sharp surfaces

· Polishing edges to reduce friction

· Removing heat tint or grind marks

· Blending welded areas into surrounding metal

· Jaw parallelization and gap correction

· Straightening bent instruments (hemostats, clamps, retractors, curettes)

· Restoring closing pressure, tension, and instrument balance

· Ratchet tooth alignment and engagement correction

· Loosening an overly tight hinge caused by corrosion or metal deformation

· Re-machining worn joint surfaces

· Removing burrs or metal fragments inside the hinge

· Correcting metal galling (friction welding damage)

· Cleaning out built-up debris from the hinge

· Restoring box‑lock flat surfaces for proper contact

· Rebuilding worn areas with micro-welding if metal loss is significant

· Polishing hinge surfaces to reduce friction

· Re-aligning the hinge to restore smooth opening/closing

· Replacing hinge screws or hinge pins if damaged

· Straightening a bent hinge area

· Hinge pin removal and replacement

· Re-seating a loose hinge pin

· Replacing hinge screws (Phillips, slot, torque screw)

· Correcting cross-threaded hinge screws

· Re-machining hinge screw recesses

· Lubricating and conditioning hinge hardware

· Reinserting or resizing hinge bushings (if present)

· Re-forming worn ratchet teeth

· Rebuilding missing/damaged ratchet teeth

· Restoring ratchet bar geometry

· Adjusting ratchet engagement strength

· Eliminating ratchet slippage

· Correcting over‑tight ratchet lockup

· Repairing or replacing ratchet springs

· Re-aligning ratchet tooth engagement

· Removing burrs or wear grooves

· Straightening bent ratchet bars

· Rewelding or reinforcing cracked ratchet attachments

· Tip alignment correction

· Jaw parallelization

· Correcting gap/offset in jaws or blades

· Ensuring ratchet engages evenly on both sides

· Realigning handles for symmetry

· Adjusting closing force (tensioning)

· Ensuring box lock movement is smooth and centered

· TIG or micro-welding cracks around hinge area

· Reinforcing weakened box-lock shoulders

· Rebuilding missing metal on hinge sides

· Removing and replacing fractured hinge sections

· Correcting heat damage or metal distortion

· Resetting hinge tension after realignment

· Ensuring jaw tips meet evenly under proper force

· Correcting uneven jaw compression

· Smoothing or adjusting rubbing points in the hinge

· Eliminating friction caused by metal burrs or misalignment

· Ratchet Engagement Pressure Adjustment

· Increasing pressure for weak-closing instruments

· Decreasing pressure for overly tight instruments

· TIG/micro-welding for stainless steel reconstruction

· Rebuilding/Recutting chipped jaws or worn serrations

· Reattachment of broken rings, shafts, or box-lock components

Component replacement

To include every individual part of any surgical instrument that can be removed, replaced, rebuilt, or fabricated, including:

· Screws & pins

· Springs

· TC inserts

· Jaws & tips

· Handles

· Ratchet/locking parts

· Shafts & tubes

· Connectors

· Frame & retractor components

· Slide mechanisms

· Polymer/insulated parts Cosmetic/ID elements

· Hinge screws

· Box‑lock pins

· Pivot screws

· Set screws

· Micro screws (ophthalmic)

· Threaded bolts

· Thumb screws

· Shoulder screws

· Locking bolts on retractors

· Slide‑rail screws

· Captive fasteners

· Washers (nylon, metal, fiber)

· Spacers

· Bushings

· Leaf springs

· Double leaf springs

· Coil springs

· Compression springs

· Tension springs

· Spring bars

· Insulator bushings for spring assemblies

· TC inserts for needle holders

· TC scissor blades/inserts

· TC jaws for graspers

· TC “waffle” pattern jaw replacements

· Replacement jaws for needle holders

· Replacement jaws for graspers

· Replacement rongeur tips

· Replacement punch tips

· Replacement serrated jaws (atraumatic or toothed)

· Tip rebuild components (rebuilt from base metal or added inserts)

· Blade/tip plates (e.g., specula, rongeur cups)

· Instrument ring handles (scissor rings, needle holder rings)

· Thumb loops for laparoscopic instruments

· Squeeze handles

· Pistol‑grip handles

· Rotating knobs

· Handle covers (insulated or silicone)

· Ratchet handles

· Ratchet teeth

· Ratchet bars

· Pawls

· Latching springs

· Locking cams

· Cam‑lever assemblies

· Locking plates

· Clamping jaws for table-mounted retractors

· Insulated shafts

· Insulated jaws or tips

· Insulation sleeves

· Insulation bushings

· Silicone or polymer handle inserts

· Insulated knobs and rotation collars

· Connector ends (ESU connectors, grounding connectors)

· Laparoscopic instrument shafts

· Cannulated shafts (hollow tubes)

· Suction tube replacements (Frazier/Yankauer tips)

· Crossbars for retractor frames

· Extension shafts or adapter shafts

· Bent or damaged sleeves/tubes

· ESU/electrosurgical connectors

· Light guide connectors (on some insulated instruments)

· Coupling rings

· Snap‑lock connectors

· Ball‑socket connectors

· Quick‑connect fittings

· Bayonet or threaded connectors for shaft attachments

· Retractor blades (Bookwalter, Thompson, Omni, etc.)

