Developed by the author and now being employed by a number of businesses, Quick Response Manufacturing (QRM) is an expansion of time-based competition, aimed at a single target with the goal of reducing lead times. The key difference between QRM and other time-based programs is that QRM covers an entire organization, from the shop floor to the office, to sales and beyond. Providing guidelines for establishing a QRM enterprise, this volume builds upon kaizen, TQM, TPM, and other practice to help organizations streamline all functions of their operation. It shows how to quickly introduce products, along with ways to rethink materials and production management.
In the decade since the publication of Rajan Suri’s landmark book, Quick Response Manufacturing, the innovative principles of QRM have been proven with impressive results at many companies, big and small, in a variety of industries. While the key principles of QRM remain unchanged, after a decade of teaching QRM workshops to senior executives, Suri has developed a clear, concise, and accessible method of presenting QRM strategy using four core concepts: 1. The Power of Time – the huge impact time has on your entire enterprise 2. Organization Structure – how to structure your organization to reduce lead times 3. System Dynamics – understanding how interactions between jobs and resources impact time to make better decisions on capacity, lot sizes, and similar issues 4. Enterprise-Wide Application – QRM is not just a shop floor strategy, it extends across your whole enterprise including material planning and control, supply management, office operations, and new product introduction Presenting new case studies on QRM implementation, It's About Time: The Competitive Advantage of Quick Response Manufacturing illustrates how QRM can not only reduce lead times but also improve quality, reduce operating costs, and enable companies to gain substantial market share. This practical reference explains how factories in advanced nations can use QRM strategy to compete with manufacturers in low-wage countries. In addition, it provides helpful pointers for QRM implementation, including accounting strategies, novel cost-justification approaches, and a stepwise process for implementation. Also included are downloadable resources with five appendices that provide a number of practical details to assist in the success of your QRM implementation. When you are ready to start implementing QRM, you will find that these appendices contain time-saving tips to help you work through implementation issues¿including simple calculation methods and tools to support the design of your QRM strategy. You can also access these Appendices on the Downloads and updates tab on https://www.crcpress.com/9781439805961. The author, Rajan Suri, recently became one of only 10 people to be inducted into Industry Week's 2010 Manufacturing Hall of Fame.
POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a card-based visual control system that manages the flow of jobs through the shop floor: at each operation, it controls which job should be worked on next to meet delivery targets. POLCA ensures that upstream operations use their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly. POLCA is particularly suited to companies manufacturing high-mix, low-volume and customized products. Such companies struggle with long lead times, late deliveries, and daily expediting to meet delivery dates. ERP systems are not designed to deal with this highly variable environment, and add-on software such as Finite Capacity Scheduling systems can require complex installation. Also, the Kanban system does not work well with low-volume or custom production. POLCA has delivered impressive results in such environments. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system. This book: Provides a step-by-step roadmap on how to implement POLCA; invaluable for both companies that wish to implement POLCA as well as consultants and academics advising such companies. Explains the concepts in practical and easy-to-understand terms by showing detailed shop-floor examples. Includes more than 100 illustrations for understanding how POLCA works as well as for elaborating on details of the implementation steps. Contains case studies written by company owners and executives documenting their POLCA implementation process and the results achieved in various industries in six countries.
Quick Response (QR) policy is a market-driven business strategy in which supply chain members work together to react quickly to volatile market demand. Nowadays, with advances in information technologies (such as RFID and ERP systems), new challenges and opportunities arise for the application of QR. This handbook explores QR extensively with a view to discovering innovative QR measures that can help tackle the observed and emerging challenges. The book is organized into four parts, which include chapters on analytical modeling and analyses, information technologies, cases, reviews, and applications. This handbook provides new analytical and empirical results with valuable insights, which will not only help supply chain agents to better understand the latest applications of QR in business, but also help practitioners and researchers to know how to improve the effectiveness of QR using innovative methods.
