MANUFACTURING AND PRODUCTION AT LENSKART

ABOUT

LENSKART Solutions Private Limited is a leading E-Commerce portal of eyewear,

Pioneered in 2010.

FOUNDERS: Mr. Peyush Bansal

Mr. Sumeet Kapahi
Mr. Amit Chaudhary

“Lenskart’s MISSION is to give India a VISION.”

There are over: 1100+ Lenskart Stores in India and serves

Internationally across Singapore, UAE, USA.

Lenskart is an OMNI_CHANNEL industry, a customer can place order through several channels;

Online through Lenskart website/app, Amazon, Flipkart.

Offline through Lenskart Stores and Franchise.

Home Try On (HTO) Services.

Brand associate with Lenskart are:

 Vincent Chase Eyeglasses (Single Vision, Bifocal/Progressive Specs)

 Hooper (For Kids)
 Lenskart Air (Flexible Frame)
 Lenskart Blue (Zero Power Blue Cut Specs)
 Aqua Lens (Contact lenses with disposable cover)
 Tommy Hilfiger Eyeglasses
 John Jacobs (Imported Premium Products-Sunglasses)
 Oxydo Eyeglasses
 Ray Ban Eyeglasses
CONTENTS

1. INBOUND

2. INTRODUCTION TO NEXS SOFTWARE

3. WAREHOUSE

4. MEI

5. FITTING

6. QUALITY CHECK

7. PACKING

8. MANIFEST

9. BULK

10. FRAME MANUFACTURING

11. LENS MANUFACTURING

12.OTHER

13. ABBREVIATIONS
CHAPTER 1. INBOUND

INBOUND, also termed as STOCK-IN is the process of inwarding of stock from various sources.

In lenskart, 3 types of shipments are inwarded:

 Import shipment (china, Japan &USA)

 Domestic shipment (through local vendors)
 In – house (manufactured in lenskart – Frames (TR, Acetate), JIT lenses)

There are seven type of products that are received:

1. Eye Frame

2. Contact Lens

3. Prescription Lens

4. Sun Glass

5. Contact Lens Solution

6. Aqua Drop Solution

7. Non Power Reading Glasses.

Process of Stock- In department

 First step is Invoice verification – After receiving the shipment, invoice verification is done by
stock-in team.
 Unloading & Physical verification- Shipment unloading and verification of Box Qty. as per invoice
is conducted.
 Sharing of shipment details with the Merchant team - After unloading, an email is sent to the
merchant team informing shipment details to get PO and packing list.
 Sampling for IQC - 5 Qty. for IQC and 1 Qty. for Photo-Shoot (In case of New PID) need to be sent
and the same need to be collected after completion of the process.
IQC- INCOMING QUALITY CHECK
The IQC Team performs tracing of frame using Tracer and Espresso software.
If the PID exists in the lenskart ecosystem, the tem checks the history of the product and if the PID is
new, then tracing is done (tracer saves the shape of each frame PID and stores it in the database for
MEI).
IQC also checks the alignment, colour code, model no., frame quality (coating, finishing) and trial of
lenses in frame.

After IQC there can be two outcomes:

IQC passes the product - A green sticker is pasted and the box is handed over to the QC team.

IQC fails the product – If rework is possible then it is initiated.

If not, then we return the product (if the vendor is local),
and if the shipment is Imported, then a Debit Note is sent forward.
Based on Quality rejected, wrong received material and warehouse damaged parts need to be
returned to the domestic vendor.
Also need to inform The Merchant Team to get approval for return.
Documentation for return- Challan, Gate pass and debit note.
Loading is done as per Qty. mentioned in return documents.

The further process of passed items is as follows:

