Book description
POLCA stands for Paired-cell Overlapping Loops of Cards with Authorization. This system combines the best features of MRP and Kanban systems while overcoming their drawbacks for low-volume production. It includes novel features that are specifically designed to enable consistent delivery performance for high-mix/low-volume production. Finally, the crowning aspect of POLCA is that it is simple and yet remarkably effective: it is a visual card-based system that does not require investing in any specialized software, is easily understood by planners, schedulers and shop floor operators, and when properly implemented has resulted in disciplined, smooth operations at many companies.
Table of contents
- Cover
- Half Title Page
- Title Page
- Copyright Page
- Dedication
- Contents
- Acknowledgments
-
Part I Understanding POLCA
- Chapter 1 POLCA—Simple Yet Highly Effective: A Tale of Two Companies
- Chapter 2 POLCA Explained: How It Works
-
Chapter 3 Operational Benefits of POLCA
- Tailored to High-Mix, Low-Volume and Custom Production
- No Complex Software Implementation Required
- Works With Your ERP System—or Without It
- Makes Effective Use of Capacity at Each Step
- Avoids Congestion and Excessive WIP Build-Up
- System Is Adaptive
- By Holding Off on Jobs the System Results in Multiple Benefits
- Provides Formal Framework for Improvement Activities
- Prevents Inventory Proliferation for Products with Low Demand
- Allows Complete Flexibility in Product Routings and Works Seamlessly for Custom Products
- Creates Customer-Supplier Relationships between Cells
- Installs a Visual System
- Builds on the Capabilities of People in the System
- Provides Fast Response through Decentralized Decision-Making
- Builds on Your Existing Structure and Systems
-
Part II Implementing POLCA
- Chapter 4 Pre-POLCA Assessment, Prerequisites, and Preparation for POLCA
-
Chapter 5 Designing the POLCA System for Your Situation
- Create an Implementation Team and Designate a POLCA Champion
- Begin by Determining All the POLCA Loops
-
Lay Out the POLCA Chains
- Starting Point for the POLCA Chains
- Including the Lead Time for the Planning Cell
- Starting Points for POLCA Chains When Implementing in a Subset of Your Shop Floor
- Ending Points for the POLCA Chains
- Define the Procedure for Incorporating Outside Operations into the POLCA System
- Consider Whether You Will Use the Simpler Release-and-Flow POLCA (RF-POLCA) Version
- Situations Where Standard POLCA Is Recommended
- Decide on Details Related to the POLCA Cards
- Add the Finishing Touches with Some Final Details
-
Chapter 6 Accommodating Exceptions within the POLCA Framework
- Dealing with an Unexpected Shortage of a Component Part
- Dealing with an In-Process Quality Problem
- Dealing with Machine Downtimes
- Expediting a Rush Job for an Urgent Customer Need
- Accommodating Schedule Changes Seamlessly
- Adjusting for Non-Synchronized Delivery of In-House Manufactured Components to Assembly
- Preventing Gridlock When Loops Form Cycles
- Summary: POLCA Accommodates Exceptions Smoothly
-
Chapter 7 Launching POLCA
- Continue to Use the POLCA Implementation Team and the POLCA Champion
- Conduct Training for Everyone Impacted by the System
- Create a Standard Process for Secondary Activities Initiated by Decision Time Rules
- Schedule Frequent Review Sessions and Management Updates
- Have a Plan for Rolling Out Adjustments and Corrections
- Design the Checks That Will Ensure POLCA Discipline Is Followed
- Start Tracking and Debugging Key Metrics
- Chapter 8 How We Designed and Launched POLCA in Three Days
- Chapter 9 Sustaining POLCA: Post-Implementation Activities
-
Part III Industry Case Studies
- Chapter 10 From the United States: Using POLCA to Eliminate Material Flow Chaos in an Aluminum Extrusion Operation
- Chapter 11 From Canada: Applying POLCA in a Pharmaceutical Environment
-
Chapter 12 From the Netherlands: Creating Flow and Improving Delivery Performance at a Custom Hinge Manufacturer through QRM and POLCA
- Section I: The Journey to POLCA
- I Get a Rude Wake-Up Call
- Our Initial Improvement Efforts
- The Pastry Shop Needs a Breakthrough
- Our First Step: The Rhineland Model
- We Are Introduced to POLCA
- Implementing the Color-Coded Visual System
- Initial Results from POLCA
- Section II: From Physical POLCA to Digital POLCA
- Implementing the Quantum through Load-Based POLCA
- Impact of PROPOS and POLCA on the Company’s Operations
- Chapter 13 From Belgium: Metalworking Subcontractor Reduces Lead Times by 85% Using QRM and POLCA
- Chapter 14 From Poland: Dancing the POLCA in a Glass Factory
- Chapter 15 From Germany: Yes, Even Small Companies Can Benefit from Implementing POLCA
- Introduction to the Appendices
- 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
- For Further Reading
- 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
- References
- Appendix I Additional Resources for POLCA Training and Games
- Index
- About the Author
Product information
- Title: The Practitioner's Guide to POLCA
- Author(s):
- Release date: April 2018
- Publisher(s): Productivity Press
- ISBN: 9781351170741
You might also like
book
The 108 Skills of Natural Born Leaders
A refreshingly different look at an old question: Are leaders born or made? Some people appear …
book
Hearing the Voice of the Shingo Principles
For more than 50 years, organizations of all types have struggled to achieve lasting benefits from …
book
Adobe® Photoshop® CS6 on Demand, Second Edition
Need answers quickly? Adobe Photoshop CS6 on Demand provides those answers in a visual step-by-step format. …
audiobook
Catch of the Decade
In Catch of the Decade, two of Australia's most successful online superstars reveal how they've built, …