POLCA: The Production Control System for High-Mix, Low-Volume and Custom Products

13.00 uur

This half-day masterclass will explain POLCA (Paired-cell Overlapping Loops of Cards with Authorization), an alternative to Kanban for material control on the shop floor.

POLCA is a card-based visual control system that manages the flow of jobs through the shop floor: at each operation, it controls which job should be worked on next to meet delivery targets. POLCA ensures that upstream operations use their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly.

POLCA is particularly suited to companies manufacturing high-mix, low-volume and customized products, for which Kanban systems do not work well. Such companies struggle with long lead times, late deliveries, and daily expediting to meet delivery dates. POLCA has delivered impressive results in such environments. The crowning aspect of POLCA is that it is simple. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system.

Masterclass Content

The masterclass will begin with a tutorial on POLCA, followed by a computer simulation demonstration of POLCA. The class will include several case studies of industry applications, as well as an overview of Suri’s new book on POLCA. The detailed content of the masterclass follows.

The Need for a New Material Control Strategy
Why MRP systems can result in an increasing spiral of long lead times and late deliveries, and why concepts such as takt time and Kanban do not work well in low-volume or custom environments.

Detailed Explanation of POLCA
POLCA stands for Paired-cell Overlapping Loops of Cards with Authorization. This hybrid push/pull system called combines the best features of card-based pull (Kanban) systems and push (MRP) systems while overcoming their drawbacks for low-volume and custom production.

Computer Simulation of POLCA
A computer simulation will be used to demonstrate how POLCA works for a company making low-volume and custom-engineered products.

Overview of new book on POLCA

Attendees will get a “walk-through” of Suri’s new book to provide them with an overview of the contents and tips on how to best use the book.

Industry Case Studies of POLCA Application
Several industry case studies will be presented to show the effectiveness of POLCA for companies in many different industries, including applications in European companies.

In summary, through the theory and examples in this masterclass, attendees will see the impact of POLCA on product lead times and on-time delivery, and learn how POLCA can provide companies with a powerful competitive advantage.

** Bonus **

Attendees will receive a copy of Suri’s newly published book:
The Practitioner's Guide to POLCA: The Production Control System for High-Mix, Low-Volume and Custom Products By Rajan Suri, Productivity Press, 2018.


This masterclass will be conducted in English.

Over de spreker(s)

Rajan Suri

Rajan Suri is Emeritus Professor of Industrial Engineering at the University of Wisconsin-Madison. He received his Bachelors degree from Cambridge University (England) and his M.S. and Ph.D. from Harvard University.

Professor Suri is the Founding Director of the Center for Quick Response Manufacturing (QRM) at the University of Wisconsin-Madison, a consortium in which around 300 companies have worked with the University on developing and implementing QRM strategies. Dr. Suri is author of the original book on QRM, Quick Response Manufacturing: A Companywide Approach to Reducing Lead Times (Productivity Press, 1998), as well as the latest book on QRM, It’s About Time: The Competitive Advantage of Quick Response Manufacturing (Productivity Press, 2010).

Dr. Suri has consulted for leading firms including Alcoa, Boeing, AT&T, Danfoss, Ford, Harley-Davidson, Hewlett Packard, IBM, John Deere, National Oilwell Varco, Pratt & Whitney, Rockwell Automation and TREK Bicycle. Consulting assignments in Europe and the Far East have given him an international perspective on manufacturing competitiveness.

Praktische Informatie

dinsdag 30 oktober 2018
13.00 - 18:00
Van der Valk Hotel Nijmegen-Lent
€ 295,-
€ 236,-