ZAMST "INSIDE MEN"

ZAMST orthoses are entirely designed and manufactured in Japan. What sets them apart is a team of passionate men and women. They include a surgeon who is also doctor to the Japanese national volleyball team, an R&D engineer who is a physical trainer and a perfectionist production manager.
Toshiyuki Hirama

Sports engineer

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  Dr Mitsutoshi Hayashi

The doctor who
revolutionized orthotics !

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  Takayuki OKAZAKI

Innovation even in
manufacturing!

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Dr. Mitsutoshi Hayashi ^ Top of page


Dr. Hayashi is an orthopedic surgeon at the Kyorin University Hospital of Tokyo (Japan) and doctor to the Japanese men’s national volleyball team.
Dr. Hayashi has been collaborating with ZAMST for more than 16 years.


Dr. Hayashi, you played a key role in developing the first sports ankle brace…
MH: It was one year before the 1992 Olympic Games in Barcelona. A key player on the national volleyball team suffered a severe ankle injury. To help him recover faster and to prevent him from being injured again, I asked him to wear a medical orthosis.
I wanted a brace with rigid guards on both sides of the ankle to make sure the talocrural joint was stabilized enough to prevent a recurring injury. Unfortunately, the orthosis broke after less than two weeks of intensive training. The material used in the brace was not resistant enough to extreme demands and the product’s shape had not been designed to allow athletic movements, but rather to restrict all motion.
I then began working with ZAMST to develop an ankle brace that could resist extreme movement while protecting the player. We came up with a new product just before the Olympics. All the players on the team wore at least one ankle brace during the Olympic Games and none of our players was injured.

What were the key design changes that you requested ?
MH: It was important for me to provide the player with an ankle brace that could restrict excessive joint motion while not impeding his movements. A volleyball player has to run, jump, move from side to side and front to back, as well as bend his knees and ankles. Consequently, the ankle should be able to retain its full range of motion. We decided to change the material, the thickness and the design of the lateral guards, which had to be rigid but non-breakable. We also modified the thread used to sew up the brace fabric to prevent it from breaking under repeated friction. Then we widened the strap and Velcro fastener and sewed them to the plastic guards to enhance the durability and strength of the fastening system. Last but not least, the plastic guards were attached to the soft brace with rivets to allow the ankle to facilitate plantar flexion and dorsiflexion.

It sounds like the product is very technical. Are all the products available in the market so advanced ?
MH: They should be!
The ideal brace for sports should provide the functionality of a medical brace (to protect the joint in the best way possible) and respect the specificities of athletic movements and limitations, which are quite different from those encountered in daily life! In this respect, the sports orthosis should combine the qualities of a medical brace and the supportive action of taping. When this is achieved, as is the case for ZAMST products, you have a solution that is even better than taping in some aspects. Indeed, while taping is the most anatomically appropriate solution to support the joints, it also has two disadvantages: you need the expertise of a healthcare professional to get a good taping, which is not possible for all athletes, and you can’t adjust the compression level once the taping is in place, which you can do with a well-designed brace.

So what makes the ZAMST products so different ?
MH: To me, ZAMST products are simple, comfortable, functional and easy to use—these are the mandatory characteristics that all braces should have. They are also designed for sports, which means that they freely allow non-harmful movements while restricting dangerous ones. Last but not least, the ZAMST team has excellent medical knowledge and the researchers work closely with doctors, coaches and professional athletes on an ongoing basis to continue improving the quality and effectiveness of the products. Thus these researchers are fully capable of providing detailed information to customers to ensure users get the most out of ZAMST products–-and the ZAMST team works hard to make sure they do.

As a doctor do you recommend that all athletes use this kind of sports orthosis ?
MH: Thinking about the athletes that I monitor on a day-to-day basis, of course I would prefer that they did not use such products. And I’m sure that all the coaches, athletic trainers and doctors who work for sports teams are working to enhance their players’ performance while making them more resistant to injuries. In this respect, I do not recommend wearing orthoses everyday unless you have pathological joint weakness or you’ve already incurred a severe injury. However, even for “perfectly healthy” athletes, there are situations that demand the use of orthoses to supplement the body’s natural protection against injury, such as during a competition (the injury rate during competition is much higher than when training for many sports). Orthoses may also be required during an intensive training camp (when fatigue can be very high) or when the athletes feel they have accumulated too much fatigue during the season. In the end it’s a choice the player has to make, but to make the right decision, he should be informed about his risks, the consequences of an injury (abstention from training, long recovery, residual weakness afterwards, etc.) and the means at his disposal to prevent it (voluntary training, taping, sports orthoses, etc.).

Don’t you think one of the side effects of using sports orthoses is that the body may weaken and lose its capacity for self-protection ?
MH: With sophisticated sports orthoses like those manufactured by ZAMST, this can’t happen. Don’t forget that these supports will preserve freedom of movement and only protect the joint from excessive and dangerous exertion. Therefore, a full injury prevention regimen is necessary even though the athlete is wearing a sports brace. Weight training, proprioceptive training, coordination training and other exercises are indispensable. Think of a sports orthosis as being the last defense when all natural defenses have failed. And in modern sports, with the increased intensity of competition, these defenses fail quite often.




