- 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
-
No Comment
..................Content has been hidden....................
You can't read the all page of ebook, please click here login for view all page.