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PURPOSE: The competitive and variable business environment forces organizations not only to flexibly adapt to changes, but also to predict them. A desirable capability of an organization is agility, understood as the ease and speed with which companies can reconfigure, redesign and adapt their processes in order to respond to the needs, threats and opportunities. QRM is a management concept that focuses on time as the key factor in competitive manufacturing. The objective of this article is to analyze the effect of QRM implementation on key business agility characteristics., DESIGN/METHODOLOGY/APPROACH: The research methods used to accomplish this goal are literature studies and questionnaire surveys using the agility attributes matrix. Based on literature studies as well as the conducted interviews, a model of the effect of QRM implementation has been developed., FINDINGS: The results obtained show that QRM implementation definitely has an impact on all areas of the company's agility., PRACTICAL IMPLICATIONS: The article brings several valuable pieces of information and provides practical tips. The results may be taken advantage of by entrepreneurs. They constitute indications for selecting competition instruments during the crises., ORIGINALITY/VALUE: The previous studies on Quick Response Manufacturing (QRM) were conducted in various dimensions, while there is no research linking this method to business agility. It is the first such research., The publication was financed by a subsidy for the Faculty of Management of AGH University for the maintenance and development of research potential., peer-reviewed

To remain competitive in today’s increasingly dynamic and complex environments, manufacturing enterprises must build resilience to respond to changes quickly. As such, lean production has provided firms with an alternative to "fat and lazy" mass production. In addition, Quick Response Manufacturing has been presented as a credible supplement to lean production, specifically in High Mix, Low Volume environments. Drawing on practical insights from two case studies, we present a Quick-Scan method as an initial step towards creating resilient and responsive value chain strategies. The approach combines manufacturing critical-path time mapping from Quick Response Manufacturing with Gemba-based discovery and learning from Lean - to find, face, and frame real problems, and thereafter form solutions together with managers and front-line personnel. The method has been adopted in both cases as a means of revitalizing operations with the intention of enabling more effective delivery of customer-specific products.

The industrial entities has been facing challenges in the external environment, such as competition, globalization, and the high costs of raw materials needed for production, which has led to higher production costs and consequently high unit costs per product as well as the apparent scarcity of most resources and the difficulty in obtaining them. This has led to the inevitable introduction of systems with the aim to keep pace with such rapid developments, such as the rapid response manufacturing system, which is a Japanese-originated system that was introduced by Toyota, which has already employed the application of this system to meet customers’ demands and the rapid response to the technological developments and competition pressures. The factories are obliged to deliver products to their customers as fast as they can, which means gaining a competitive advantage and increasing their market share. The standard of delivery is defined as the ability of operations to deliver the contracted product to the customer on time and specified avenue .It is an effective solution for factories that cannot achieve a competitive advantage in the field of cost reduction or the quality field as they can inevitably achieve this by reducing Lead Time in its operations and then work to reduce delivery times and this is the basis on which the modern production system is represented (the rapid response manufacturing system), which urges factories to compete on the basis of the fastest date for delivering the product to customers. The problem: 1. What are the problems of production planning facing the ready-made garment factories in Medina Al-Menorah? 2. What is the relationship between QRM and production planning? 3. What is the applicability of the QRM system? 4. What is the effect of applying the QRM system on production planning in the study sample ready-made garments factories? Objectives: 1. Determining the problems of production planning facing the ready-made garment factories in Medina Al-Menorah. 2. Studying the relationship between the quick response manufacturing (QRM) and production planning. 3. Applying the quick response manufacturing system (QRM) in the sample study factories. 4. Measuring the effect of applying the quick response manufacturing (QRM) system on production planning in the study sample factories.Methodology: The experimental approach: To measure the effect of the quick response manufacturing system on production planning in the ready-made garment factories in Medina Al-Menorah. Results: - The quick response manufacturing system (QRM) affects the production planning in the ready-made garment factories in Medina Al-Menorah and the degree of impact was significant, which shows the validity of the fourth hypothesis of the study.

This paper presents a novel lean tool called Project Time Deployment (PTD) whose objectives are to classify, analyse, and eliminate losses in order to reduce production lead time in Engineer-to-Ord...