Toshiyuki Hirama ^ Top of page


Mr. Toshiyuki Hirama has been an engineer at ZAMST for 10 years. He is also a volleyball player, a sports trainer and, of course, a ZAMST user.


Mr. Hirama, what are the key characteristics of a ZAMST product ?
TH: When we develop a new ZAMST orthosis, we want it to provide excellent protection without affecting the user’s performance. To me, that’s the whole difference between a support designed for medical purposes and a support created for sports. The product design, materials selected and quality of manufacturing are meant to ensure effectiveness, comfort and ease of use.

How does that translate in the development process ?
TH: First, we spend a lot of time analyzing the shape of the joint that the new product is intended to protect. We also carefully study this joint’s range of motion during intensive sports to make sure that the finished product will not impede it. For these two analyses, we work closely with doctors and coaches and we collect body measurement statistics at our research center. Then, of course, we analyze existing products—from our ZAMST product line or those made by other manufacturers—and brainstorm to find ideas to improve upon them and make the new product even better.

What makes one orthosis better than another ?
TH: First and foremost, the product must fulfill its purpose of protecting the joint, i.e. it should prevent the excessive movements that could lead to injury. The second important point is freedom of movement for the user. If you consider an ankle brace meant to provide inversion protection, for instance, this product should allow the player to run, jump and bend freely, while at the same time protecting the ankle if lateral movements become too exaggerated. Product comfort is another key aspect since sports orthoses may be worn for five to six hours a day by professional athletes. At ZAMST we are able to combine different materials in one product to make sure we have the best fabric for each key area. This includes flexible material where freedom of movement is important, breathable material where there is a risk of excessive sweat and rigid and compressive material where joint support is needed.
Last but not least, the product should be easy to use. This is a cornerstone of the development process. If you have the best product design made from the best materials, but the product is complicated to put on, there is a risk that the user will not position the product properly. In that case, the product is no longer effective and can potentially affect the athlete’s performance.

What is the ultimate dream of ZAMST R&D today ?
TH: Our products are known for delivering maximum protection; they are very easy to put on and remain comfortable during exercise. I wish we could develop materials that deliver strong support, but that are so comfortable the user forgets he’s wearing them. It’s a dream, but this is what we are aiming for when we work on new product development.

What is the biggest challenge during the development process ?
TH: I think that the conflict between function and simplicity is the most challenging and the most interesting aspect. It forces us to develop advanced designs and put quality materials together to find the best solution. Indeed, we don’t want the best compromise between performance, comfort, quality and ease of use, but rather the best of these four characteristics in each product.

What makes ZAMST R&D proud today ?
TH: First, our medical background: the company has 35 years of history in the medical field, which gives us the knowledge and experience we need to develop the best products. Second, the fact that we were the pioneers of sports ankle braces in Japan. We developed our first ankle brace for the national volleyball team for the 1992 Olympic Games. Professional sports inspire us and they define our very high standard. Finally, the quality of products in terms of performance and in terms of durability.




Takayuki OKAZAKI ^ Top of page


Mr. Takayuki OKAZAKI, a production manager at Zamst for 12 years, shares some of the secrets of Zamst superiority and his production values.


Which particular criteria do you pay particular attention to when manufacturing ZAMST products ?
TO: Product quality and safety are my main concerns. On the safety side, we carefully search for any foreign object that could be accidentally inserted into the orthoses. In our sewing workshop, the object that poses the greatest risk is undoubtedly the needle since it can easily break during the sewing process. Each workshop is equipped with the most advanced metal detectors and all products are checked before being packed. We are very strict on this point. On the quality side, we strive to follow the specifications defined by the ZAMST R&D team to the letter. The engineers always come up with new ideas that often turn into manufacturing challenges for us! Fortunately, our engineers and ZAMST engineers collaborate very early in the development process to find the best manufacturing solutions and make these innovative ideas a reality.

From your point of view as a production manager, what does “quality” mean ?
TO: It means manufacturing products that deliver on their promises and that are durable, with no hidden or visible defects. And believe me, achieving all this for ZAMST is a full-time learning process because the brand is very demanding. Our quality control processes, whether they involve incoming materials, the manufacturing process or finished goods, are meant to achieve a target of 0% defects. We deliver 0.07%, which is not too far off !

What are your biggest challenges? What makes your life difficult ?
TO: ZAMST orthoses are very precisely designed and complex in the sense that each product is made from at least seven different materials and parts. Soft, thick fabrics might need to be sewn together with thin, rigid ones, while keeping a high quality seam (i.e. tight, even and centered). Sewing involves human action and has direct consequences on product functionality and durability. To ensure the highest sewing quality, we constantly provide intense training to our production teams.

What are you proud of today ?
TO: ZAMST is one of the very few manufacturers that use innovative and custom-made fabrics, especially multi-layered fabric. An innovative fabric often requires a new sewing technique, which means that we need to come up with new ideas all the time. And so far we have always risen to the task!




FROM JAPAN