Background & Objectives
Summary
This interim report highlights details in the proposed lean implementation procedures and Product Flow Optimization techniques in producing AI-powered contact lenses. This report emphasizes the background, the desired objectives, and the proposed methodology. A Gantt chart is provided for the tentative timeframes for the project. The intention is to elaborate on injection molding as the best alternative to manufacturing contact lenses. In the proposed manufacturing approach, the lens material is subjected to heat until it reaches the melting point before being inserted into a casting. When the material dries, it assumes the mold’s contact lens contour. In the project, the hydrogel is employed as the polycarbonate contact lens. This project contacts Alcon Inc as one of the leading companies in designing and manufacturing contact lenses.
The idea of attaching a lens to the cornea to act as a refractive device seems to have emerged from concerns over the ineffectiveness and distress of wearing eyeglasses. The project proposes accelerating the design of contact lenses based on glass scleral through a lean implementation process. Studies show that glass scleral lenses have since been applied to repair visual flaws and irregularities (Hopp & Spearman, 2021). This project recognizes that new materials, exceptionally soft hydrogel lenses are accessible, allowing pleasant contact lenses to be manufactured in any design required. Statistics also show that most of the 125 million worldwide contact lens consumers are female and young (Hopp & Spearman, 2021). This project’s product designs would be gender-sensitive, with the young female demographic as the target market.
Project Objectives
There are two main objectives for the proposed project. First, the goal is to advance the quality of AI-powered contact lenses to make them gas-permeable with the durability of not less than three years. This project proposes integrating lean manufacturing and Product Flow Optimization to develop contact lenses and improve customer access by 33%. Quality and reliability are the defining checks for evaluating the project. Controls that are currently in place are non-conformances. This project’s acceptance criteria are based on over 98% success on tests on random selection at a 15% rate per 100-carton set. The in-process checks will evaluate defective contact lenses from the quality products. A batch of manufactured contact lens cartons will be withheld from distribution until the sample quantity and quality are determined. The quality of the developed contact lenses is derived based on the sampled representation.
The second objective is to ensure overnight vision correction technology in the lenses while optimizing customer confidence with a 40% improvement in satisfaction ratings. The intention is to achieve elaborate technology incorporation and quality evaluation procedure to match customer satisfaction. As proposed, in case faulty lenses are detected, a certificate of conformance will be publicized to demonstrate that boxes containing faulty contact lenses have already been separated and investigations completed. After the quality checks, all cartons from the day’s batch will be reworked or dispersed. This procedure is likely to assist in avoiding future recalls and boost client confidence.
Method
The contact lenses design and manufacture process is based on the DMAIC phases that target improvement in customer experience, quality vision, analysis of the science behind hydrogel in design, optimized production flow, and application of the Statistical Process Control (SPC) approach in the monitoring process behavior. The Product Flow Optimization adopts the agile technique through the lean implementation steps, including specifying the value, developing the map, articulating the flow, facilitating the pull, and completing the perfection phase as a recurrent cycle. Special test requests will be used to implement Product Flow Optimization checks by certifying new products and components.
Injection Molding in Contact Lenses Manufacture
This project recognizes that injection molding is the most cost-effective and widely utilized process for mass-producing soft contact lenses. The lens material is heated to the point of melting during contact lenses. After that, the liquid lens composition is pumped into a mold. When the lens substance hardens, it solidifies into the configuration of the mold. The lens is then polished and tested to meet the highest quality standards.
Gas-permeability and Overnight Vision Correction Design
Gas-permeable lenses are more effective than standard solid lenses and are more pleasant. Although specific gas-permeable lenses are designed for extended usage to eight hours, today, many opticians advise avoiding wearing contact lenses at night due to their inefficiencies (Brito et al., 2019). This project proposes the design of overnight vision correction technology on the lenses to address the problem.
Shadow Diagramming
The contact lens production is designed to adhere to health safety standards. The quality control examination of contact lenses involves product examination under high magnification to look for flaws. The curvature and thickness of the lens are measured using shadow diagramming (Alves et al., 2019). The quality assessment tests are necessary for product approval.
The Finishing Process
After a contact lens has been sliced; the final procedure is quality assurance and packing. After passing quality assurance and being examined, the contact lenses are prepared for packing. Lenses are often packed in a plastic and foil-vacuumed compact box. The vial is filled with saline solution, comparable to human tears in composition. The contact lenses’ hydrophilic substance absorbs the solution. Because the lens is now packed and hygienic, it is ready for use.
Student Contribution
This project proposes a lean implementation procedure and product flow optimization in producing AI-powered contact lenses. At this stage of the project, the main contribution is creativity in improving contact lenses. Three specific areas are combined in this project to give contact lens users an optimum experience. These areas include AI-powered experience, gas-permeable design, and overnight vision correction that can support prolonged use into the night. The project also engages knowledge in managing the DMAIC phases. This project focuses on target improvement in customer experience, quality vision, optimized production flow, and application of the Statistical Process Control (SPC) approach in monitoring process behavior. The Product Flow Optimization adopts the agile technique through the lean implementation steps, including specifying the value, developing the map, articulating the flow, facilitating the pull, and completing the perfection phase as a recurrent cycle. My contribution is to articulate these steps in facilitating Alcon Inc to develop the proposed prototypes.
References
Alves, A. C., Ferreira, A., Maia, L. C., Leão, C. P., & Carneiro, P. (2019). A symbiotic relationship between Lean Production and Ergonomics: insights from Industrial Engineering final year projects.
Brito, M. F., Ramos, A. L., Carneiro, P., & Gonçalves, M. A. (2019). A continuous improvement assessment tool, considering lean, safety, and ergonomics. International Journal of Lean Six Sigma.
Hopp, W. J., & Spearman, M. S. (2021). The lenses of lean: visioning the science and practice of efficiency. Journal of Operations Management, 67(5), 610-626.