Result Recording and Sample calculation

Question

Dear Experts,
I have a concern regarding the sampling designed
According to the sampling plan in local SOP the samples to be taken for all ZAPI and ZRAW as per below points.
Withdraw sample from each container for Identification test. Here the sample size will very form material to material.
Make a pool of sample according to No. of containers /5 for Other tests, like Assay,LOD,Potency,Microbiological tests etc...
And there is Retention Sample.
To meet this requirement, I have designed the sample management like this......
There will be two partial Samples for Sample drawing procedure
Partial Sample 010 has formula for Primary Samples :- P2.
Partial Sample 010 has no Pooled Sample
Partial Sample 010 has Reserved Sample; Fixed No 1;  along with Sample Size.
Partial Sample 020 has Primary Sample IF P2>=5 THEN P2/5 ELSE P2 to meet the pooling of containers for other test than Identification.
Partial Sample 020 has Pooled sample 1
Partial Sample 020 has no Reserved Sample.
No at the other end In inspection plan we have two operations;
Operation 0010 ; Identification where all the MICs will be linked with Partial Sample 010 and Sample size for Identification test will be assigned along with Sampling procedure.
Operation 0020; QC Laboratory where all the MICs will be linked with Partial Sample 020 and Sample size for Chemical and Micro Analysis tests will be assigned along with Sampling procedure.
For an example for Material X:-
Sample Size = 2gm, for Identification (ID) is maintained at respective MICs in Inspection plan
Sample Size = 50gm, for Chemical and Micro Analysis tests  maintained at respective MICs in Inspection plan
Sample Size = 150gm maintained at SDP for Reserved.
If we receive a consignment 10 Containers for Material X. Then system will create sample as below.
10 Primary samples from Partial Sample 010 of SDP each have sample size 2 and result needs to be recorded for each sample. This is very lengthy hence not acceptable to business.
02 Primary samples from Partial Sample 020 of SDP each have sample size 25 and result not required to be recorded for it.
01 Pooled samples from Partial Sample 020 of SDP each have sample size 50 and result needs to be recorded for it.
01 Reserved Sample (There is no issue with this so not elaborating more)
Total Sample size is 220 (20+50_150)
{10*2=20 Primary Samples for ID
2*25=50 Pooled Samples for Chem and Micro
150 Retain Sample}
Now the requirement is We don't want to record result for all 10 Primary sample from Partial Sample 010 but want to calculate the sample size as per above quantity.
Kindly give me some guidance!!!!!!!
Regards,
Shyamal

Answer 1

I think what you'll need to do is create a sampling procedure for each container type you expect to receive. So if you get BUOM KG's  in 55 gal drums, you'll need a sampling procedure for drums. If you get it in a 2000lb super sac, you'll need a sampling procedure for that.  And of course separate inspection plans for the drum material and one for the super sac material since the same characteristic will specify different sampling procedures.
The sampling procedure will specify a sampling scheme for that container.  I.e. for the super sacs with normal inspection you would specify 0-2000 = 2 g sample.  2001-4000  - 4 g sample.  4001-6000 = 6 g.  etc. etc..
When the sample size for the ID characteristic is figured out, it will be 10g or 20 g.  Whatever.  It is based on the total lot size.
The sample drawing procedure will take the sample size of 20 g now, and apply that to the pooled sample.  That will be divided by the primary samples, (P2 = 10) for a set of 10 primary samples of 2 g each.
A second alternative would be to create the inspection plan in the alternative UOM. Say super sacs.  You receive in 10.  You could create a large sampling scheme for this where a lot size of 1 = 2 g.  2 = 4 g, 3 = 6 g, etc...   While it would be a large sampling scheme, you'd only need one sampling procedure and one sampling scheme.  The inspection plan will see a BUOM of 20,000Kg but convert that to 10 super sacs.  The sampling procedure would see an inspection lot qty of 10 super sacs.  The sampling scheme calcualtes a sample size of 20 for a lot size of 10.  The sample size is applied to the pooled sample and then distributed to the 10 primary samples. 
This should work for all container types.  If the plan was in drums, 20,000 kgs might calcuate out to 30 drums.  The sampling procedure looks up 30 to find that is 60 and returns a sample size of 60g. That is applied to the pooled sample and divided amoung the primary samples, (P2 = 30), for 2 g per primary sample. 
FF