Simulation-based POLCA integrated QRM approach for smart manufacturing

Sandeep Kumar*, Sanyapong Petchrompo, Tanveer Ahmed, Amit Kumar Jain

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Digitalisation and Industry 4.0 have enabled real-time interaction of customers and suppliers with manufacturing systems. However, this requires a high level of reactivity in the value chain to sustain in a competitive economy. As a result, Quick Response Manufacturing (QRM) in dynamic conditions such as wide product variety, change in demand, volatile market conditions, uncertainty in supply, and machine failures is critical in capturing the benefits of digitalisation in industries. To empower QRM, Paired-cell Overlapping Loops of Cards with Authorization (POLCA) is suitable for a manufacturing environment with a wide variety and highly dynamic conditions. The combination of QRM and POLCA provides a significant competitive advantage through their quick response to dynamic conditions. Such a combination is not reported in the literature. Accordingly, this paper proposes a simulation-based POLCA integrated with the QRM approach for smart manufacturing. The offered approach evaluates a dynamic sequence of jobs at each machine to meet the due date and at the same time control the material flow to improve system performance. The approach is illustrated with the help of a complex manufacturing scenario. A simulation-based technique is used to evaluate the system performance. Further, the performance of the approach under dynamic conditions is analysed. Results show that improved system performance can be achieved by considering QRM and POLCA in dynamic conditions.

Original languageEnglish
Title of host publicationIndustry 4.0 and Advanced Manufacturing: Proceedings of I-4AM 2022
EditorsAmaresh Chakrabarti, Satyam Suwas, Manish Arora
Number of pages14
ISBN (Electronic)9789811905612
ISBN (Print)9789811905605
Publication statusE-pub ahead of print - 24 Jul 2022
Event2nd International Conference on Industry 4.0 and Advanced Manufacturing - Online
Duration: 10 Jan 202211 Jan 2022 (Link to conference website)

Publication series

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364


Conference2nd International Conference on Industry 4.0 and Advanced Manufacturing
Abbreviated titleI-4AM 2022
Internet address


  • Industry 4.0
  • Quick Response Manufacturing (QRM)
  • modelling and simulation

ASJC Scopus subject areas

  • Automotive Engineering
  • Aerospace Engineering
  • Mechanical Engineering
  • Fluid Flow and Transfer Processes


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