THEPOWEROF TIME

SYSTEMDYNAMICS

ENTERPRISE-WIDE APPLICATION

ORGANIZATIONSSTRUCTURE

Workshop Quick Response Manufacturing

Workshop 1 24th September QRM with MCT mapping

Workshop 2 25th September QRM with POLCA

24th-25th September 2014 – Warsaw

Welcome to the most important event on the Quick Response Manufacturing QRM Workshops - The concept of Rapid Manufacturing! We prove that the fast response and short delivery time are as important as price and product quality. Our special guest will be Rajan Suri - the creator of the method of QRM , author of " Gain time " who will share with us his 20 years of experience in this field.

Magdalena Marczak – Project Managerm.marczak@pb.pl

Organiser

→ high mix low volumes production; → for specific needs and requirements of the client; → designed / engennered to order → ...and wherever compete in a short lead time gives the company a competitive

advantage!

Explore the 4 foundations of Quick Response Manufacturing:

This method is dedicated to manufacturing companies that produce:

The power of time – the huge impact time has on your entire enterprise.

Organizations Structure – how to structure your organization to reduce lead time.

System Dynamics – understanding how interactions between jobs and resources impact time to make better decisions on capacity, lot sizes, and similar issues.

Enterprise-Wide Application – QRM is not just a shop floor strategy, it extends across your whole enterprise including material planning and control, supply management, office operations, and new product introduction.

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Substantive patron

Theoretical Part: Overview of QRM Strategy

This will provide an overview of QRM strategy, which includes four core concepts:

a. The Power of Time: The non-obvious reasons why lead time is important (much more important than most managers realize), how it influences total operating cost and quality, and how to take advantage of this realization.

b. Organizational Structure: How to restructure your organization to minimize lead time throughout the enterprise.

c. System Dynamics: How interactions between machines, people and products impact your lead times. As a result, capacity planning policies (e.g. machine and labor utilization) and lot sizing policies need to be rethought for QRM.

d. Enterprise-wide Application: QRM is not just a shop floor approach; it is applied throughout the organization. This includes material planning and control, purchasing and supply chain management, office operations such as estimating and order processing, and new product development. You will also see data on the “bottom line” impact of QRM on product cost, quality, and lead times.

Practical Part: Using MCT-Mapping to Identify Lead Time Reduction Opportunities

In partnership with colleagues from major corporations, Suri has developed the concept of Manufacturing Critical-path Time (MCT), a precise metric which highlights improvement opportunities by clearly quantifying system-wide waste. The metric can be used for both your internal operations as well as for your supply chain.

In this “Hands-On” portion of the Workshop you will first learn the detailed definition of MCT, and understand the business case for using MCT. Then you will learn how to calculate MCT correctly for various situations by working on numerical examples. You will see how to use MCT-Mapping to communicate opportunities and convince management. You will also learn the differences between MCT-Mapping and Value Stream Mapping (VSM), and see why MCT-Mapping more clearly identifies opportunities for lead time reduction.

Both parts of this workshop will combine theory with practical examples using case studies of many companies that have implemented QRM in both USA and Europe.

Quick Response Manufacturing (QRM) is a companywide strategy for lead time reduction throughout the enterprise. Using QRM, companies have reduced their lead times by 80-90%. As a result these companies have not only seen large increases in market share, but also experienced 15-20% cost reduction and huge quality improvement.

Although Lean Manufacturing techniques can be powerful in certain situations, for companies making low-volume or custom-engineered products, Lean techniques do not apply too well.

Quick Response Manufacturing (QRM) can be a more effective competitive strategy for companies targeting such markets. In addition, companies find that the lead time and cost reductions resulting from QRM enable them to compete effectively against low-cost countries.

Quick Response Manufacturing (QRM) can be a more effective competitive strategy for companies targeting such markets. In addition, companies find that the lead time and cost reductions resulting from QRM enable them to compete effectively against low-cost countries.

MCT-Mapping to Identify Lead Time Reduction Opportunities24th September

→ QRM Overview: Very brief review of the companywide QRM strategy and its benefits.

→ The Need for a New Material Control Strategy: Why concepts such as takt time and Kanban do not work well in low-volume or custom environments.

→ Detailed Explanation of POLCA: POLCA stands for Paired-cell Overlapping Loops of Cards with Authorization. This hybrid push/pull system called combines the best features of card-based pull (Kanban) systems and push (MRP) systems while overcoming their drawbacks for low-volume production.

→ Computer Simulation of POLCA: A computer simulation will be used to demonstrate how POLCA works for a company making low-volume and custom-engineered products.

→ Industry Case Studies of POLCA Application: Several industry case studies will be presented to show the effectiveness of POLCA for companies in different industries including: a manufacturer of large equipment, an aluminum extrusions company, a manufacturer of custom hinges, and a company making large electromechanical controllers. (The case studies will include both US and European companies.)

In summary, through the theory and examples in this workshop, attendees will see the “bottom line” impact of QRM and POLCA on product cost, quality, lead times, and

on-time delivery and learn how QRM and POLCA can provide companies with a powerful competitive advantage.

POLCA: The Shop Floor Control Strategy forHigh-Mix, Low-Volume or Custom Products

25th September

This workshop will explain POLCA, an alternative to Kanban for material control on the shop floor. POLCA is designed specifically for high-mix, low-volume or custom-engineered products, for which Kanban systems do not work well.

Another advantage of POLCA is that it can build on your existing MRP (ERP) system, instead of replacing it.

POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a component of the Quick Response Manufacturing (QRM) strategy, a companywide strategy for lead time reduction throughout the enterprise.

Thus, the workshop will begin with a brief overview of QRM. This will be followed by a tutorial on POLCA, a computer simulation demonstration of POLCA, and several case studies of industry applications. The detailed content of the workshop follows.

Rajan Suri – Honorary Director Center for Quick Response Manufacturing

He is Emeritus Professor of Industrial Engineering at the University of Wisconsin-Madison. He received his Bachelors degree from Cambridge University (England) and his M.S. and Ph.D. from Harvard University.

Professor Suri is the Founding Director of the Center for Quick Response Manufacturing (QRM) at the University of Wisconsin-Madison, a consortium in which around 300 companies have worked with the University on developing and implementing QRM strategies. Dr. Suri is author of the original book on QRM, Quick Response

Manufacturing: A Companywide Approach to Reducing Lead Times (Productivity Press, 1998), as well as the latest book on QRM, It’s About Time: The Competitive Advantage of Quick Response Manufacturing (Productivity Press, 2010). Dr. Suri has consulted for leading firms including Alcoa, AT&T, Danfoss, Ford, Harley-Davidson, Hewlett Packard, IBM, John Deere, National Oilwell Varco, Pratt & Whitney, Rockwell Automation and TREK Bicycle. Consulting assignments in Europe and the Far East have given him an international perspective on manufacturing competitiveness.

Professor Suri has received awards from the American Automatic Control Council, The Institute of Management Sciences and the IEEE. In 1999, Suri was made a Fellow of the Society of Manufacturing Engineers (SME), and in 2006 he received SME’s Albert M. Sargent Progress Award for the creation and implementation of the Quick Response Manufacturing philosophy. In 2010 Rajan Suri was inducted into the Industry Week 2010 Manufacturing Hall of Fame.

� YES, I want to participate in the QUICK RESPONSE MANUFACTURING WORKSHOP Date: 24-25th September2014 Price:

1295 PLN (313 €)+ 23% VAT (till 29th August 2014) 1695 PLN (410 €) + 23% VAT (after 29th August 2014)

� participate in MCT workshop

1295 PLN (313 €) + 23% VAT (till 29th August 2014) 1695 PLN (410 €) + 23% VAT (after 29th August 2014)

� participate in POLCA workshop

2295 PLN (555 €) + 23% VAT (till 29th August 2014) 3095 PLN (749 €) + 23% VAT (after 29th August 2014)

� participate in both workshops MCT & POLCA

� YES, I want to receive more information about the QUICK RESPONSE MANUFACTURING WORKSHOP

�NO, I will not participate in the workshop but I would like to be informed about planned events related to subject matter.

REGISTRATION FORM

Workshop Quick Response Manufacturing

24-25th September 2014 Warsaw

Correspondence addressBonnier Business Polska Sp. z o.o., ul. Kijowska 1, 03-738 Warsaw

Tel.+48 22 333 97 77

Faks+48 22 333 97 78 konferencje.pb.pl

konferencje@pb.pl

Bonnier Business (Polska) Sp.z o.o. is the publisher of the daily business newspaper Puls Biznesu and web portal pb.pl with its head office in Warsaw (03-738), ul. Kijowska 1 has been entered in the Register of Entrepreneurs, kept by the District Court for the capital city of Warsaw, XIII Economic Department of National Court Register under No. KRS 24847, NIP 113-01-55-210, equity capital: PLN 2 000 000,00PLN.

Participation conditions:

1. The cost of one person participating amounts to: in the MCT workshop: 1295 PLN (313 €)+ 23% VAT (till 29th August 2014) 1695 PLN (410 €) + 23% VAT (after 29th August 2014)

in the POLCA workshop: 1295 PLN (313 €)+ 23% VAT (till 29th August 2014) 1695 PLN (410 €) + 23% VAT (after 29th August 2014)

in the bouth MCT & POLCA workshops: 2295 PLN (555 €)+ 23% VAT (till 29th August 2014) 3095 PLN (749 €) + 23% VAT (after 29th August 2014)

2. The price includes lectures, Conference materials,coffee breaks, lunch and the participation in the Evening Logistics Banquet.

3. Sending, by fax or e-mail, a filled out and signed participation form to Bonnier Business (Polska) shall be regarded as concluding a binding agreement between the sender and Bonnier Business (Polska). A pro-forma invoice shall be normally issued and sent by e-mail after the reception of participation form.

4. We kindly request that you transfer the payment amount within 14 days of sending your notification, but not later than 2 days before the beginning of the Conference.

5. Payments should be transferred to the following bank account:

Bonnier Business (Polska) Sp. z o.o. Kijowska 1, 03-738 Warszawa Danske Bank A/S SA Oddział w Polsce PL 14 2360 0005 0000 0045 5029 6371

6. Resignations from participation should be sent by registered mail to the organizer’s address.

7. If you resign from participation 21 days before the event starts you will be charged with an administrative fee in the amount of 20% of the price.

8. If you resign from participation 21 days after the event starts you will be charged with an administrative fee in the amount of 100% of the price.

9. If you do not cancel your notification and do not take part in the Conference, you will be charged 100% of the participation fee.

10. Not making the payment shall not be regarded as synonymous with resignation from participation.

11. Another employee of the company may participate in the Conference instead of the person sending the notification.

12. The organizer reserves the right to introduce changes in the program agenda, and to call off the Conference.

Send your form to fax +48 22 333 97 78or register online konferencje.pb.pl

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