Apr 8, 2020

POLCA: a simple visual control system for high-mix, low-volume, or custom engineered products


Presented by:  Center for Quick Response Manufacturing
Location:  Fluno Center   (601 University Ave., Madison, WI 53715)
Time: 8:00am - 4:30pm
Featured Speaker: Rajan Suri


Join Rajan Suri for this one-day workshop on the POLCA system.

POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a 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 their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly.

POLCA is particularly suited to companies manufacturing high-mix, low-volume and custom products, for which Kanban systems do not work well. These companies struggle with long lead times, late deliveries, and daily expediting. POLCA has delivered impressive results in such companies in the US, Canada, and Europe, including 50-75% reduction in inventory and lead times, on-time delivery improved to over 98%, and increase in shipments by 10-20%.

The crowning aspect of POLCA is that it is simple. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system.

What you will learn: 

  • Why MRP and Kanban don’t work well in low-volume and custom environments
  • Understanding POLCA: How it works
  • Operational benefits of using POLCA
  • Case studies from companies in several types of industries
  • Next steps for designing and implementing POLCA in your company

Registration: http://qrm.engr.wisc.edu/index.php/component/registrationpro/event/97/Introduction-to-POLCA?Itemid=171#overview