ABSTRACT
Using Paired-cell Overlapping Loops of Cards with Authorization (POLCA) between the sub-assembly and final assembly cells was an obvious starting point. The next item on the POLCA implementation roadmap was to calculate the number of POLCA cards. From a POLCA prerequisite point of view, we felt comfortable about the level of planning. In parallel, one of their facilities in Canada also expressed interest in implementing POLCA and approached the Quick Response Manufacturing Center for assistance. Since the POLCA quantum is an indication of capacity, clearly the quantum should consider the difference in assembly times needed for small and large cabinets. As part of setting the goals for the POLCA implementation, we set targets for work-in-process (WIP) and lead time reduction. The difference between the shop floor observation and the POLCA card calculation was the WIP reduction opportunity, and in fact corresponded well with the targets we had set on the previous day.
