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

Wanzhu Wang, Qazi Salman Khalid, Muhammad Abas, Hao Li, Shakir Azim, Abdur Rehman Babar, Waqas Saleem and Razaullah Khan
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Wanzhu Wang: School of Economics and Finance, Xi’an Jiaotong University, Xi’an 710061, China
Qazi Salman Khalid: Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25000, Pakistan
Muhammad Abas: Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25000, Pakistan
Hao Li: Guanghua School of Management, Peking University, Beijing 100000, China
Shakir Azim: Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25000, Pakistan
Abdur Rehman Babar: Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25000, Pakistan
Waqas Saleem: Department of Mechanical and Manufacturing Engineering, Institute of Technology, F91 YW50 Sligo, Ireland
Razaullah Khan: Department of Mechanical Engineering Technology, University of Technology, Nowshera 24100, Pakistan

Sustainability, 2021, vol. 13, issue 6, 1-22

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.

Keywords: quick response manufacturing (QRM); POLCA; lead time; production planning and scheduling (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2021
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