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

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Listed:
  • 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
    Department of Engineering Management, University of Engineering and Technology, 19060 Swat, Pakistan)

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.

Suggested Citation

  • Wanzhu Wang & Qazi Salman Khalid & Muhammad Abas & Hao Li & Shakir Azim & Abdur Rehman Babar & Waqas Saleem & Razaullah Khan, 2021. "Implementation of POLCA Integrated QRM Framework for Optimized Production Performance—A Case Study," Sustainability, MDPI, vol. 13(6), pages 1-22, March.
    • Handle: RePEc:gam:jsusta:v:13:y:2021:i:6:p:3452-:d:520924
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    References listed on IDEAS

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