Production Control Mechanisms and POLCA Performance in a Divergent Production Line

Authors

  • Alireza Farnoush School of Innovation, Design and Engineering, Mälardalen University, Eskilstuna, Sweden
  • Magnus Wiktorsson Associate Professor, School of Innovation, Design and Engineering, Mälardalen University, Eskilstuna, Sweden

DOI:

https://doi.org/10.37591/joprm.v2i1-2-3.7137

Keywords:

Production control mechanism, divergent production line, POLCA

Abstract

Production control mechanism is a critical element in today’s production situation, where production systems compete on quick response and resource efficiency. The purpose of a production control mechanism is to define the best time to release material and orders. POLCA is a simple production control mechanism that on one hand tries to reduce throughput time and on the other hand helps the manager to control work-in-process inventory. In addition to reviewing the history of the production control mechanism and looking into some of them, the paper classifies production control mechanisms in different categories and studies more specifically a POLCA system performance in a divergent production line situation with long changeover time in the supplier cell (the shared cell which has to supply different routes). It is concluded that the best form of POLCA in a divergent production line is to push material in the first stage without any limit and then control and limit it in the second stage.

References

Fernandes F. C. F and Filho M. African Journal of Business Management. 2011. 5573–5582p.

Ziengs N., Riezebos J. and Germs R. International Journal of Production Research. 2011.

Fernandes N. O., Carmo-Silva S. International Journal of Production Economics. 2006. 104(1). 74–84p.

Bergamaschi D. Cigolini R., Perona M, et al. International Journal of Production Research. 1997. 35(2). 339–420p.

Land M. J. and Gaalman G. J. C. International Journal of Production Economics. 1996. 46-47. 535–548p.

Ragatz G. L. and Mabert V. A. Decision Sciences. 1988. 19. 167–189p.

Spearman M. L., Woodruff D. L. and Hopp W. J. International Journal of Production Research. 1990. 28(5). 879– 894p.

Yucesan E. and Goorte X. D., European Journal of Operational Research. 2000. 120. 118–130p.

Spearman M. L. and Zazanis M. A. Operations Research. 1992. 40(3). 521– 532p.

Graves R., Konorka J. and Milne R. Production Planning and Control. 1995. 6. 395–403p.

MacCarthy B. L., Fernandes F.C. F. Production Planning and Control. 2000. 11(5). 481–496p.

Gupta M. and Snyder D. International Journal of Production Research. 2009. 47(13). 3705–3709p.

Kimball G. Journal of Manufacturing and Operations Management. 1988. 1. 119– 130p.

Karaesmen F. and Dallery Y. International Journal of Production Economics. 2000. 68. 59–71p.

Marek R. P, Elkins D. A. and Smith D. R. Proceedings of Winter Simulation Conference. 2001. 2. 921–929p.

Lage Jr. M. and Godinho Filho M. International Journal of Production Economics. 2010. 125(1). 13–21p.

Suri R. and Krishnamurthy A. How to Plan and Implement POLCA: A Material Control, System for High-Variety or Custom- Engineered Products. Technical Report Center for Quick Response Manufacturing (www.qrmcenter.org). University of Wisconsin-Madison, USA. 2003.

Goldratt E. and Cox J. The Goal: A Process of Ongoing Improvement. Revised edn. North River Press, Croton-on-the- Hudson, New York. 1986.

Schragenheim E. and Ronen B. Production and Inventory Management. 1990. 31. 18–22p.

Framinan J. M., Gonzalez P. L. and Ruiz- Usano R. Production Planning and Control. 2003. 14. 255–265p.

Lödding H.,Yu K. W. and Wiendahl H. P. Production Planning and Control. 2003 14(1). 42–54p.

Suri R. Quick Response Manufacturing.

Portland. Productivity Press. 1998.

Riezebos J. International Journal of Production Research. 2010. 48(5). 1455– 1477p.

Krishnamurthy A. and Suri R. Production Planning and Control. 2009. 20(7). 596– 610p.

Little J. D. C. Operations Research. 1961. 9. 383–387p.

Riezebos J. In: Riezebos J. and Slomp J. (Eds). Proceedings of the Third International Conference on Group Technology/Cellular Manufacturing. 2006 University of Groningen, The Netherlands.

Germs, R. and Riezebos, J. International Journal of Production Research, 2010. 48(8), 2345–2360p.

González-R, P. L., & Framinan, J. M. Production Planning & Control, 2009. 20(3), 276–287p.

Melnyk, S.A., and G.L. Ragatz. Production and Inventory Management Journal, 1988. 29(2), 13–17p.

Wisner, J.D. International Journal of Operations & Production Management, 1995. 15(6).

Wight, O.W. Production and Inventory Management Journal, 1970. 11(3), 9–31p.

Dingwei Wang D. and Xu C-G. Production Planning & Control: The Management of Operations, 1997. 8(2). 142–151p.

Downloads

Published

2023-07-26

Issue

Vol. 2 No. 1-2-3 (2012)

Section

Articles

License

Declaration and Copyright Transfer Form

(to be completed by authors)

I/ We, the undersigned author(s) of the submitted manuscript, hereby declare, that the above manuscript which is submitted for publication in the STM Journals(s), is not published already in part or whole (except in the form of abstract) in any journal or magazine for private or public circulation, and, is not under consideration of publication elsewhere.

  • I/We will not withdraw the manuscript after 1 week of submission as I have read the Author Guidelines and will adhere to the guidelines.
  • I/We Author(s ) have niether given nor will give this manuscript elsewhere for publishing after submitting in STM Journal(s).
  • I/ We have read the original version of the manuscript and am/ are responsible for the thought contents embodied in it. The work dealt in the manuscript is my/ our own, and my/ our individual contribution to this work is significant enough to qualify for authorship.
  •  I/We also agree to the authorship of the article in the following order:

Author’s name                                    

 

1. ________________

2. ________________

3. ________________

4. ________________

 

We  Author(s) tick this box and would request you to consider it as our signature as we agree to the terms of this Copyright Notice, which will apply to this submission if and when it is published by this journal.