Abstract: Based on the concept of quick response manufacturing (QRM), the operation mechanism of paired-cell overlapping loops of cards with authorization (POLCA) is analyzed. A fine division method of production periods is proposed to improve the average of the Little's Law for lead time and the number of work in process (WIP). Then a novel mathematical programming formulation is developed for the determination of the number of POLCA cards. By this model, it can minimize the production cost that is a weighted combination of the number of POLCA cards. The global optimal number of POLCA cards is found such that the system operates under high efficiency. By two examples, it shows that the model is reasonable and valid for two different operational modes. The proposed method is helpful for the mangers to accurately and effectively control the whole POLCA system for QRM. 

Key words: quick response manufacturing (QRM), paired-cell overlapping loops of cards with authorization (POLCA), Little's law