What Is POLCA?

POLCA stands for Paired-Cell Overlapping Loops of Cards with Authorization and was developed by Rajan Suri around 1990. It is sometimes mentioned alongside kanban and CONWIP as a production control system. Let me explain to you how POLCA works. In my next post I look at the pros and cons of POLCA. In my last post of this mini-series, I will show you the calculation for the number of POLCA cards, including some critical comments.

The similar-sounding word Polka is also a Czech dance music and textile pattern, hence the colorful illustration of the polka dots on the left (don’t worry, more technical diagrams will follow below). Continue reading What Is POLCA?

Lean and Industry 4.0

Industry 4.0 is one of the hot topics of modern manufacturing, although some (myself included) say that it is overrated. Lean is one of the older but also still important topics in manufacturing. In this post I would like to compare lean and Industry 4.0. What are the differences, what are the commonalities? Can they complement each other or do they conflict? Continue reading Lean and Industry 4.0

Examples of Jidoka

In my last two posts I talked a lot about what jidoka is, and the underlying philosophy. Many articles do so. But there are almost no actual examples out there of jidoka. But without examples it is difficult to really understand a concept. A great historic example of this is the Toyoda Model G automatic loom from 1925. This is well known, but here I would like to show you how it connects to jidoka. I will also give you a more modern example of a product that you may even own.

Continue reading Examples of Jidoka