 Photoshoot- 1 item is selected for photoshoot in case of new PID. Photoshoot is done to
launch the eyeglass on the app (details like height, width, colour, category, PID are shared)
 QC - After getting IQC sampling reports, 100% physical Quality checking is executed. This
includes checking the colour code, scratch, alignment, PID, quantity (as per packing list) and
in polarised sunglass (checking is done by polarised tester).
In case of a missing barcode on any of the lenses and frames then a new barcode is
generated and added on to the item.
 Invoice creation - As per given details by Merchant team, invoice is created on NEXS
software.
 GRN process- Goods Received Notes (basically confirming that items have been received as
expected) process is initiated after completing Quality check of all received items.
Scanning of all boxes is done in software (NEXS, ATHENA) to complete GRN and create
Putaway.
 SED (Short/Excess/Damage/Quality Issues- After completing GRN, if there is a case of SED and
Quality rejected items from vendor end, then The Merchandising Team needs to be
informed in order to raise debit note to concerned party.
In case of domestic supplier, Quality rejected parts need to be returned to the vendor and
issuing of credit note is initiated.
 Invoice closer- Invoice needs to be closed in system and handover to The Finance team with
proper documentation is done (Invoice, AWB bill custom, flyover cargo advance, Insurance,
logistics, costing sheet, invoice summary, debit).
 Handover to Warehouse team- All Physical Qty. is moved to warehouse after completing
putaway by SMT Team.
CHAPTER 2. INTRODUCTION TO NEXS SOFTWARE

WHAT IS NEXS?

NexS is a tech offering to lenskart, entailing the end to end process of supply chain management. It
is a consolidated view of all the different processes around lenskart that includes inbound (stock- in),
inventory management, order processing, manifest.

This will further be processing all different operating domains of lenskart on NexS like the Singapore
plant, the national and international stores/ facilities etc.

We started a pilot order processing for NexS in the DK02-Manesar Facility. Starting with FR1_NON-
JIT customer orders only to test the complexities that we might face in the future. The application
we use to process these orders is NexS Apk. which was primarily called the Pulse App.

Test facility for NexS was NXS0, which is no more in use.

Facility for Bhiwadi plant is NXS1, on which we are currently operating.

Monitor Panel

On the monitor panel, under FR1 we can see the number of orders to be processed and against it
twice the lens under category Prescription-Lens.
As we keep scanning the respective barcodes after each process, their order status gets updated on
the monitor panel.
This way it makes it easier to keep track of the orders and the system maintains a record of all orders
and actions performed by user through their employee code.
CHAPTER 3. WAREHOUSE

CATEGORIES

FR0: Fitting not required; this includes: Sunglasses, Contact Lenses, Contact Lens Solution.

FR1: Eye frames that require fitting: Single Vision, Bi-focal, Progressive.

FR2: Powered Sunglasses

FRAME TRAY LENS MEI

PICKING MAKING PICKING ENTRY

Picking
Picking of frames by scanning the barcodes against each PID in their respective locations and
collecting all the picked items in a basket. After all barcodes have been scanned we can see the
picking history which shows the number of pending/skipped barcodes. We can also resume picking if
we missed any and then click “Yes, picking completed”.

Tray Making
To map an item to a tray, we first scan the item barcode followed by scanning the tray barcode. A
pop-up appears saying “Item mapped to tray”. Now this tray barcode will contain all the order
details like Fitting-ID etc.

Lens Picking
After the tray has been mapped, we pick the lens. First we scan the item barcode (frame barcode). A
panel opens up with lens details (location, PID, power). We scan the barcodes of the lens followed
by scanning of Tray ID. A pop-up comes up “Item picked”.

This is the last step as per the Apk. After this we remove the lens cover carefully using gloves to
prevent any lens from damaging.
After we have finished with the above processes, the order is then sent to MEI for lens edging
through conveyor.

On the NexS panel, under Order processing > MEI, we select MEI_ENTRY and scan the tray barcodes.
This will update on the panel showing that the order is currently in edging state.
After the lens is cut. On the same panel we select MEI_EXIT.

*[Ideally MEI_ENTRY and MEI_EXIT will be done through sensors on Bosch conveyors]
CHAPTER 4. MEI

The tray enters the MEI section through conveyor belts;

1. MEI department 15 machines (3 lines with 5 machine) in Bhiwadi plant.

2. The tray enters the MEI machine through the EZ LINE.
3. The first barcode reader assigns the Tray to the different MEIs on that particular line.
(software used JOB FEEDER to connect all the MEI machines together and with the
Supervisor PC)

Lens inspection chamber (Left side) Machine lens edging chamber(Right side)

Lens Lens Lens rough

Lens loading/
loading inspection cutting/ first
unloading
cutting

Lens Lens final

Lens
power & Safety bevel cutting &
thickness
centration & drilling bevel
inspection
inspection preparation

