1. POLCA Implementation at Olsen Engineering International QRM Conference Madison, Wisconsin October 29th 2002

6. Processes Many dissimilar routings- examples of just a few

7. PROJECT BACKGROUND

15. POLCA Cards

16. POLCA Station

17. POLCA Management

18. POLCA Staging Racks

21. IMPLEMENTATION

27. Quality Improvement

28. Quality Improvement We Increased Communications, Improved In-process Controls and Killed Many Root Causes!

29. Set-Up Reduction

30. Set-Up Reduction We Installed Set-Up Hours Tracking at Every Department We Held Formal Set Up Reduction Events In Every Process on the “POLCA path”

31. We did 5S Installed Cleaning Stations- 1) Posted Work Instructions 2) Trained & Made Assignments 3)Performed Audits Relentlessly We removed unnecessary items from the plant for three months running!

32. Cross Training MASS Cross Training of 34 employees in 240 positions was started after first POLCA loop was implemented A cross training matrix was planned with employees and posted along with daily job assignments.

34. COSTS

37. BENEFITS OF POLCA

40. Cycle (Lead) Time Reduction

41. POLCA WIP Reduction

46. Immediate Bottleneck Visualization

47. Card Holders

51. LESSONS LEARNED