Improvement of Contact Lens Field Complaint Rate Using the DMAIC Approach

Abstract

Contact lenses are susceptible to a defect call “tearing”. This is common but seldom condition detected in the field by the customer. The manufacturing process of a contact lens is a very precise method of combining an injection molding processes with a chemically bonded monomer. The liquid monomer is automatically placed between two half’s of plastic injected molds then forming the lens ,subsequent process of curing ,de-molding , hydration and packaging would form the final product for sale. The purpose of this study is to demonstrate that the application of the 6 sigma DMAIC approach to problem solving would provide a methodical and enriched conclusion to the root cause determination of contact lens “tearing” thus reducing the defect rate, subsequently customer complaints. Key Terms - Define, Measure, Analyze, Control