· Blade posts

· Blade mounting knobs

· Blade sockets

· Blade adjusting screws

· Rail clamps

· Table post assemblies

· Frame rings (Bookwalter‑type frames)

· Center posts and crossbars

· Mounting plates

· Articulating arm joints

· Adjustment knobs

· Locking bars

· Slide blocks

· Track guides

· Slide pins

· Detent pins

· Tension plates

· Glide bushings

· Slide rail clamps

· Suction tips (Frazier, Yankauer)

· Suction tube stylets

· Kerrison rongeur footplates

· Kerrison shafts and housings

· Biopsy forcep cups

· Trocars and obturator tips

· Laparoscopic scissor blades

· Grasper jaw inserts

· Needle holder jaw plates

· Chest spreader ratchets

· Dermatome plates (manual types)

· Silicone rings (color coding)

· Silicone handle grips

· Plastic bushings

· Insulated collars

· Plastic/nylon washers

· Rubber grommets

· Nonmetal stabilizers in retractor systems

· Replaceable punch tips

· Removal of orange/brown discoloration

· Treatment of early‑stage pitting

· Neutralization of corrosive residues within crevices and joints

· Chemical stain removal

· Surface scrubbing and polishing to eliminate discoloration

· Mineral and scale removal

· Buffing to remove scratches, scuffs, and tool marks

· Polishing to restore uniform finish

· Re-establishing OEM finish type:

· Satin

· Matte

· Brushed

· Mirror polish

· Gold Dipping

· Deburring inside serrations, jaws, and tips

· Deburring of sharp unintended edges

· Blending repaired areas into the original metal surface

· Removing grind marks from previous poor repairs

· Passivation of stainless-steel instruments

· Laser etching cleanup and metal surface repair

· Adhesive tape removal

· Adhesive residue removal

Insulated instrument repair

· All mechanical repair to the instrument body

· Localized patch repair

· Full-shaft re‑insulation

· Rebuilding small damaged sections

· Recoating tips, shafts, and joints

· Remove corrosion under insulation

· Fix worn or grooved shafts

· Eliminate burrs that can rupture insulation

· Refinish metal surfaces prior to re‑insulating

· Connector tip tightening or replacement

· Rebuilding worn contacts

· Fixing loose or broken grounding connectors

· Ensuring electrical continuity from handle to tip

· Recoating insulated jaws

· Rebuilding chipped insulation on jaw faces

· Correcting exposed metal between insulation segments

· Refinishing metal beneath jaw insulation

· Micro‑welding to correct burrs, cracks, or exposed metal beneath insulation before re‑coating.

· Handled repairs

· Jaw actuation repair (sticky or uneven movement)

· Trigger/squeeze handle adjustments

· Replacement of worn handle components

· Push rod or linkage realignment

· Insulator bushing replacement

· Cleaning/debriding internal moving parts

· Cannulated insulated

· Clearing internal blockages

· Removing internal rust or debris

· Straightening cannulated shafts

· Re-rounding/tuning internal lumen

· Re-rounding of the internal lumen

· Ensuring smooth passage for rods, wires, or cleaning brushes

· Internal rust removal

· Internal pitting repair where possible

· Internal surface smoothing

· Smoothing internal abrasions

· Re-rounding worn edges

· Adjusting lumen diameter to OEM tolerances

· Repairing broken solder joints

· Rewelding separated shafts

· Reinforcing weakened connection points

· Tip alignment

· Jaw repair (if applicable)

· Cutting edge sharpening (for cannulated rongeurs, biopsy punches, etc.)