4. Once the tray enters the MEI machine it goes through 8 steps:
 Inspection station
a. Loading /unloading
b. Lens inspection
c. Thickness Inspection
d. Power Inspection
 Cutting Station
a. Loading/ Unloading
b. Rough cutting (Has two spindles, one for CR, and one for poly carbon)
c. Finishing cut (polishing liquid is used in this step for rimless frame lenses)
d. Drill/ Bevel/ Groove: Drill, Bevel and Groove is made of Rimless, Full-rim and
Half-rim frame lenses respectively.
5. During this process various Pop- ups are shown on the supervisor pc which is removed by the
operator:

a. To mark the Engravings for JIT

b. To accept or reject the power tolerances
c. Small diameter lenses
d. To mark the optical centre

The errors that are rectified are processed further. The ones that are rejected are sent to
the escalation team.

 The trays that have been processed properly are sent to Fitting Station through acceptance
belt, else sent to rejected belt.

Escalation
There are three main reasons for escalation:

• Wrong power

• Diameter issue

• Engraving issues

The Escalation team sorts the tray with respect to the error. If the error can be rectified, it marks
okay and sent to the MEI again. Else it is sent to be checked and separated as good inventory or
bad inventory. Good inventory is further sent to warehouse, whereas bad inventory is further
checked. If the issues can be rectified, it counts as good inventory else gets discarded
completely.

Some reasons for escalation can also be: Lost in

production

• If lens is not picked from warehouse

• If lens has wrong coating
• Cut lens is broken in MEI
• Lens if cut of wrong shape
• Barcode not scanned
After selecting the reason job goes to OMT which fulfils the requirements.
TRACING

Software used – Espresso

Calibration is done before any tracing by JIG and this is done to check if there is no error and there is
accuracy or not.

Bevel Type Bevel Position Position Value Groove D/W

Full Rim Pin Bevel Relative 33,33 0,0

Half Rim Grooved Relative 33,33 0.5,0.6

Rimless Flat Auto/?? 0,0 0,0

*Groove is the thread dimension.

Steps for Tracing of FULL RIM:

a. Frame dimensions are traced through tracer.

b. Fitting id is scanned which is on picklist through barcode scanner. It is done 2 times.
c. After scanning of fitting id all the details of order are entered in Espresso.
d. Then edging is selected.
e. Bevel type and bevel position is checked. For full rim bevel type is Pin Bevel and position is
Relative.
f. Shape is selected and checked if it’s similar to the frame.
g. Trace is selected and done yes.
h. Click save and then proceed to the next order.

Steps for Tracing Half Rim and Rimless:

NOTE- For rimless and half rim dummy lens is traced by device called supra.

a. Fitting id is scanned through scanner

b. For tracing the dummy lens is traced by supra device.

Any one of the lens is traced which tells both lens dimension. If right lens is kept on supra
then left lens is traced. Below image shows the position of lens to be placed on supra. The
dummy lens in this image is right lens and when kept on tracer it gets opposite so left is
clicked.
c. After tracing of dummy lens DBL is entered which is the Distance Between Lens. This is
written after PID on frame.

d. After that the process is similar to full rim.

CHAPTER.5 FITTING

FITTING/ASSEMBLY includes fixing of lenses in the frame through various processes. Every fitter is
assigned a target per hour which they have to achieve. First they check the details of the lens and
frame by verifying it with the details shown to them on the NexS Panel, then follow the process as
describes below.

Spray IPA+ Water

Scan Tray Barcode Fitting of lenses in
solution to wipe
in Fitting Panel frame
off smudges

Grinding/grooving/ Scan tray barcode

Dip Lens in soapy
again to complete
solution if lens is big in size fitting

Wipe Lens Heating frame

carefully with (Rimless, Acetate)
Tissue if required

Fitting Process is as follows:

 Scan tray barcode on Fitting Panel on NexS under Order Processing.
 Dip the both lenses in soapy solution to remove any dust particle and then wipe with tissue.
 Fitter heats the frame front side from its corner side and insert the lens one by one in the
circumference in case of acetate frame.
 Chamfering and grooving is performed in case lens is slightly bigger in order for it to perfectly
fit inside the frame.
 After the lens is fit in the frame IPA+ Water solution is sprayed and cleaned using tissue to
avoid any smudges.
 Scan tray barcode to complete the fitting process and put the tray on conveyor.

