QRM Shop Floor Mastery Cell Design and Scheduling for High-Mix, Low-Volume, and Custom Production
interpro.wisc.edu/RA00057See upcoming datesCourse Overview
Gain expert insights into designing effective shop floor cells that address the complexities of variable product mixes and fluctuating volumes. Learn to implement POLCA, a visual, card-based scheduling system that enhances team coordination and minimizes work-in-progress. Through hands-on exercises and real-world case studies, you'll achieve sustainable improvements in shop performance and on-time delivery.
Learning Outcomes
- Master the design of shop floor cells to enhance product flow and reduce lead times in high-mix, low-volume environments.
- Implement POLCA to overcome the limitations of traditional Kanban for custom and low-volume production.
- Address key challenges in cell design, including managing shared resources and adapting to dynamic production requirements.
Who Should Attend?
- Manufacturing professionals who optimize shop floor performance in high-mix, low-volume, and custom production environments.
- Operations managers and production engineers who improve production flow and manage complex scheduling and capacity planning challenges.
- Team leaders and process improvement specialists who refine strategies and implement advanced solutions for sustainable shop floor operations.
Course Outline
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.
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.
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.
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.
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.
Instructor
Vince Clark
Vince Clark is an accomplished manufacturing leader with more than 30 years of experience driving operational excellence across global organizations. He brings a proven record of leading large, complex operations in industries ranging from consumer products to heavy equipment and mining.
Vince spent over two decades with Caterpillar Inc., progressing through roles that included Six Sigma Master Black Belt, Factory Product Manager, Global Manufacturing Engineering Director, and Operations Director. He led organizations with hundreds of employees, managed large-scale global engineering teams, and oversaw complex operations, including Caterpillar’s Ultra Class Mining Shovels and off-highway trucks, developing deep expertise in low-volume, high-mix production environments.
Following his time with Caterpillar, Vince held senior leadership roles with Enerpac, Briggs & Stratton, and Andis Company, where he most recently served as Business Unit Director. Across these organizations, he managed operations of more than 600 employees, oversaw annual capital project portfolios exceeding $60 million, and consistently delivered measurable improvements in safety, quality, delivery, and cost.
A certified Six Sigma Master Black Belt, Vince is recognized for his ability to combine Lean, Six Sigma, continuous improvement, and lead-time reduction principles with a people-centered leadership style, delivering both cultural change and bottom-line results.
He holds a BS and MS in Industrial Engineering from the University of Illinois at Urbana–Champaign and an MBA from Millikin University.
As an instructor with the University of Wisconsin–Madison’s Center for Quick Response Manufacturing (QRM), Vince brings a wealth of real-world expertise to help companies reduce lead times, improve responsiveness, and thrive in today’s competitive manufacturing landscape.