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.

• 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.

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.