With the onset of the Fourth Industrial Revolution, the business environment becomes inherent in changes that occur with maximum speed, as well as characterized by the systemic nature of the consequences. One of them is the transformation of operational management models in industrial enterprises. The modern manufacturing system should focus not only on speed of response and flexibility, but also on the cost and quality of products. Integration of effective models: agile manufacturing, quick response manufacturing and lean production, in order to extract the best from them is proposed. The purpose of this study is to analyze this flexible manufacturing system and to relate it to the current state of the Russian industrial development. Theoretical and practical aspects of this model are presented. The examples of the flexible models introduction in the Russian industrial sector is allocated. The conclusion about the necessity of the flexible manufacturing systems implementation for the Russian industrial development is drawn.

Quick response manufacturing (QRM) is a relatively new concept that enfolds all the preceding approaches, namely, just in time (JIT), flexible manufacturing, agile manufacturing, and lean production. QRM is compatible with existing materials requirement planning (MRP) systems and can be implemented efficiently. The ideas from QRM have been highly influential in custom-made engineer-to-order and make-to-order (ETO/MTO) high-mix and low-volume production environments. This study investigates the effectiveness of the POLCA (paired cell overlapping loops of cards) integrated QRM framework for reducing lead time. The POLCA integrated QRM approach was implemented in a precise product manufacturing industry. The industry was facing high penalties due to improper planning and uncontrolled lead times. The implementation of QRM with the POLCA framework indicated optimized production scheduling and significant improvement in lead time and work in process (WIP). After implementing the new manufacturing strategy, the performance parameters showed significant improvement in terms of reducing the percentage loss of profit.

The new era of industrial revolution 4.0, requires a lot of improvement especially in automotive assembly line. A poor flow on supply chain especially on logistic in the company affect the company performance. Insufficient planning may lead to less efficiency, quality and productivity loss. The objective of this study is to improve the critical supply chain in the automotive industry by studying the current data given by the company and used it to simulate on WITNESS. The output from the current simulation will determine on how to improve the supply chain by doing some changes in which lead to the optimized condition. After series of simulations, the output shows improvement especially on idle time and busy time. The idle time that possessed was under 20% while the busy time between 70% until 90% across the mechanical and trim sections.

[EN] The aim of this paper is to propose a simulation model based on system dynamics and the elements that compose the Quick Response Manufacturing (QRM) strategy. The developed model is a very useful decision-making tool as it helps to obtain process flow times and lot sizes in manufacturing environments whose competitive strategy focuses on markets that demand wide variability and product customization. By simulating four different scenarios, the effects of variability and machine resources utilization are evaluated. The results show that a minimal change in machine resources utilization strongly impacts process flow times and, consequently, another critical QRM variable like Manufacturing Critical-Path Time (MCT)., This research work has been funded by the draft national R&D plan entitled "Optimization of zero-defect production technologies enablers for supply chains 4.0 (CADS4.0)" (Ref. RTI2018-101344-B-I00).

Production has undergone many evolutionary stages and paradigm shifts in recent times. The fourth industrial revolution poses challenges to the industrial community. New business environment conditions initiate the genesis of new concepts for industrial enterprises. Integration of industrial paradigms – lean production, quick response manufacturing, agile manufacturing can be an effective solution. The goal of the research is to analyze this integration and to relate it to the current Russian economy state. Theoretical and practical aspects of the offered production concept are presented. The introduction of the «virtual design bureau» in the PJSC United Aircraft Corporation is examined. This is successful example of using of contemporary production technologies combination in Russian industry. Concluding, symbiosis of several production paradigms can become promising strategy for Russia in the context of modern trends of the world industrial development.

Para la capacitación del Sistema Paired-cell Overlapping Loops of Card Authorization (POLCA), se han diseñado algunos juegos para incrementar la efectividad de su aprendizaje. Sin embargo, estos juegos aún presentan elementos complejos que no permiten usarse con pocos recursos y tiempo limitado. El objetivo es presentar unas simplificaciones de esos juegos en uno que considere esas restricciones. El diseño del juego fue basado en el proceso de aprendizaje por juegos de simulación para administración de operaciones, considerando los pasos de implementación del POLCA. Para verificarlo, el juego se aplicó en una clase de Ingeniería Industrial. Según los resultados, las simplificaciones fueron efectivas para la enseñanza del sistema. Sin embargo, es necesario mejorar las instrucciones iniciales y los detalles usados en la información simulada dentro del juego. Para el uso del juego se recomienda modificar las instrucciones iniciales para obtener mejores resultados. For the training of the system Paired-cell Overlapping Loops of Card Authorization (POLCA), some games have been designed to increase learning effectiveness. However, these games still have complex elements that do not allow to be used with few resources and limited time. The objective is to show some simplifications of these games in one game considering these restrictions. The design of the game was based on the learning process by simulation games for Operations Management, considering the steps of the implementation of POLCA. To verify it, the game was applied in an Industrial Engineering class. According to the results, the simplifications worked effectively for the training of the system. Nevertheless, it is necessary to improve the initial instructions and details used in the simulated information within the game. For the use of the game it is recommended to modify the initial instructions to obtain better results.