· External corrosion removal

· Ratchet/hinge realignment (if the instrument has them)

· Clearing blocked or cemented lumens Using micro‑drills or reamers

· High-pressure flow systems

· Manual lumen reconstruction (rare but possible)

· Correcting warped or twisted support bars

· Repairing cracks in frame components

· TIG welding of fractured sections

· Reinforcing weak points or stress cracks

· Rebuilding worn mounting surfaces

· Restoring OEM geometry for alignment

· Rebuilding worn pivot joints

· Tightening or re-machining loose joints

· Repairing cam-locks and ratcheting hinges

· Replacing locking mechanisms

· Realigning pivot angles

· Removing burrs that interfere with locking

· Restoring smooth rotation without drift

· Cleaning and debriding slide tracks

· Re-machining worn or grooved slide rails

· Restoring proper tension on slide clamps

· Polishing rails for smooth travel

· Replacing broken slide pins or locking teeth

· Straightening bent blades

· Sharpening (if designed for cutting or scraping)

· Smoothing or refinishing blade edges

· Removing burrs that damage tissue

· Rebuilding blade attachment points

· Welding cracked holders or posts

· Correcting blade angle alignment

· Restoring table rail clamp tension

· Repairing or replacing worn clamp teeth

· Straightening bent posts

· Rebuilding locking knobs, screws, or levers

· Welding cracked or fractured clamps

· Reconditioning quick-release mechanisms

· Replacement of stripped or cross‑threaded screws

· Replacing missing bolts, knobs, and thumb screws

· Restoring thread integrity

· Lubrication and reconditioning of threaded assemblies

· Replacing worn washers, bearings, or spacers

· Rust removal from joints, frames, blades

· Pitting repair (when safe and superficial)

· Removing hardened bioburden in crevices

· Re-polishing surfaces (satin, matte, or OEM finish)

· Removing scratches and gouges

· Re-passivation of stainless steel to prevent future corrosion

· Recoating protective surfaces

· Repairing chipped or worn insulation

· Removing exposed metal points

· Adjusting holding force/tension

· Making sure arm drift is eliminated

· Restoring locking strength on articulating arms

· Ensuring blades hold stable under load

· Calibrating rotational resistance

· Replacing cracked or broken handles

· Fixing slipping levers

· Adjusting torque and grip strength

· Realigning lever arms for correct movement

Rongeurs (All Types)

· Multi‑component sliding mechanisms

· Footplate alignment

· Cutting edge precision

· Shaft and throat tolerances

· Rebuild of bite cups and footplates

· Two‑stage hinge & linkage

· Cutting geometry

· Jaw alignment under load

· Rotor replacement

· Bearing replacement (ceramic or steel)

· O‑ring replacement

· Chuck mechanism rebuild or replacement

· Autochuck spring replacement

· Chuck grip strength restoration

· Rotor balancing

· Spindle replacement

· Impeller replacement

· Complete cartridge replacement

· Cartridge bearing replacement

· O‑ring & seal replacements

· Chuck cartridge component repairs

· Cleaning & debridement of chuck

· Chuck tightening/loosening calibration

· Worn chuck jaw replacement

· Push‑button mechanism replacement

· Lever‑style chuck mechanism repair

· Chuck shaft polishing or resurfacing

· Air leak diagnosis and repair

· Water leak repair

· Water tubing replacement

· Airline seal replacement

· Blockage clearing in air/water pathways

· Spray port cleaning or replacement

· Water coolant flow restoration

· Replacement of cracked or dented housings

· Grip sleeve replacement

· Nose cone rebuild

· Exterior shell refinishing

· Thread repair

· Handle ring and collar replacement

· Motor vane replacement

· Motor gear rebuild

· Bearing replacement

· Clutch repair or replacement

· Air motor cleaning (carbon, debris, moisture)

· Motor seal replacement

· Gear train rebuild

· Head gear replacement

· Drive shaft replacement

· Latch mechanism repair

· O‑ring replacement

· Sheath and coupling repairs

· Gear train alignment and replacement

· Head rebuild, bearings & drive gears

· Chuck rebuild or replacement

· Head/neck cartridge replacement

· Shaft straightening (if safe)

· Internal gear lubrication and servicing

· Fiber optic rod replacement

· Light port cleaning

· Fiber optic lens replacement

· Light transmission test & restoration

· Replacement of damaged glass/plastic light guides

· Coupler O‑ring replacement

· Coupler water filter replacement

· 4‑hole/5‑hole/6‑pin coupler rebuild

· Swivel coupler repair

· LED coupler repair (if LED type)

· Thread and connector repair

· Replacement of protective windows or distal lenses

· Replacement of mirrors and internal reflective components

· Alignment of optical paths for proper beam delivery

· Repair of micromanipulator joints and bearings

· Rebuild of micromanipulator locking mechanisms

· Replacement of damaged beam shapers or focusing tips

· Cleaning of internal carbonized deposit or tissue buildup

· Replacement of laser fiber connectors or adaptors

· Refurbishment of laser fiber cleaved tips (non-disposable types)

· Adjustment of aiming beam alignment (if applicable to the handpiece)

