QRM for Consultants Driving Client Success through Quick Response Manufacturing

This two-day intensive workshop is designed for consultants who aim to master Quick Response Manufacturing (QRM) principles and tools to deliver significant value to their clients. As manufacturing companies increasingly seek to reduce lead times, improve operational efficiency, and gain a competitive edge, consultants equipped with QRM expertise are uniquely positioned to drive transformational change.

This course provides in-depth knowledge of QRM’s strategic and tactical aspects, from implementing office and shop floor cells to leveraging advanced scheduling systems like POLCA. Participants will learn how to assess client needs, design tailored QRM solutions, and guide successful implementations that lead to measurable improvements in lead times, costs, and market responsiveness. Consultants will gain the skills necessary to become trusted QRM advisors through hands-on exercises, case studies, and practical frameworks.

Key Learning Outcomes:

• Understand the role of QRM alongside Six Sigma, Lean, TOC, and Agile to enhance time-based competitiveness.
• Master QRM principles to reduce lead times and eliminate waste across manufacturing and office environments.
• Develop tailored QRM solutions for high-mix, low-volume, and custom production to address specific client challenges.
• Guide clients through successful QRM implementations, overcoming resistance to change and resource constraints.
• Utilize advanced QRM tools like POLCA and MCT Mapping to optimize scheduling, capacity planning, and operational efficiency.
• Build the business case for QRM transformations, highlighting both financial and non-financial benefits.
• Engage in practical exercises and simulations to confidently lead QRM initiatives and drive continuous improvement.

Day 1: QRM Fundamentals and Client Applications

1. Introduction to QRM for Consultants
• Overview of QRM principles and their impact on client competitiveness.
• Understanding how QRM complements Six Sigma, Lean, TOC, and Agile.
• The consultant’s role in identifying and capitalizing on QRM opportunities for clients.
2. QRM Office Cells: Streamlining Business Processes
• Designing office cells to reduce hand-offs, lead times, and operational complexity.
• Implementation steps for creating Quick Response Office Cells (Q-ROCs) within client organizations.
3. Shop Floor Cell Design and Scheduling Solutions
• Advanced strategies for designing shop floor cells in high-mix, low-volume, and custom production environments.
• Introduction to POLCA: a visual control system to enhance shop floor performance.
4. Building the Business Case for QRM Transformations
• Developing both financial and non-financial justifications for QRM.
• Demonstrating ROI through case studies and real-world examples of QRM success.

Day 2: Advanced QRM Tools, Implementation, and Consulting Skills

1. Advanced QRM Tools: POLCA and MCT Mapping
• In-depth exploration of POLCA and its benefits for client scheduling and flow management.
• Using Manufacturing Critical-path Time (MCT) as a diagnostic tool to uncover client inefficiencies.
2. Guiding Clients Through QRM Implementation
• Step-by-step approaches to QRM implementation tailored to various client needs.
• Managing the change process: gaining client buy-in and sustaining momentum.
3. Overcoming Challenges in QRM Adoption
• Addressing common client obstacles such as resistance to change and resource limitations.
• Case studies on successfully overcoming barriers and achieving client success with QRM.
4. Consulting Best Practices and Client Engagement Techniques
• Effective communication strategies for presenting QRM recommendations.
• Building long-term relationships through ongoing support and continuous improvement initiatives.
5. Workshop: Customizing QRM Solutions for Clients
• Group exercises to apply QRM concepts to real-world consulting scenarios.
• Peer feedback and expert guidance on tailoring QRM strategies to specific client challenges.
6. Wrap-Up: Next Steps for QRM Consultants
• Key takeaways from the course and how to integrate QRM with existing consulting practices.
• Q&A session to address consultant-specific questions and challenges.