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Enhancing the POLCA Production Control System by Indirect Load

Author

Listed:
  • Nuno Fernandes
  • Moacir Godinho Filho

    (Métis Lab EM Normandie - EM Normandie - École de Management de Normandie = EM Normandie Business School, UFSCar - Federal University of São Carlos)

  • Matthias Thurer

    (Chemnitz University of Technology / Technische Universität Chemnitz)

  • Fernando Gómez

    (Carmen Campos Panisse)

Abstract

Paired-cell overlapping loops of cards with authorisation (POLCA) is a card-based production control system (PCS). The original POLCA system uses authorisation dates based on an MRP list to release jobs to the shop. However, when jobs present high variability in processing times, POLCA may refuse a job to start production on a station, even if available capacity exists, negatively impacting performance. To limit this problem, we adapt POLCA to consider the stations' indirect load (IL) at job release to gain flexibility. We compare the mechanisms through simulation experiments. Results suggest that the indirect load mechanism helps this system to improve operational performance, especially concerning job throughput times and customer delivery time. This research implies that managers should consider the indirect load at stations when using POLCA for production control in a lean production context with high variability.

Suggested Citation

  • Nuno Fernandes & Moacir Godinho Filho & Matthias Thurer & Fernando Gómez, 2025. "Enhancing the POLCA Production Control System by Indirect Load," Post-Print hal-04978193, HAL.
    • Handle: RePEc:hal:journl:hal-04978193
    DOI: 10.1504/IJSOM.2023.10061806
    as

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