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| p.1 #14 · p.1 #14 · DPR Interview with the Canon L lens production plant... |
You sound like the American managers I used to work with, back when they had a factory. Of course, the factory couldn't keep up with the competition, so they later outsourced the work to Asia. Those managers said what you said, and they proudly showed their reports that demonstrated they made defective products cheaper and faster which marketing couldn't sell. "Good enough (usually) quality, just-in-case manufacturing, with erroneously-calculated economic lot sizes".
"Zero rejects is great if they're all great lenses. Zero rejects isn't great if the QC misses things."
This sounds like a punchline to a QC joke. You can't inspect...Show more →
I mean... these are basic facts. Each surface in a lens that isn't a plano surface has a unique radius of curvature. To fabricate it by traditional grinding and polishing requires a unique set of tools specifically for that element. If you make 200 lenses, each with 14 elements you have 200*14*2 = 5,600 unique surfaces to fabricate. You need three grinders (coarse/medium/fine) to work efficiently and produce a high quality surface, and at least one polisher. Even if 50% of surfaces are plano, equiconvex elements, equiconcave, whatever, this is still 10,000 tools.
To make everything everyday, then you need 10,000 grinders and polishers. Optimistically, each one is 5sqft, so you need 50,000sqft of floor space just to hold them, let alone places to stand, walk, slurry delivery and egress, etc.
How do you propose N-FK51A lenses during months the glass isn't available? Do you stockpile tons and tons of it when it is avaialble to purchase, risking environmental damage and wasting floorspace? Would you not rather stockpile it as finished optical assemblies that are coated and housed for protection?
I do encourage you to not project experience from other types of manufacturing onto optical manufacturing. The process of making lenses is quite tremendously different to almost everything else.