Quick Response Manufacturing (QRM) In Job Shop Environment

Wong , Yun Shi (2012) Quick Response Manufacturing (QRM) In Job Shop Environment. Project Report. UTeM, Melaka Malaysia. (Submitted)

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Abstract

Today, manufacturing companies have to supply high variety or custom engineered products to fulfill customers’ requirement and thereby advance to competitive advantage. However these companies found that Lean Manufacturing concepts are not helping improve their needs in such environment. On the other hand, drawbacks such as longer lead times and increased WIP inventories are generated with these lean concepts if applied at those high mix and low volume manufacturing environment. In a high mix and low volume manufacturing environment, Quick Response Manufacturing (QRM) is more suitable to improve company’s performance. One of the tools of QRM is Paired-cell Overlapping Loops of Cards with Authorization (POLCA), a technique used to control material movement in order to control the level of WIP and reduce lead time. POLCA card was used to control the material movement and hence shorten the lead time and improve delivery performance. The number of POLCA card of each paired loop is the key role in the POLCA implementation. In this project, a spreadsheet is developed to determine the POLCA paired loop and to calculate the number of POLCA card for each paired loop. Moreover, a suggestion about the machine layout based on the high frequency of POLCA paired loop is suggested and this layout could contribute to the advantages of better material handling and shorter lead time.

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