Tools and instruments used in fitting Department Cutter, Nose plier, side plier, bend plier, screw
drivers (plus, minus), and punch pliers, IPA+ Soap solution, heater, drilling machine, Hand edger
machine (chamfering machine).

Soap Solution
Soapy solution is made by mixing a few drops of liquid soap in water. When we receive lens from
MEI, it has a lot of dust. Dip the lenses in soapy solution to prevent any scratches on the lens.
IPA+ Water Solution
This consists of 70% water and 30% IPA (Isopropyl alcohol). The solution is sprayed after fitting of
lens is done to clean any smudges on lens.

Hand Edger Machine (Chamfering Machine)

If lens is not of exact size, then chamfering is done.

Grinding and buffing is done on this machine for the lenses which requires little edging and polishing.
Grinding is done for reducing the size of the lens to fit it in the frame, it is done at an angle of 90º.
Buffing (Polishing) is done to give finishing and shine to the lens. Wax is used for buffing, usually yellow
wax is used for giving shine to lens, for removing deep scratches from acetate frame red/pink wax is
used (in frame manufacturing area).

Bevel can also be made manual through hand edger machine by moving the lens on the bevelling
wheel at an angle of 45º. Bevel is required if the size of lens s reduced.

Hand edger machine (chamfering machine) Yellow Wax

Fitting Tools

Screw drives are used for metal frames to fit the lens by removing the screws and fitting it after the
fitting of lenses is done. Pressing Plier is used is generally used for Rimless frames to press the rivet
inserted in between nose bridge and lens. Cutting pliers are used to cut the extra part of the rivet.
Nose pliers are used to bend the wires.
 Plus- minus screwdrivers, pressing plier, one side plier Rivet

Heater & Drilling Machine

 Heater is used to heat the Nose Bridge of Rimless frames to remove it, so that dummy glasses
can be removed and lens can be fitted.
 Drilling machine is used for Rimless frames to drill the holes in the lenses so that rivet can be
inserted.

Heater Drilling Machine

CHAPTER 6. QUALITY CHECK

Check for any

scan tray barcode Check PID and Check power in
damage or scratch,
in Order QC Colour code Lensometer
Fix alignment

Scan all three Pack in Hard-case

Clean with selvet In case of Blue-cut
barcodes(1 frame and monocarton (in
and pack in heatlon lens check with
& 2 lens) to case of customer
sheet BLue-cut Torch
complete QC order only)

Quality check of orders is the most crucial process. This is the final stage for confirmation of all three
items. The step-wise process is as follows:

1. Open Order QC under Order Processing on NexS and scan tray barcode.
2. Check PID and colour code of the frame as shown on NexS Panel.
3. Checking of Power through lensometer.
4. Alignment, Scratch and bubble Checking in the lens. (was the frame checked for fitting defects
turning 360 degree taking around 10-20 seconds?)
5. Checking Blue-cut through the Blue-cut torch.
6. Cleaning of the Lens with selvet.
7. Pack the Frame in heatlon sheet followed by hard-case.
8. Scan all three (2 lens and 1 frame) barcodes to complete QC.

In QC, an orders either gets passed or failed. In case, any item was found to be damaged or missing a
part, alignment issue, scratch, wrong power, then the tray is sent to escalation section.

The escalation team tries to fix the issue if possible. If they are not able to fix it, then it is declared as
QC Fail and it goes to the OMT team. OMT team re-picks damaged items then it transfers the tray to
the respective department and the process starts.

Violations in QC

1. Not more than one operator should be allowed on one system.

2. No stacking of trays should be done
3. Handling of only one order at a time should be allowed on station to avoid the mixing of
orders.
4. No personal item should be kept on the station.
5. SOP should be on the upper side of the table i.e. Visible to the operator.
6. Leaving orders unattended is prohibited.
7. To check the Blue cut, Photo chromatic, Transition Blue cut torch should be used no other
way is accepted.
CHAPTER 7. PACKING

Under Order Processing on NexS Panel> Packing, scan the tray barcode, this automatically triggers
printing of shipping label and invoice and the order is packed in its respective Hard-case and
monocarton along with vouchers, etc.
For Store Packing, under Order Processing we have Store Packing where all store shipments
are packed together.
This is slightly different from Customer Order as the package is unboxed at the store and
collected by the Customer.
CHAPTER 8. MANIFEST

Dispatch or Manifest is the final step in processing of an order at production end.

