8:15 am -
9:05 am |
Realigning Administrative Processes to Meet Quick Response Shop-floor Requirements (GPI Consultores)
Francisco Tubino – Director
Javier Sarquis – Consultant |
Küpfer, a leading Chilean-based metal fabricator that serves mining, construction and other industries, needed to meet growing requests for shorter lead times, all the while facing decreasing margins due to higher raw material prices. GPI assisted with a QRM implementation, facilitating administrative and shop-level changes to allow for overall flow improvements targeting a 50% reduction in lead time.
- Needed to reduce lead times in metal shop serving mining and construction
- Implemented lead time reduction principles on shop floor
- Realigned administrative tasks to complement shop-floor changes
- Reduced lead times from 30-50% from order receipt to shipment of high-mix parts
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| 9:05 am - 9:55 am |
Changing Mindsets: First Step to Reducing Office Lead Times in a Highly Engineered Product Environment (LeanTeam)
Paul van Veen –Owner
Thomas Luiten – Director |
The changes in mind-set involved in implementing QRM can be daunting for employees. This presentation will highlight lessons learned from several office projects in engineered-product companies
- Overcoming resistance to change in the office culture
- Using a simulation game to understand people’s roles, demonstrate power of lead time reduction
- How time-slicing can be used to solve issues of people with specialized knowledge
- What’s the right reporting structure for a Q-ROC ?
- Results: 50% and higher reductions in lead times, enthusiasm from office employees
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| 10:15 am - 11:30 am |
Panel Discussion: Securing the QRM Commitment in Your Organization
Paul Ericksen – Principal (Lean Supply Chain Performance)
Chuck Gates – President (RenewAire LLC)
Bill Ritchie – Principal (Customer Chain Consulting LLC)
Brian Sobczak – Manager, Corporate Quality Continuous Improvement (Trans-Coil Inc.)
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Every organization that implements QRM has its share of successes, unexpected positive outcomes (Aha! moments) and unforeseen challenges. Hear from four seasoned QRM proponents who have experience with large and small companies. They’ll share their experiences with QRM implementation and answer your questions:
- How should QRM grow in an organization: top-down or bottom-up?
- How do you overcome resistance and change mind-sets?
- When QRM is used in an organization, can it complement or blend with other approaches such as lean, Six Sigma or kaizen ? Or should it be the overall strategy ?
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| 12:30 pm - 4:30 pm |
Manufacturing Critical-path Time (MCT): The Enterprisewide Metric to Support Order Fulfillment and Drive Continuous Improvement
Nathan Stoflet – Supervisor Supplier Development
(John Deere Worldwide C&CE Division)
Mike Ketter – Supplier Project Engineer
(Harley-Davidson Motor Company Inc.) |
POLCA: The QRM Alternative to Kanban for Low-Volume and Custom-Engineered Products
Ananth
Krishnamurthy – Director
Debjit Roy – Research Assistant
(UW-Madison QRM Center) |
Prior to the formulation of Manufacturing Critical-path Time, or MCT, no precise definition for internal lead time or supplier lead time existed. Such a definition is essential to QRM: If you want to reduce lead time, you need to precisely define it.
- MCT definition and explanation of advantages of this definition
- Business impact of MCT reduction
- How to apply MCT to your internal operations and to your supply chain, with examples from several industries
- MCT and Value Stream Mapping (VSM) – how MCT complements the VSM
approach and sharpens a VSM analysis
- How to use the QRM Center’s Web-based MCT Mapping Tool (available free of charge) to analyze your situation
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POLCA is a production-control system suited for low-volume or custom-engineered products. MRP (push) systems can result in long lead times, high WIP and lack of real-time coordination on the shop floor. On the other hand, kanban (pull) systems and other lean concepts such as flow and takt time fail to meet the needs of low-volume or custom-engineered product manufacturers.
The hybrid push/pull system called POLCA (Paired-cell Overlapping Loops of Cards with Authorization) combines the best features of pull and push systems, and it overcomes their drawbacks for low-volume or custom production.
- Drawbacks of push (MRP) systems with respect to lead time and WIP
- Why pull (kanban) doesn’t work well in a low-volume or custom-products environment
- Explanation of the POLCA system
- Computer simulation to visualize POLCA operation
- Hands-on activity – attendees make products using the POLCA system!
- Benefits of POLCA and case studies from several industries
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