· End tip cleaving and polishing

· Removal of carbonized deposits on contact tips

· Replacement of fiber jacket/sheath

· Replacement or repair of proximal connectors

· Testing for light transmission loss

· Inspection for fiber fractures and burn-out points

· Straightening minor sheath bends

· Rebuild of connectors for specific laser systems

· Rebuilding worn light-posts

· Replacement of sheath/strain relief sections

· Re-termination of camera coupler light inputs

· Realignment and polishing of optical faces

· Correction of cable stiffness or kinking

· Cleaning and refurbishment of multi-port connectors

· Cleaning and polishing of laser handpiece optics

· Replacement of protective windows or distal lenses

· Replacement of mirrors and internal reflective components

· Alignment of optical paths for proper beam delivery

· Repair of micromanipulator joints and bearings

· Rebuild of micromanipulator locking mechanisms

· Replacement of damaged beam shapers or focusing tips

· Cleaning of internal carbonized deposit or tissue buildup

· Replacement of laser fiber connectors or adaptors

· Refurbishment of laser fiber cleaved tips (non-disposable types)

· Adjustment of aiming beam alignment (if applicable to the handpiece)

· Dielectric testing for insulation breakdown

· Insulation repair or full re-sleeving

· Replacement of damaged connectors (banana plugs, blade connectors, proprietary fittings)

· Repair of cable strain reliefs

· Correction of intermittent energy delivery

· Replacement of broken grounding leads

· Rebuild of mono- and bipolar cable ends

· Continuity testing

· Replacement of melted or arced conductor sections

· Re-insulation of stressed or cracked segments

· Re-pinning or re-seating multi-pin connectors

· Replacement of damaged or broken fiber bundles

· Re-termination of connectors (male/female ends, universal adapters)

· Repair or replacement of ferrules

· Straightening or re-shaping bent connectors

· Removal of burn marks or melted sheath material

· Sheath replacement (cut, split, heat-damaged sheathing)

· Grip/strain relief replacement

· Cleaning and polishing optical end faces

· Replacement of light‑post adapters

· Correction of intermittent lighting issues

· Rebuild of angled or bifurcated light cables

· Replacement of autoclave‑damaged components

· Light transmission testing & certification

· Latch repair or replacement

· Hinge repair and pin replacement

· Rebuilding or straightening damaged lids

· Filter retention plate repair

· Replacement of silicone mats and holders

· Frame straightening

· Repair of dented or damaged corners

· Replacement of handles and locking tabs

· Spot repairs for localized chips, scratches, or wear‑through

· Repair of blistered or bubbled coating caused by poor adhesion or heat cycles

· Re‑coating instrument trays after autoclave‑induced breakdown

· Heat curing to restore a uniform, durable shell

· Adding color‑coding or functional color sections

· Multi‑layer coating for high‑wear zones

· Edge trimming and smoothing of sharp powder coat ridges

· Removing coating overspray from masked areas

· Replacing hardware damaged during coating processes

· Reassembly of coated components

· Functional clearance testing (ensuring drawers, lids, hinges operate normally)

· Re‑coating modular components like handles or knobs

· Eliminating lateral shift or rotational misalignment

· Re-establishing micro‑jaw parallelism

· Ensuring tips close evenly along their entire micro‑length

· Correcting tip “scissoring” caused by hinge imbalance

· Rebuilding bent or deformed micro‑tips

· Straightening twisted tips under magnification

· Reconstructing chipped or broken tips (0.1–0.3 mm range)

· Matching tip symmetry under high magnification

· Refinishing tip edges to remove micro‑burrs

· Re‑peening or tightening micro‑hinge pivots

· Polishing hinge contact surfaces at a micro‑scale

· Removing microscopic debris or corrosion from the pivot

· Replacing miniature screws or pins

· Restoring smooth, friction‑free motion with minimal opening resistance

· Ultra‑light tension adjustment (grams of force)

· Eliminating hinge “stutter” or micro‑binding

· Ensuring no over‑tightening, which can damage tips

· Balancing spring or hinge resistance

· Re‑cutting micro‑serrations

· Rebuilding worn gripping surfaces

· Restoring traction patterns under magnification

· Polishing serrations without flattening them

· Restoring fine diamond‑cut gripping surfaces

· Replacing micro TC inserts

· Recutting or retexturing micro-grip patterns

· Aligning micro jaws to prevent needle “twist”

· Sharpening micro‑scissor blades with exact geometry

· Restoring ride line and blade set

· Ensuring scissor tips cut at the very extreme ends

· Removing micro-burrs that can tear tissue

· Straightening thin shafts without introducing stress fractures

· Polishing surfaces without altering dimensions

· Removing corrosion without pitting structural integrity

· Restoring anti-glare or matte finish