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

Von:

Suri, Rajan, 1952- [aut]

Resource type: Ressourcentyp: Buch (Online)Buch (Online)Sprache: Englisch Verlag: Boca Raton : CRC Press, Taylor & Francis Group, 2018Beschreibung: 1 Online-Ressource (1 online resource)ISBN:

1351170759
1351170740
9781351170758
9781351170741

Schlagwörter:

Andere physische Formen: 1351170740. | 9781351170741. | 1138210641 | 9781138210646 | 1351170759. | 9781351170758. | Erscheint auch als: Kein Titel Druck-Ausgabe | Print version: Kein Titel DDC-Klassifikation:

658.5

LOC-Klassifikation:

TS155.8

Online-Ressourcen:

Zugang im Netz des KIT

Zusammenfassung: IIIINDUSTRY 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 IJourney 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 IIFrom 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.Zusammenfassung: Machine generated contents note:pt. IUNDERSTANDING 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. IIIMPLEMENTING 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 OnePOLCA Overview and Factory Tour --Day TwoChecking the Prerequisites and Some Initial Design --Checking the Remaining Prerequisites --Initial Design: The POLCA Loops --Deciding on the Quantum --Designing the POLCA Card --Day ThreeFinal 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.PPN: PPN: 102635319XPackage identifier: Produktsigel: ZDB-4-NLEBK | ZDB-4-EBU | ZDB-4-EBA

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