O Quick Response Manufacturing (QRM) é uma importante ferramenta para redução de lead time em todas as operações de uma empresa de manufatura. Embora existam trabalhos empíricos mostrando a aplicação do QRM no chão de fábrica, poucos trabalhos tratam de operações de escritório. Dentre estas operações, o desenvolvimento de produtos é uma área ainda muito pouco explorada. Este trabalho busca trazer contribuições para a literatura ao mostrar a possibilidade de implantação do QRM no processo de desenvolvimento de novos lápis de olhos em uma empresa fabricante de cosméticos. Após estudo de caso foi possível apresentar três propostas, viáveis economicamente, que se implantadas conjuntamente, poderá reduzir 55% do lead time desse processo. As propostas mostram também a importância de se repensar novas formas de se realizar o trabalho em escritório.

This research investigates the application of Quick Response Manufacturing (QRM) practices by enterprises in Brazil, Europe, and the USA. QRM is a management concept that focuses on time as the key factor in competitive manufacturing, particularly in customer-oriented Engineer and Make to Order (ETO/MTO) production environments. A literature review identifies QRM principles, divided into four core concepts. Next, an exploratory survey in 20 manufacturing companies that operate under ETO/MTO conditions and are known to have already implemented QRM shows that: (i) the degree of the application of QRM practices is not the same for the four core concepts of QRM; (ii) the extent of the implementation of each core concept is similar among all the world regions studied; (iii) the use of Lean Manufacturing favours the adoption of QRM; and (iv) the QRM practices least applied by the surveyed organizations are those related to the abandonment of a mentality based on economies of scale and cost reduction.

Várias abordagens têm surgido para incrementar o desempenho das operações. Entre elas, cabe citar a Lean Manufacturing, pelos resultados em produtividade, e a Quick Response Manufacturing (QRM), pelo tratamento de alta variedade. Porém, a literatura ainda não tem mostrado como utilizá-las em conjunto ou se podem ser complementares entre si. O objetivo neste artigo é encontrar as semelhanças, diferenças e complementaridades entre as duas abordagens. Para isso, realizou-se uma revisão de literatura, classificando as publicações de acordo com as suas abordagens e ferramentas utilizadas, principalmente. As diferenças encontradas destacam-se pela programação de produção, os seus indicadores. As semelhanças destacadas são estratégias em reduzir desperdícios, uso de agrupamento celular e redução de set-up. As abordagens são complementares no incremento de flexibilidade do QRM para o Lean, tanto nos produtos como na cadeia de suprimentos. Futuras pesquisas podem explorar uma combinação das duas em forma empírica.

30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2021) 15-18 June 2021, Athens, Greece., POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a decision support system for material flow control under Quick Response Manufacturing. It operates in the context of low-volume, high-mix, and cellular manufacturing. While there is an increasing literature on POLCA performance, current studies usually assume full availability of components (or parts) at assembly stations, neglecting parts manufacturing and feeding. Therefore, this study uses simulation to assess POLCA performance in a two-stage production system, where at the first stage parts are manufactured and at the second, they are assembled into end-products. The study demonstrates that using POLCA to control both production stages, manufacturing and assembly, significantly outperforms the use of POLCA at the assembly stage only, leading to important reductions of the total throughput time of orders and on the percentage of tardy orders. Statistical analysis of our results was conducted using ANOVA., This work has been supported by FCT – Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020