The gap between demand for consumer goods and their efficient supply is greater now than at any other time, and is widening as consumers' wants become less predictable, and suppliers struggle to meet them. Quick Response (QR) is both a management paradigm and a methodology that allows supply systems to react quickly to changes while improving their performance. QR aims to help organize a business in the face of problems associated with the vast array of goods and services now to be found in consumer markets. It is particularly relevant to the Fast Moving Consumer Goods (FMCG) and Fashion industries. QR works by compressing the time between product or service design concept and appearance on the retail shelf. It then takes advantage of such recent technologies as Point of Sale (PoS) tracking and Electronic Data Interchange (EDI) to constantly up-date estimates of true consumer demand, and then places intelligent re-orders for goods with flexible manufacturers and their suppliers. One of the features of this book is the demonstration that the range of industries able to benefit from the application of QR methodologies is extremely wide. However, this apparent universality comes with a strong 'health warning'. By placing QR in a broad framework of management thinking, the book allows comparison with other paradigms and their off-shoots - partnerships and alliances, measurement and benchmarking, Information Systems Technology strategies, Total Quality Management, and change management. Belief systems such as World Class Manufacturing, Lean Production, Agile Manufacturing, Virtual Organization, Time-Based Competition, Supply Chain Management (SCM) and chaos theory, are also reviewed and contrasted. The book then quantifies the performance benefits that accrue from the application of QR using examples from the US and European industries as well as computer simulation. Lessons are also drawn from a wide variety of SMEs (Small and Medium sized Enterprises) who are using QR as a strategic tool, as well as those who have not yet adopted it. For the latter, there are recommendations for implementing QR. The future management and research directions required for full exploitation of QR are also explored in a separate section. The most important aspect of this book is that it concentrates on the practical, hands-on management of a supply pipeline as opposed to the generalized theories of Supply Chain Management.
This book presents part of the proceedings of the Manufacturing and Materials track of the iM3F 2020 conference held in Malaysia. This collection of articles deliberates on the key challenges and trends related to manufacturing as well as materials engineering and technology in setting the stage for the world in embracing the fourth industrial revolution. It presents recent findings with regards to manufacturing and materials that are pertinent towards the realizations and ultimately the embodiment of Industry 4.0, with contributions from both industry and academia.
This handy book is a working reference for practitioners using the MCT metric. MCT is a time-based metric that supports continuous improvement projects, since it quantifies an organization's total system-wide waste. Properly used, MCT does not need to be data-intensive and can be relatively easy to apply. Thus, by comparing "before" and "after" values, MCT provides a simple yet powerful metric with which to measure improvement.Although the origins of MCT are in manufacturing - the acronym stands for Manufacturing Critical-path Time - the metric can be used in many other contexts including insurance, banking, health care, and other industries.This Guide provides the key rules and guidelines for using MCT. It serves as a reminder of the main points as well as a checklist to ensure that you have taken into account the major items needed for MCT calculation and use.Practitioners will appreciate the concise and easy-to-follow format. In particular, the formatting and binding of the Guide allows you to lay the Guide flat and easily reference all the points for a given topic at one time.This Guide is a "must-have" for anyone using MCT in continuous improvement projects!
The managed flow of goods and information from raw material to final sale also known as a "supply chain" affects everythingâ€"from the U.S. gross domestic product to where you can buy your jeans. The nature of a company's supply chain has a significant effect on its success or failureâ€"as in the success of Dell Computer's make-to-order system and the failure of General Motor's vertical integration during the 1998 United Auto Workers strike. Supply Chain Integration looks at this crucial component of business at a time when product design, manufacture, and delivery are changing radically and globally. This book explores the benefits of continuously improving the relationship between the firm, its suppliers, and its customers to ensure the highest added value. This book identifies the state-of-the-art developments that contribute to the success of vertical tiers of suppliers and relates these developments to the capabilities that small and medium-sized manufacturers must have to be viable participants in this system. Strategies for attaining these capabilities through manufacturing extension centers and other technical assistance providers at the national, state, and local level are suggested. This book identifies action steps for small and medium-sized manufacturersâ€"the "seed corn" of business start-up and developmentâ€"to improve supply chain management. The book examines supply chain models from consultant firms, universities, manufacturers, and associations. Topics include the roles of suppliers and other supply chain participants, the rise of outsourcing, the importance of information management, the natural tension between buyer and seller, sources of assistance to small and medium-sized firms, and a host of other issues. Supply Chain Integration will be of interest to industry policymakers, economists, researchers, business leaders, and forward-thinking executives.
