Contents

Acknowledgments

IUnderstanding POLCA

1POLCA—Simple Yet Highly Effective: A Tale of Two Companies

Overview of This Book

Guide to the Reader

2POLCA Explained: How It Works

Introducing the MMC Factory Example

Authorization Date and Authorization List

Paired-Cell Loops of Cards

Cell Team’s Decision on What to Work on Next

Overlapping Loops

Differences from MRP and Kanban Systems

Putting It All Together with an Example

3Operational Benefits of POLCA

Tailored to High-Mix, Low-Volume and Custom Production

No Complex Software Implementation Required

Works With Your ERP System—or Without It

Makes Effective Use of Capacity at Each Step

Avoids Congestion and Excessive WIP Build-Up

System Is Adaptive

By Holding Off on Jobs the System Results in ...

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