High capital and labor costs, coupled with high rates of technological and competitive change, present challenges for manufacturers in developed countries, often spurring them to offshore production to low cost sources. However, the electronics industry provides an exception to this trend, where dynamic, high cost conditions have given rise to a new production system – seru – a cellular assembly approach. Seru evolved as an alternative to lean systems approaches, manifesting important differentiated system design choices that appear to offer promise for manufacturing in dynamic, high-cost markets. This paper reports the results of in-depth, longitudinal case studies of two electronics giants who have implemented seru. The case studies describe seru's fundamental extensions to, and departures from, lean production, agile production, and group technology-based cellular manufacturing. We explain how Sony and Canon have applied seru to improve productivity, quality, and flexibility in ways that have enabled them to remain competitive. In addition, our findings elaborate the theory of swift, even flow, with implications for future research of trade-offs related to production efficiency, responsiveness, and competitiveness in high-cost, technologically dynamic markets.

Quick response strategy (QRS) has been widely adopted in a supply chain where members collect timely market information for better forecasting, and then respond promptly to the market changes by adjusting initial inventory decision. After adopting the QRS, sustainability issues such as greenhouse gas emission and energy waste may be more serious as production lead time is shorter. In this study, due to this dilemma, we develop a two-stage quick response supply chain with cleaner technology, where the manufacturer determines the cleaner technology investment and afterwards the retailer decides the ordering quantity. Based on Bayesian theory, we depict an information updating process for the QRS with cleaner technology. First, we find that the inventory service level significantly affects both manufacturer’s and retailer’s performance under the QRS with cleaner technology. Moreover, our analytical results indicate that the performance of centralised supply chain system is always better than the decentralise...

O mercado de flores no Brasil necessita de reestruturação para conseguir oferecer produtos sensíveis com maior qualidade para o consumidor. Essa reestruturação permitirá que as flores cheguem ao consumidor mais rapidamente e com mais tempo de durabilidade. O objetivo deste estudo foi analisar o lead time dos processos logísticos de uma rede varejista de flores com sede na cidade de Campinas/SP, utilizando a ferramenta MCT - Manufacturing Critical-path Time, da abordagem QRM – Quick Response Manufacturing. Algumas ferramentas auxiliaram a pesquisa, como Fluxograma, Mapa de Fluxo de Valor, Diagrama de Ishikawa e Brainstorming. Os dados coletados relacionados aos tempos de processamento das operações levantam características dos processos logísticos envolvidos na distribuição da matéria-prima, desde a sua aquisição até a entrega em cada filial. Ao fim da pesquisa foi possível propor mudanças nos locais de compras das flores e no modo de distribuição para as lojas, simulando a redução no lead time de aproximadamente 80%.

Nowadays, in a new era of industrial revolution 4.0, there are still many manufacturing companies that tend to neglect the knowledge of optimizing the factory layout. By doing so, the productivity can be increase and lessen the burden of the operator while making sure the quality and also the number of products are also at optimum. The objective of this study is to conduct an analysis on the actual arrangement assembly line using witness software based on QRM in V model assembly and also to propose a new arrangement of the assembly line using Witness software. The data has been collected and recorded through some observation during the visit to X Company. The current layout of the V model assembly line is simulated in the Witness software to get its actual process, percentage of idle, and also the setup time. The software is also used for the new improvement of the assembly line layout to get the comparison for the current layout and after the improvement. Based on the current result, there is some station that has a high percentage of blockage occur in the layout and after the improvement, the percentage of blockage has been reduced which help in increase the production of the model per day. The data that has been recorded from the current is compared with the data after the improvement has been made to the assembly line.

The fourth industrial revolution initiates a change in the strategic guidelines of industrial enterprises. The rapid trend towards a wide variety of finished products with a short development and production time has led to a number of problems for enterprises with inventory, overhead and efficiency. The imperative of implementing lean production is becoming irrelevant due to new challenges in the external environment and is giving way to more competitive paradigms. Now the modern production concept should be focused not only on the cost and quality of goods, but also on the speed of response and flexibility. Quick response manufacturing (QRM) is one of them, which is a corporate strategy to reduce time of execution of the order at the industrial enterprise. And it is an extremely new and unfamiliar management paradigm in Russia. The purpose of this study is to analyze quick response manufacturing and to relate it to the current state of the Russian industrial development. Theoretical and practical aspects of this concept are given. The examples of the quick response manufacturing implementation in the Russian industrial sector are presented. Summarizing, QRM is offered as a promising manufacturing paradigm for Russian industry.

