Just published! 

The Practitioner's Guide to POLCA
The Production Control System for
High-Mix, Low-Volume and Custom Products

POLCA stands for Paired-cell Overlapping Loops of Cards with Authorization. POLCA is a simple, yet highly effective 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.

The crowning aspect of POLCA is that it is simple. 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.
• Explains the concepts in practical and easy-to-understand terms with detailed shop-floor examples.
• Includes over 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.

"A very comprehensive and well-written book... " writes a highly respected and widely read European Blogger who is an expert on Business Improvement methods. Read his detailed and highly complimentary review...

See a detailed Table of Contents.

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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. POLCA has delivered impressive results in such environments.

“Dr. Suri has created a truly innovative alternative to Kanban for companies that do non-repetitive work in small batches rather than in automotive-style volumes. This book gives clear direction to manufacturers so they can implement POLCA to dramatically improve the way they meet their customers' needs now and for years to come.”

– Bill Ritchie, President
  Tempus Institute, Maryville, Tennessee