I'm running into an issue and hoping someone has seen this before.
We want to print out two labels, one to label a container, (box, bag, vial,etc.) that contains material for QC samples that are destroyed. A second label to label a container, (box, bag, vial, etc) that contains the material for reserves that is simply stored on a shelf in a retains room. To create the labels we have to use a sample drawing procedure. The two labels are different as the reserves label has "Retain Sample" printed on it. The person pulling the samples determine the qtys to pull for each based on SOP's.
We first simply defined a fixed primary sample of 1 and a reserve sample of 1. No problems. Labels come out.
But, when posting the QC samples, if sample size is for instance, 1 ea, but testing calls for 20 ea to be tested, we get an error when posting to QC samples in the UD screen that the sample size is exceeded. This causes problems because the postings are automated via interface and error message sometimes comes up and sometimes doesn't which causes a failure.
We then increased a visual inspection sampling procedure to be 100%. This worked great. The inspection qty was the full lot for the one primary sample and we can post any qty. But because the entire quantity of material is committed to the primary sample, the reserve sample doesn't think there is any available and doesn't actualy create the reserve physical sample anymore.
The only solution we have found for this is to use a percentage in the sampling procedure of something like 90%. That leaves material for the reserve. But now, in the inspection lot, the inspected qty for visual inspection, the value shown is only 90% of the full amount even though the entire shipment is subjec to a visual check. This doesn't look right. It seems to indicate that for a shipment of 100 EA, we only visually inspected 90 of them.
Everything would work great if the reserve sample was calculated first and the 100% inspection was done on the reminaing qty. But it doesn't.
Any ideas?
Craig