This article parts from the importance of sugarcane based energy to the Brazilian economy and, consequently, the important role of the process that involves cutting/loading/transportation (CLT) of cane in the supplies and production cost of sugar, alcohol and its derivates. For this purpose, a study case was carried in a sugarcane factory from São Paulo state, aiming to build a proposal that could reduce the lead time in the CLT process through the analysis of the Manufacturing Critical-Path Time (MCT) of the studied industry. With the data collected in the field visits, the MCT of one tone of sugarcane during its logistic process was done. This tool revealed a long waiting time of the cane waiting to be milled in the patio of the factory. Through the theory of dynamic of the systems it was concluded that this time was high due to the variability of the field as a consequence of an inefficient use of the harvester and the logistic system of dynamic allocation of the transportation resources ahead in the harvest. To make the harvester more efficient, a reduction of 40% of the laying time “awaiting transshipment” was proposed, which would result in a save of R$ 1.172.784,00/year. For this reduction five proposals were identified to be implemented in parallel: integration of the systems of the board computer and the traffic control system; integration of the board computers of the harvester and the transports; implementation of truck filling volume sensors; focus in the management of basis leaders; and, implementation of a multitask worker. Resumo A partir da importância do setor sucroenergético para a economia brasileira, e da importância do processo de corte/carregamento/transporte (CCT) de cana no suprimento e no custo da produção do açúcar, álcool e derivados, este artigo tem como estudo de caso uma usina de cana-de-açúcar paulista. O objetivo deste trabalho foi construir propostas de redução do lead time do processo CCT de cana-de-açúcar, através da análise do Manufacturing Critical-Path Time (MCT) da usina estudada. Com os dados coletados nas visitas à campo, foi feito o MCT de uma tonelada de cana ao longo de seu processo logístico. Essa ferramenta apontou para o grande tempo de espera da cana aguardando para ser moída no pátio da usina. Por intermédio da teoria da dinâmica dos sistemas, concluiu-se que esse tempo era alto decorrente da variabilidade no campo, consequência da ineficiência do uso da colhedora e do sistema logístico de alocação dinâmica dos recursos de transporte nas frentes de colheita. Para melhorar a eficiência da colhedora, foi proposto uma redução de 40% de seu tempo de parada por “aguardando transbordo”, que resultaria em uma economia de R$1.172.784,00/ano. Para realizar essa redução, foram identificadas cinco propostas a serem implementadas em paralelo: integração dos sistemas de computador de bordo e o sistema do controlador de tráfego; integração dos computadores de bordo da colhedora e dos transbordos; implementação de sensores de volume de preenchimento da julieta; foco na gestão dos líderes de frente; e, implementação do trabalhador multifuncional.

Many methods can be used in manufacturing industries to minimize the wastage. Waste occurred when the output was below the production target and the high rejection rate of the products due to quality issues. One of the reasons is because of the wrong way of working set-up. Inappropriate working environment can cause workers to feel grievances on their limbs with the frequent complaints are fatigue and musculoskeletal. With this complaint, it has an impact on the smooth production process. Many Methods can be used to minimize waste in the manufacturing industry. One of the methods that can be used is Quick Response Manufacturing (QRM) embedded with ergonomics for the work process. Implementation of the QRM and ergonomic methods in manufacturing companies in different countries is still experiencing some constraints. Therefore, this article contains an analysis to identify and evaluate the application of QRM and ergonomics in the Manufacturing industry based on published articles. The approach can be used to assist in formulating the right model in evaluating the strategies for QRM and ergonomic application in the manufacturing sectors.

Neste artigo é abordada a metodologia da manufatura responsiva (Quick Response Manufacturing – QRM) que tem como objetivo reduzir o lead time das operações, aqui, o objeto de estudo será uma empresa de linha branca. A utilização do gráfico Manufacturing Critical-path Time (MCT) permitiu identificar que o estoque de produtos acabados seria a etapa foco de redução de lead time, com este fim, é apresentada uma proposta de adoção de estratégia de produção para disponibilidade (Make to availability – MTA) em substituição a atual estratégia de produzir para estoque (Make to Stock – MTS). O objetivo é reduzir o lead time de produção e, consequentemente, diminuir os custos desses produtos em estoque resultando em redução de aproximadamente 50% no MCT atual.