Implementation of POLCA Integrated QRM Framework for Optimized Production Performance—A Case Study

Abstract

Quick response manufacturing (QRM) is a relatively new concept that enfolds all the preceding approaches, namely, just in time (JIT), flexible manufacturing, agile manufacturing, and lean production. QRM is compatible with existing materials requirement planning (MRP) systems and can be implemented efficiently. The ideas from QRM have been highly influential in custom-made engineer-to-order and make-to-order (ETO/MTO) high-mix and low-volume production environments. This study investigates the effectiveness of the POLCA (paired cell overlapping loops of cards) integrated QRM framework for reducing lead time. The POLCA integrated QRM approach was implemented in a precise product manufacturing industry. The industry was facing high penalties due to improper planning and uncontrolled lead times. The implementation of QRM with the POLCA framework indicated optimized production scheduling and significant improvement in lead time and work in process (WIP). After implementing the new manufacturing strategy, the performance parameters showed significant improvement in terms of reducing the percentage loss of profit.

Lean Maturity Assessment in ETO Scenario

“…This results in efficiency loss, which is unacceptable in highly competitive global markets [29]. This is a contributing factor to the growing interest in lean methods and tools in ETO organizations [29][30][31]. However, some barriers in the implementation of lean practices in an ETO scenario remain [32].…”