POLCA stands for Paired-cell Overlapping Loops of Cards with Authorization. It i
s a variant of Kanban, suitable for companies who produce many different and/or customer-specific products. POLCA was invented by the American professor Rajan Suri. He positions this workload controlling system as part of a broader management philosophy, called Quick Response Manufacturing (QRM). In that approach, lead time reduction is the Holy Grail. The cellular (capacity-controlled) organization To apply POLCA and/or QRM, the shop floor is divided in flexible and multidiscip linary staffed work cells. These cells only make semi-finished products for rece iving cells, when these have (at that moment) free capacity to process the produ cts further. To assure that, adapted Kanban-cards are used, which circulate betw een the workcells. These POLCA-cards signal which workcells downstream have free capacity.
POLCA (introduction article)
POLCA: the (capacity-controlled) cellular factory By Dr Jaap van Ede, editor-in-chief business-improvement.eu. The first version w as published in a Dutch specialist journal, PT Industrieel Management (may 07). Since then, the article has been regularly up dated. Use one, make-one is the basic principle of Lean Manufacturing and the matching Ka nban-system. However, the number of customer-specific producing companies for wh ich this approach doesn t work without adaptation is growing. Their hope is among others placed in a adapted version of Kanban: the POLCA-system. POLCA divides the job floor in flexible and multidisciplinary staffed workcells. These only make semi-finished products for receiving workcells which have free capacity. To assure that, POLCA-cards circulate between the workcells, which sig nal if and where there is room for further processing. The inventor of POLCA, Rajan Suri, positions this system as part of a broader ma nagement philosophy, called Quick Response Manufacturing (QRM). In that approach , lead time reduction is the Holy Grail. One of the key questions to be answered by this article: What do POLCA (and QRM) add to alternative (and older) logisti c improvement methods, like Lean Manufacturing and the Theory of Constraints?