TYPES OF BUSINESS

 B2B: Business to Business

 B2C: Business to Customer

TYPE OF
BUSINESS

B2B (Business B2C (Business

to Business) to Customer)

TYPE OF SHIPMENT PROCESSING METHOD

 Lenskart own store shipments

 Franchise store shipment
 Marketplace shipment
 International shipment

TYPES OF
SHIPMENT

LENSKART OWN FRANCHISE

MARKETPLACE INTERNATIONAL
STORE STORE
SHIPMENT SHIPMENT
SHIPMENTS SHIPMENT
Processing of shipment on NexS Panel

Adding shipments to the manifest based on their courier service provider.

For creating a Manifest, we select:

Courier type: Bluedart, ECOM, KerryInDev, etc.

STC: for ship to customer
STS: for ship to store

Shipment method: COD, Prepaid, Any.

Store Consolidation

Process through which count of Shipments is consolidated in one unique manifest ID through NexS
portal. It has to be put into the required size box as per shipment’s count. Final packaging of store
order is done in grey Flyer.

Types of box using to pack the order of store and franchise’s store:

SIZE OF BOX NUMBER OF ORDER FLYER

PACKED

24*17*2(bulk) 10 White(15*17*2)

15*17*2 8 White(15*17*2)

7.87(medium) 1 Medium white(9*12)

15*17*2 6 White(15*17*2)

9*12*2 4 Silver(9*12*2)
Flyer used for Final packing with slam/Shipping label which contains information as shown below:

Assigned courier
Tracking ID

Shipment ID

Customer
detail

Order detail

Invoice detail

Franchise store - ST

Courier assign

Store detail
(will b e either Tracking ID
Lenskart or
franchise)

Order detail

Invoice detail
Marketplace
Marketplace is a platform where Multiple Sellers can sell their Products or services.

And Lenskart is also using the marketplace ecommerce platform like Amazon, Myntra, Tata Cliq to
sell their Products or services and even dealing in bulk orders which is usually stock-in Marketplace
vendor’s fulfilment centre such as Amazon, Flipkart, TATA-Cliq, 1Mg and so on.

Customer can customize their requirement even on Marketplace platform as per Lenskart provided
services.

Current Customer relationship partners of Lenskart are amazon, Tata-Cliq, Myntra and 1Mg.

Identification of Marketplace orders physically.

It can be easily identifying marketplace orders by their flyer bag as the packing resources basically
provides by Marketplace vendor.

Shipped to customer
1. Amazon- own courier service partner (ATS)

2. TATA Cliq- courier service partner are:

• Bluedart (BD-AIR)

• DELHIVERY(DL-AIR)

• XPRESSBEES(XB-AIR)

3. 1 Mg- courier service partner are:

• DELHIVERY(DL-AIR)

• XPRESSBEES(XB-AIR)

Bulk orders
• Flipkart: courier service partner is XpressBees

• Amazon: courier service partner is ATS

• Third party vendor of amazon Cocoblue: courier service partner is S2

logistics
RTO (Return to Origin)
The full form of RTO is Return to origin i.e. the process where the asked(placed) order gets fail in
delivery due to customer cancellation or any other reasons, and the product get return back to the
fullfilable or their origin.

RTO shipments include order like:

 Invalid user information like Incorrect customer address may be wrong provided by them,
Ambiguous information, spelling error, forgot to provide essential information such as pin
code, house no., flat no. etc., not available at the doorstep.
 Post-Cancellation from Customer while in-transit of order’s delivery.

Flow Chart of RTO Process:

RETURN ORDER

ONLINE(CUSTOMER
OFFLINE(STORE RTO(RETURN TO
END CANCELLED
INVENTORY) ORIGIN)
ORDER)

COCO(COMPANY FOFO(FRANCHISE
OWNED COMPANY OWNED FRANCHISE
QUALITY CHECK AS PER OPERATED) LENSKART OPERATED) FRANCHISE
DEFINED PARAMETERS STORE(LKST) STORE ORDER(ST)

AS PER RESULT OF QC
MARK THE
QUALITY CHECK
INVENTORY(EITHER
GOOD OR BAD)

AS PER RESULT OF QC
MARK THE
HANDOVER TO SMT
INVENTORY(EITHER
GOOD OR BAD)

HANDOVER TO SMT
CHPATER 9. BULK

This section deals with B2B orders only.

