The practitioner's guide to POLCA : the production control system for high-mix, low-volume and custom products /

"POLCA (Paired-cell Overlapping Loops of Cards with Authorization) isa 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 th...

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Detalles Bibliográficos
Clasificación:Libro Electrónico
Autor principal: Suri, Rajan
Formato: Electrónico eBook
Idioma:Inglés
Publicado: Boca Raton : CRC Press, Taylor & Francis Group, 2018.
Temas:
Production control.
Lean manufacturing.
Card system in business.
New products.
Production > Contrôle.
Production allégée.
BUSINESS & ECONOMICS > Industrial Management.
BUSINESS & ECONOMICS > Management.
BUSINESS & ECONOMICS > Management Science.
BUSINESS & ECONOMICS > Organizational Behavior.
Acceso en línea:Texto completo (Requiere registro previo con correo institucional)
Tabla de Contenidos:
  • Machine generated contents note: pt. I UNDERSTANDING POLCA
  • 1. POLCA
  • Simple Yet Highly Effective: A Tale of Two Companies
  • Overview of This Book
  • Guide to the Reader
  • 2. POLCA Explained: How It Works
  • Introducing the MMC Factory Example
  • Authorization Date and Authorization List
  • Paired-Cell Loops of Cards
  • Cell Team's Decision on What to Work on Next
  • Overlapping Loops
  • Differences from MRP and Kanban Systems
  • Putting It All Together with an Example
  • 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
  • pt. II IMPLEMENTING POLCA
  • 4. Pre-POLCA Assessment, Prerequisites, and Preparation for POLCA
  • Clarify the Motivation and Goals for Pursuing POLCA
  • Check for Symptoms That Have Led Companies to Consider POLCA
  • Review Your Company's Operating Environment
  • Set Your Goals
  • Check These Prerequisites Before Deciding to Implement POLCA
  • Review Your Shop Floor Organizational Structure
  • Make Sure That You Have POLCA-Enabling Cells
  • Engage in Effective Planning Before Control
  • Limit the Occurrence of Material and Part Shortages
  • Prepare for the POLCA Implementation
  • Ensure the Availability of Authorization Dates and Lists
  • Implementation Without Using an ERP System
  • Implementation through Your ERP System
  • Ensure That Manufacturing Metrics Will Not Conflict with POLCA Rules
  • Secure the Upfront Understanding and Commitment of Management
  • 5. Designing the POLCA System for Your Situation
  • Create an Implementation Team and Designate a POLCA Champion
  • Begin by Determining All the POLCA Loops
  • Implementing POLCA throughout Your Shop Floor
  • Do Not Include Stocking Points in the POLCA Loops
  • Implementing POLCA in a Subset of Your Shop Floor
  • Should You Put in Single or Multiple Loops for a Given Area?
  • 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
  • Design Your POLCA Cards
  • Decide on the Quantum
  • The Amount of Work to be Done per POLCA Card
  • Determine the Process for Returning the POLCA Cards
  • Calculate the Initial Number of POLCA Cards in Each Loop
  • Add the Finishing Touches with Some Final Details
  • Identify the Triggers for Decision Time
  • Hedging with Lead Time or with Cards?
  • Adding Safety through Lead Time
  • Adding Safety through Number of Cards
  • 6. Accommodating Exceptions within the POLCA Framework
  • Dealing with an Unexpected Shortage of a Component Part
  • Introducing the Safety Card Concept
  • Procedure When a Safety Card Is Available
  • Adding a Shortage Tracker
  • Procedure When a Safety Card Is Not Available
  • 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
  • 7. Launching POLCA
  • Continue to Use the POLCA Implementation Team and the POLCA Champion
  • Conduct Training for Everyone Impacted by the System
  • Training for the Core Group
  • Training for the Rest of the Organization
  • 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
  • 8. How We Designed and Launched POLCA in Three Days / Ananth Krishnamurthy
  • Setting: A Factory in Canada
  • Day One POLCA Overview and Factory Tour
  • Day Two Checking the Prerequisites and Some Initial Design
  • Checking the Remaining Prerequisites
  • Initial Design: The POLCA Loops
  • Deciding on the Quantum
  • Designing the POLCA Card
  • Day Three Final Design Decisions
  • Defining the Decision-Time Rules and Exceptions
  • Decision to Launch
  • Postscript: Keys to Success and a Challenge to Others
  • About the Author
  • 9. Sustaining POLCA: Post-Implementation Activities
  • Create a Steering Committee and Stay the Course
  • Track the Key Metrics and Celebrate Successes
  • Use Surveys and Feedback Forms to Assess the Qualitative Benefits
  • Conduct Regular POLCA Audits
  • Periodic Audits
  • Random Audits
  • Use POLCA to Drive Long-Term Improvements
  • pt.
  • III INDUSTRY CASE STUDIES
  • 10. From the United States: Using POLCA to Eliminate Material Flow Chaos in an Aluminum Extrusion Operation / Todd Carlson
  • Start of Our POLCA Journey
  • Experimenting with a Small-Scale POLCA Implementation
  • System Design and Training
  • System Startup and Early Results
  • Extending POLCA to the Whole Factory
  • What We Learned, and Advice to Other Practitioners
  • Impact of POLCA on Our Organization
  • About the Authors
  • 11. From Canada: Applying POLCA in a Pharmaceutical Environment / Susan Ferris
  • Why Did We Pursue POLCA?
  • POLCA Kaizen Workshop
  • Deciding on All the Fundamentals of the POLCA System
  • Rules to Break Rules
  • Senior Leadership Plays the POLCA Game
  • Training, Training, Training
  • POLCA Boards and POLCA Dashboard
  • Life with POLCA
  • About the Authors
  • 12. From the Netherlands: Creating Flow and Improving Delivery Performance at a Custom Hinge Manufacturer through QRM and POLCA / Robert Peters
  • Section I Journey To Polca / Godfried Kaanen
  • I Get a Rude Wake-Up Call
  • Our Initial Improvement Efforts
  • 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 / Robert Peters
  • Implementing the Quantum through Load-Based POLCA
  • Impact of PROPOS and POLCA on the Company's Operations
  • About the Authors
  • 13. From Belgium: Metalworking Subcontractor Reduces Lead Times by 85% Using QRM and POLCA / Ben Proesmans
  • Motivation for Rethinking the Shop Floor System
  • Implementing the Stove Cell
  • Introducing Color-Coded Visual Work Management
  • Expanding to the Rest of the Factory with POLCA
  • Customizing the System for Better Use of Scarce Resources
  • Results: The People Side
  • Results: The Commercial Side
  • About the Authors
  • 14. From Poland: Dancing the POLCA in a Glass Factory / Karol Bak
  • Factory and Process Flows
  • Cutting Operations and Resulting Inventory
  • Machining Department and Sequencing Problems
  • Finishing Processes
  • Initial Design of the POLCA System
  • Initial POLCA Loops, Quantum, and Number of Cards
  • Authorization Method
  • Simplifying the Design: Moving to POLCA "Lite"
  • Results of the POLCA Implementation
  • About the Author
  • 15. From Germany: Yes, Even Small Companies Can Benefit from Implementing POLCA / Markus Menner
  • Evaluating the Company's Situation
  • Opportunities and Challenges for Implementing POLCA
  • Cell Formation and POLCA Launch
  • Results from the Implementation
  • About the Author.

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