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

Wanzhu Wang,Muhammad Abas,Shakir Azim,Waqas Saleem,Abdur Rehman Babar,Hao Li,Qazi Salman Khalid,Razaullah Khan

doi:10.3390/su13063452

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.

Highlights

This study aims to deterthe level of implementation of quick response manufacturing (QRM) practices in different organizations in Brazil, the USA, mineEurope
According to the statistical estimates, 55% of the company products are not delivered on time to customers, which results in a total financial loss of USD 2.08 Million per year
POLCA integrated integrated QRM framework, which is grounded on exploiting the variability and system dynamicsby byimplementing implementinga which is grounded on exploiting the variability and system dynamics acase casestudy

Summary

Introduction

During the last few years, flexible and cycle time-focused scheduling strategies have attained much attention for their potential to maximize profit in production-based industries. In this context, Suri (2010) [1] introduced quick response manufacturing (QRM). QRM is a company-wide strategy that pursues increasing the throughput by reducing the lead times across all operations, covering all aspects of manufacturing, design, planning and control, and supply management. The QRM approach has offered a promising manufacturing paradigm. The important outcomes were a reduction in lead times (80–95%), reduction in product cost (15–50%), improved delivery performance (from 40% to 98%), and Sustainability 2021, 13, 3452.

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