QRM Shop Floor Mastery Cell Design and Scheduling for High-Mix, Low-Volume, and Custom Production

Elevate your shop floor operations with advanced strategies in cell design and shop scheduling tailored specifically for high-mix, low-volume, and custom manufacturing environments. This course combines the powerful principles of Quick Response Manufacturing (QRM) and the innovative POLCA system (Paired-cell Overlapping Loops of Cards with Authorization), providing a comprehensive approach to optimizing production flow, reducing lead times, and improving on-time delivery.

Through expert-led sessions, hands-on exercises, and real-world case studies, you will learn how to design effective shop floor cells that address the complexities of variable product mixes and fluctuating volumes. Additionally, you will gain insights into implementing POLCA. This visual, card-based scheduling system complements cell-based production by managing job flow, minimizing WIP, and enhancing team ownership and coordination. This course is ideal for manufacturing professionals looking to streamline their operations and achieve sustainable improvements in shop performance.

Key Learning Outcomes:

• Master the design of shop floor cells to enhance product flow and reduce lead times in high-mix, low-volume environments.
• Learn to implement POLCA, a practical and people-friendly scheduling system that overcomes the limitations of traditional Kanban for custom and low-volume production.
• Address key challenges in cell design, including managing shared resources, subcontracting, and adapting to dynamic production requirements.
• Explore capacity planning, scheduling techniques, and system dynamics to optimize your shop floor cells and POLCA implementation.
• Analyze industry case studies demonstrating the successful application of cells and POLCA, highlighting substantial lead time reductions and improved delivery performance.

This course is designed for manufacturing professionals, operations managers, production engineers, and team leaders responsible for optimizing shop floor performance in high-mix, low-volume, and custom production environments. It is particularly valuable for those tasked with improving production flow, reducing lead times, and managing complex scheduling and capacity planning challenges. Additionally, professionals involved in process improvement, production planning, and resource allocation will benefit from the in-depth focus on POLCA and advanced cell design. This course is ideal for individuals new to QRM and experienced practitioners looking to refine their strategies and implement advanced solutions to achieve sustainable improvements in shop floor operations.

1. Introduction to QRM and the Role of Shop Floor Cells
• Understanding the fundamentals of QRM and the importance of cells in reducing lead times.
• Key aspects of cell design for high-mix, low-volume production.
2. POLCA: A Visual Control System for Complex Production
• Detailed exploration of POLCA and its unique hybrid push/pull approach.
• How POLCA enhances team coordination, reduces scheduling stress, and improves job flow.
3. Designing and Implementing Effective Shop Floor Cells
• Identifying Focused Target Market Segments and designing cells to meet production needs.
• Practical guidance on equipment, labor considerations, and overcoming challenges with shared resources.
4. Advanced Shop Scheduling and Capacity Planning
• Techniques for managing capacity, lot sizes, and inventory in cell-based production.
• Using POLCA to support cell teams and maintain optimal flow on the shop floor.
5. Steps to Successful Implementation and Industry Success Stories
• Stepwise guide to implementing cells and POLCA, including strategic and financial justification.
• Case studies showcasing how companies have transformed their operations through cell design and POLCA.