Quick Response Manufacturing is an emerging shop floor management technique best suited for high product mix and variable demand environments. Paired Cell Overlapping Loop of Cards with Authorization or POLCA is the material control system of Quick Response Manufacturing. Pull system have problems in material controlling when the variety of products increase. At the same time, push systems using MRP have their own drawbacks in terms of worsening the Response. Time Spiral and promoting ever-longer lead times. This paper deals with the characteristics of Quick Response Manufacturing and POLCA. A discrete event computer simulation model of a Job shop environment implementing POLCA methodology is designed and its performance measures are evaluated.
Keywords - QRM; Quick Response Manufacturing; POLCA; Job Shop; Lead time reduction; Shop floor management
[...] In addition QRM puts a great deal of emphasis on creating the mindset of pursuing lead time reduction. Some of the key principles of QRM includes, Finding whole new ways of completing a job, with the focus on lead time minimization. Strategically plan for spare capacity plan to operate at 80% or even 70% capacity on critical resources. Measuring the reduction of lead times and making this the main performance measure. Elimination of traditional measures of utilization and efficiency and sticking to measuring and rewarding reduction of lead times. [...]
[...] The prerequisites of POLCA system are Cellular organization of shop floor High Level/MRP system for communication release authorization times to start a particular work in a particular cell (iii) POLCA card system. QRM has greater competitive potential for companies making a large variety of products with variable demand or companies making highly engineered products. The combination of QRM and POLCA would provide companies with significant competitive advantage through their ability to deliver customized products with short lead times. The development of the concept of Quick Response Manufacturing showed that, to compete on speed, industries must change the management mind-set and reduce lead times throughout the organization. [...]
[...] Rajan Suri, and POLCA: A Winning Combination for Manufacturing Enterprises in the 21st Century', Technical Report, Centre for Quick Response Manufacturing, May 2003. D. D'Addona, R. Teti, R. Carbone, University of Naples Federico II, Naples, Italy, ‘Quick Response Manufacturing Approach for Lead Time Reduction in PCB Fabrication'. Trevor Turner, ‘Quick Response Manufacturing: ‘When Kanban is Not the Solution', Control W. David Kelton, R. P. Sadowski, D. A. Sadowski, ‘Simulation with Arena: Second edition', McGraw Hill. Jerry Banks, J. S. Carson, B .L. Nelson, ‘Discrete [...]
[...] Initialize the working conditions of Shop floor environment IAT of parts, Batch size, Demand pattern for each part type, Types of product (Product mix), Selection Rule and Simulation length Start Production in the initial station, If Release authorization time has arrived and POLCA card available Move on the semi finished part to the next scheduled station along with the corresponding POLCA card If a part along with POLCA card is available at a station, Start Production. If more than one part with POLCA card available (and release authorization time reached), select using Selection rule to start production Repeat steps 3 & 4 until the final station is reached Collect Statistics of all parts coming out of its corresponding final stations for the entire simulation run length. [...]
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