For instance, it deals with Sale orders (flipkart, amazon etc.) and also replenish the stores and
also sell to retailers.

It deals with Eye Glass, Sunglass and blue-cut in eyewear.

In Aqua Lens it has 2 categories:

 Contact lens
 Contact lens solution.

It also deals with lenskart+ products like eye drop, disinfectant spray and immunity tablets.

It has a simple process flow:

PICKING

QUALITY CHECK

PACKING

DISPATCH
CHAPTER 10. FRAME MANUFACTURING

CLASSIFICATION
The types of frames manufactured can be classified as the following:

MATERIAL CONSTRUCTION SHAPE

Acetate Half-Rim Round

TR Full-Rim Rectangle

Metal Rimless Square

Wayfarer

Aviator

Cat Eye

Nose Bridge

Temple

Hinge

Front Nose Pad

 In frames manufacturing unit, frames are made of two types on the basis of RM:

1. Acetate Manufacturing
Acetate frames are made from a cellulose acetate sheet of dimensions
1400x170 mm & 700x 140 mm.
They are lightweight and considered better and higher quality than plastic
frames. It is a plant-based, non-petroleum product derived from wood pulp
and cotton, more durable and flexible than regular plastic.
a. Front Manufacturing
Process:

 First the edges of CA sheet are cut before using

 Rectangular slabs are cut by CNC machine
 Nose pads are attached with the slab
 Slabs are put in cold water to strengthen
 Slabs are put into oven for 48 hours at 70°C
 The front is made by milling in CNC machine through programming (MasterCAM)
 The front quality is checked and rework is done on the required area
 Acetone dipping in order to smoothen the front
 Front is put into a barrel which is a 3 stage process (Tumbling Process)
 Front is heated in the oven and bent with 3kg pressure and put in water
 Hinge is attached to the front
 Front is matched with the temple and level cutting is done

FLOW CHART: Front Manufacturing

EDGE CUTTING ACETONE TUMBLING

OF CA SHEET DIPPING PROCESS

FRONT
SLAB CUTTING QUALITY CHECK
BENDING

FRICTION
SLAB MILLING HINGE FITTING
BONDING

QUENCHING OVEN HEATING LEVEL CUTTING

b. Temple Manufacturing
Process:

 Sheet is planned in machine

 CNC machine cuts the temple
 Temple wire shooting is done at 50°C
 Excess material after wire shooting is cut by edge cutting machine
 Sharp edges are removed by knife
 Plastic caps are fit into temple
 Acetone dipping for a smooth surface
 Transferred to barrel for surface finishing and roundness (Tumbling process)
 FLOW CHART: Temple Manufacturing

WIRE
PLANNING TEMPLE
SHOOTING AT EDGE CUTTING
M/C CUTTING (CNC)
50°C

TUMBLING ACETONE
CAPPING FINISHING
PROCESS DIPPING

c. Assembly

 Front and temple are assembled together by manual or

autoscrew driver machine.
 Temple bending is done and temple is bent at 45 degrees
and as per model size we adjust auto temple bending
machine.
 Wood buff is done for corner matching. Red buff is done
for removing dent and scratches. Pink/white buff is done
for shining. Yellow buff is done for super shining.
 Printing is done using pad printer on the left temple (model
size) and embossing is done on right temple(logo).

FLOW CHART: Assembly process

EMBOSSING
FITTING BENDING BUFFING AND
PRINTING

d. Packing

 Final inspection is done and alignment is corrected

 Dummy lens are cut and fit in the frame
 Barcode printing and packing is done followed by Invoice generation
 The product is then dispatched from department

FLOW CHART: Packing process

DUMMY LENS BARCODE

QUALITY
FITTING IN PRINTING AND DISPATCH
CHECK
FRAMES PACKING
2. TR Manufacturing

Transparent Resin are extremely lightweight and flexible.TR frames are manufactured using
liquid moulding, each frame has a cycle time of 5 minutes. Granules of nylon metal is preheated
at 100°C to remove moisture using a dryer.
To prevent defects, we absorb moisture.
Injection Moulding Machine (IMM) is divided in two parts:

• Clamping Unit: We use hydraulic oil in this process.

