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Practitioner's Guide to POLCA

The Production Control System for High-Mix, Low-Volume and Custom Products

Gebonden Engels 2018 9781138210646
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POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a card-based visual control system that manages the flow of jobs through the shop floor: at each operation, it controls which job should be worked on next to meet delivery targets. POLCA ensures that upstream operations use their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly.

POLCA is particularly suited to companies manufacturing high-mix, low-volume and customized products. Such companies struggle with long lead times, late deliveries, and daily expediting to meet delivery dates. ERP systems are not designed to deal with this highly variable environment, and add-on software such as Finite Capacity Scheduling systems can require complex installation. Also, the Kanban system does not work well with low-volume or custom production. POLCA has delivered impressive results in such environments. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system.

This book:
-Provides a step-by-step roadmap on how to implement POLCA; invaluable for both companies that wish to implement POLCA as well as consultants and academics advising such companies.
-Explains the concepts in practical and easy-to-understand terms by showing detailed shop-floor examples.
-Includes more than 100 illustrations for understanding how POLCA works as well as for elaborating on details of the implementation steps.
-Contains case studies written by company owners and executives documenting their POLCA implementation process and the results achieved in various industries in six countries.


Aantal pagina's:436
Uitgever:CRC Press
Hoofdrubriek:Inkoop en logistiek


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Over Rajan Suri

Rajan Suri is Emeritus Professor of Industrial Engineering at the University of Wisconsin–Madison. He received his Bachelors degree from Cambridge University (England) in 1974, and his M.S. and Ph.D. from Harvard University in 1978. Dr. Suri founded and served as Director of the Center for Quick Response Manufacturing (QRM) from 1993 to 2008, and continues to serve the Center in an advisory role. The Center is a consortium of companies working with the University on developing and implementing QRM strategies—over 200 companies have worked with and supported the activities of the Center (www.qrmcenter.org). Suri introduced the core concepts of QRM in his landmark book Quick Response Manufacturing: A Companywide Approach to Reducing Lead Times (Productivity Press 1998). He is also author of over 100 technical publications, has chaired several international conferences on manufacturing systems, and has served on the editorial boards of leading scholarly journals in the field. Dr. Suri combines his academic credentials with considerable practical experience. He has consulted for leading firms including 3M, Alcoa, AT&T, Danfoss, Ford, Hewlett Packard, Hitachi, IBM, Ingersoll, John Deere, National Oilwell Varco, P&H Mining Equipment, Pratt & Whitney, Rockwell Automation, Siemens and TREK Bicycle. Consulting assignments in Europe and the Far East, along with projects for the World Bank, have given him a substantial international perspective on manufacturing competitiveness. In 1981, Dr. Suri received the Eckman Award from the American Automatic Control Council for outstanding contributions in his field. He was a member of the team that received the 1988 LEAD Award from the Society of Manufacturing Engineers. He is coauthor of a paper that won the 1990 Outstanding Simulation Publication Award from The Institute of Management Sciences. In 1994, he was co-recipient of the IEEE Control Systems Technology Award. In 1999, Suri was made a Fellow of the Society of Manufacturing Engineers (SME), and in 2006, he received SME’s Albert M. Sargent Progress Award for the creation and implementation of the Quick Response Manufacturing philosophy. Rajan Suri recently became one of only 10 people to be inducted into Industry Week's 2010 Manufacturing Hall of Fame.

Andere boeken door Rajan Suri


Part I: Understanding POLCA
1. POLCA—Simple Yet Highly Effective: A Tale of Two Companies
2. POLCA Explained: How It Works
3. Operational Benefits of POLCA

Part II: Implementing POLCA
4. Pre-POLCA Assessment, Prerequisites, and Preparation for POLCA
5. Designing the POLCA System for Your Situation
6. Accommodating Exceptions within the POLCA Framework
7. Launching POLCA
8. How We Designed and Launched POLCA in Three Days
9. Sustaining POLCA: Post-Implementation Activities

Part III: Industry Case Studies
10. From the United States: Using POLCA to Eliminate Material Flow Chaos in an Aluminum Extrusion Operation
11 From Canada: Applying POLCA in a Pharmaceutical Environment
12. From the Netherlands: Creating Flow and Improving Delivery Performance at a Custom Hinge Manufacturer through QRM and POLCA
13. From Belgium: Metalworking Subcontractor Reduces Lead Times by 85% Using QRM and POLCA
14 From Poland: Dancing the POLCA in a Glass Factory
15. From Germany: Yes, Even Small Companies Can Benefit from Implementing POLCA

Appendix A: Introduction to MCT: A Unified Metric for Lead Time
Appendix B: Overview of Quick Response Manufacturing (QRM)
Appendix C: Perspectives on Applying MRP, Kanban, or Some Other Card-Based Systems to HMLVC Production Environments
Appendix D: Capacity Clusters Make High-Level MRP Feasible
Appendix E: The Sociotechnical Success Factors of POLCA
Appendix F: Experiences with Using a POLCA Simulation Game
Appendix G: Explanation of Formula for Number of POLCA Cards
Appendix H: POLCA: A State-of-the-Art Overview of Research Contributions
Appendix I: Additional Resources for POLCA Training and Games

About the Author

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