Process capability measurement of frequent replacement spherical soft contact lenses

Frequent replacement soft contact lenses must have good reproducibility in order to avoid clinical problems arising from manufacturing variations in lens parameters. This study assessed the actual and potential process capability of eight frequent replacement lenses (monthly or 2-weekly replacement) in relation to back vertex power, back optic zone radius, total diameter and centre thickness. Twenty-four lenses in three powers (-1.00, -3.00, -6.00 D) were measured for eight frequent replacement lenses: Acuvue, Acuvue 2, Biomedics 55, Encore, Focus, Optima FW, Soflens 66, Surevue. In general, the lenses showed adequate reproducibility in respect of those parameters likely to affect lens fit, namely back optic zone radius, total diameter and centre thickness. The process capability results showed some variation in reproducibility of BVP between lens types and between lens powers. Process capability was found to be a useful measure of contact lens reproducibility.