• Injection Unit: It consists of a barrel. The barrel has further three sections:

 Feed Zone: The granules are fed here and have heaters here melts the granules at 280°C
to make them soft.
 Compressive Zone: softened granules are further melted to liquid state at 310-320°C.
 Matrix Zone: Here the melted granule flows to the mould.

MOULDING INJECTION HOLDING COOLING

The mould hole has a diameter of 3.5mm and the outer hole of the nozzle is 3.0mm wide.
The speed, position and pressure is decided by the operator.
Holding is done inside the machine to give the frame shape.
Water drip is provided for 17secs for every frame for cooling.

Process Flow:

Fitting front
Grinding Buffing Printing Lens cutting
& temple

Lens fit in
Dispatch Packing Final QC Cleaning
frame
CHAPTER 11. LENS MANUFACTURING

Lens can be manufactured by two ways:

LENS
MOULDING MACHINING

 Moulding: This method is primarily used to make single vision. While we actually import this
section of lens, we can still manufacture them if the stock runs out.

 Machining: This method is majorly used for the progressive lens, which we manufacture.

Classification

• Calculation & Issuance Department

• Surfacing Department
• Coating Department
• Final Quality Check Department
 Calculation & Issuance Department
Order receive by JIT Team as per customer demand classify lens, Order punching by using RX
Software.

• Bifocal Lens (KT, KD)

• Progressive Lens

BLANK LENS
SELECTION

REFRACTIVE BASE OF DIAMETER

INDEX LENS OF LENS

• calculation (RX Software)

• Issuance – Navision

SURFACING

Feeding power in the lens:

Calculation & Engraving (for De-blocking

issuance Progressive lens)

Lens cleaning
Tapping & Axis Polish (Acetone dipping)

Blocking Surface Quality Check

Generation
Tapping

• Tapping of blank lens to protect +ve side of lens.

• Marking right R &left L by white pencil move for blocking, for KT lens mark axis then to
blocking

Blocking
• Process of holding lens by chuck using alloy then lens move to cutting, power generating
machine
• Check temperature of alloy and nozzle, fit lens with ring according to the required
dimension.
• Lens chilling important for 25 min at least.

Generation Process
• Check tool counter, tool must use in limit.
• Milling: Cut lens by thickness
• Natural Dimension (ND): Rough Finishing – cutting lens
• PCD: Final Finishing- Cutting lens

Polish
Polishing require to remove tool mark because of generation.

Engraving
• This process is only for progressive lens, not for single vision, bifocal lenses.
• Mark R, L for both side of lenses, for brand also.

De-blocking
• Process of removing chuck from lens.
• Lens cleaning by dipping in acetone solution.

Surface Quality check

Checking of lens should not have any polishing, engraving, cutting issue.
COATING
Coating process is use to protect lens, Lens coatings are applied to eyeglass lenses to enhance the
durability, performance and appearance of lens.

COATING

HARD AR
COAT COATING

HARD COAT
Hard Coat (Scratch resistant coating) provide lenses with durability and increased longevity.
Plastic lens materials get scratch easily than glass materials, and durable hard coat.

PROCESS:

• Take the lens trey from passing window of SQC.

• Sort the lenses Index and process wise.
• Make 18 pair lot, assign lot no., Date and type of job on last job sheet.
• Clean the lens Surface with tissue dip into methanol for 1.49,1.5, 1.56, For Index 1.6, 1.67,
1.74 use both methanol and acetone to remove the dust particles.
• Hang the lens on Hanger with the support of clamp
• Feed the loaded hanger of lenses in machine from loading side and select the program on
machine.
• Feed the loaded trey into oven and close the door for 3 hours. ARC team will take out lens
according to our time.
AR Coating (Anti Reflection coating)
Anti-reflection coatings are specific coatings designed to decrease the amount of reflective light in
your lenses. These coatings can be applied to the both sides of lenses to control the amount of
light that enters eyes.

Sandblasting is process of remove dirt and chemicals from hard surface by forcing sand particles
across that surface at high speeds using compressed air. Sand blasting should be done on below
machine parts

PROCESS:

• Take the lens from oven with Rack.

• Scan the Job Sheet with Barcode Scanner.
• Clean the lens Surface by blowing air on lens Surface to remove the dust particles.
• Cleaning done of ARC machine Shield, Shutter and chemical pockets with vacuum cleaner
Machine
• Feed the loaded Sectors of lenses in machine with the help of handles.
• Close the chamber of Machine & Lock the machine door.
• After completing the both sides of coating unload lenses in tray and give it to FQC team.

