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by Rajan Suri
The Practitioner's Guide to POLCA
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
Overview of This Book
Guide to the Reader
Chapter 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
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
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
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
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
Chapter 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
Chapter 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
Chapter 8 How We Designed and Launched POLCA in Three Days
The 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
Chapter 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
Part III Industry Case Studies
Chapter 10 From the United States: Using POLCA to Eliminate Material Flow Chaos in an Aluminum Extrusion Operation
The 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
Chapter 11 From Canada: Applying POLCA in a Pharmaceutical Environment
Why Did We Pursue POLCA?
The 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
The POLCA Boards and POLCA Dashboard
Life with POLCA
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
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
Chapter 14 From Poland: Dancing the POLCA in a Glass Factory
The Factory and Process Flows
The Cutting Operations and Resulting Inventory
The 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
Chapter 15 From Germany: Yes, Even Small Companies Can Benefit from Implementing POLCA
Evaluating the Company’s Situation
Opportunities and Challenges for Implementing POLCA
Cell Formation and POLCA Launch
Results from the Implementation
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
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