FINAL QUALITY CHECK

To provide the lenses to the warehouse according to the Quality standards, Checking the Lenses
according to the Job sheet and as per quality standards.

• Power (Cylinder, Addition, Axis, Coating, Scratch, Dot) Lens Cosmetic parameters.
• Checking Power according to the job sheet with respect to the tolerance chart.
• Checking Lenses according to the Job sheet.
• Applying the FIFO method in QC with respect to the PO creation date.
• Preference to be given as per the job sheet colour- White and Yellow to be checked ASAP.

During the process of QC ensure all lenses should be delivered to the Warehouse on time with
respect to TAT.
CHAPTER 12. OTHER

OMT- Order Management Team

OMT deals with all sorts of delay, failed order from MEI, Fitting and QC.
It manages orders like:

 Single Vision

 JIT (Just in Time)

 International Orders
 Customer Orders
 Tokai Orders
 Failed Orders
 Double QC Fail Orders
 Lost Orders
 High Value Orders
 Critical Orders (Late)
 Escalated Orders (where customers tag higher authority people)
 TLP (True Last Piece)
 LP (Last Piece)
 LO (Lens Only)

QA- Quality Assurance

Quality: Excellence of doing something.

Quality Assurance: To assure that the work is done in an excellent way.

In simpler words, assuring that the process is executed in a proper way which means following
the proper SOP.

Quality Control: Check the quality after the product made.

There are 2 types of QC:

1. Product Quality Check: It checks the fitting Quality of the product.

2. Cosmetic Quality Check: It checks the scratch, chip, bubble of the product.
 Spectacles are divided into 3 Zones as under:

 Zone A: Front View of Frame

 Zone B: Outer Temple Side; Top view of frame
 Zone C: Inner Temple, Bottom & Rear of frame

KMT- KNOWLEDGE MANAGEMENT TEAM

KMT mainly focusses on the complains from the customers and take actions in the manufacturing
unit to rectify them. They make daily charts and collective data to figure out the root cause of any
issue and take strict action on it.

DEPARTMENTS IN LENSKART

1. Contact Centre

The contact centre takes care of the customers by providing solution to them as soon as
possible by listening to the issues faced. Contact centre is more focused on always reducing
the order to contact ratio. The Contact centre is responsible for the following type channels
for receiving feedbacks regarding their experience with Lenskart services or Lenskart
products:

• Inbound
• Email
• Chat
• Central Ticketing
• Self-Serve
• Store Feedback
 PRG Team: PRG team is responsible for the collecting queries from stores and solve
them.

CTT: Central Ticketing Team is responsible for follow-ups.

2. Logistics
This department looks over the delivery process of orders after they get dispatched from the
warehouse.
CHAPTER 13. ABBREVIATIONS

TR- TRANSPARENT RESIN

JIT- JUST IN TIME

IQC- INCOMING QUALITY CHECK

PID- PRODUCT IDENTIFICATION

QC- QUALITY CHECK

GRN- GOODS RECEIVED NOTE

SMT- STOCK MANAGEMENT TEAM

FR- FITTING REQUIRED

SV- SINGLE VISION

CL- CONTACT LENS

PL- PRESCRIPTION LENS

OMT- ORDER MANAGEMENT TEAM

KMT- KNOWLEDGE MANAGEMENT TEAM

QA- QUALITY ASSURANCE

SOP- STANDARD OPERATING PROCEDURE

OPL- ONE POINT LESSON

OMT- ORDER MANAGEMENT TEAM

KMT- KNOWLEDGE MANAGEMENT TEAM

IMS- INVENTORY MANAGEMENT SYSTEM

WMS- WAREHOUSE MANAGEMENT SYSTEM

VSM- VALYOO SYSTEM MANAGER

CMS- CONSTRAINT MANAGEMENT SYSTEM

EMS- EXCEPTION MANAGEMENT SYSTEM

RTO- RETURN TO ORIGIN

COCO- COMPANY OWNED COMPANY OPERATED

FOFO- FRANCHISE OWNED FRANCHISE OPERATED

PTL- PICK TO LIGHT

GTP- GOOD TO PICK

CA- CELLULOSE ACETATE