Perbaikan Operasi Gudang Distribution Center Dengan Pendekatan Lean Warehousing Pada Perusahaan Kosmetik

Al Farizi, Wildan Sidqi (2023) Perbaikan Operasi Gudang Distribution Center Dengan Pendekatan Lean Warehousing Pada Perusahaan Kosmetik. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT XYZ merupakan perusahaan Fast Moving Consumer Goods (FMCG) di bidang kosmetik, parfum, personal care, dan skin care. PT XYZ telah memiliki 40 Distribution center (DC) untuk mendistribusikan produknya ke seluruh toko dan retailer di seluruh Indonesia dengan toko yang dilayani lebih dari 75.000 toko. Salah satu Distribution Center yang dimiliki PT XYZ terletak di kota Surabaya dengan luas area gudang pada Distribution Center ini adalah 1.5 hektare dan menampung hingga 1.457 SKU (stock keeping unit) dengan total keseluruhan barang yang disimpan sebanyak 904.827 pcs. Perusahaan memiliki beberapa masalah terkait proses pergudangannya yaitu Terdapat kesalahan picking yang cukup banyak yaitu 268 salah picking dan 5 salah pengiriman barang ke toko selama bulan januari 2023, Adanya penumpukan barang pada area checker, dan Terdapat pekerja yang lembur cukup banyak untuk setiap harinya. Hal ini menimbulkan indikasi kegiatan yang tidak bernilai tambah dan berdampak pada kelancaran proses produksi dan biaya. Untuk mengeliminasi permasalahan tersebut dapat dilakukan perbaikan dengan pendekatan lean warehousing dengan mengintegrasikan beberapa tools yaitu Value Stream Mapping (VSM), Process Activity Mapping, Gemba shikumi, Lean Matrix 2, 5 Ws Analysis, dan Root Cause Analysis. Dengan menggunakan Value Stream Mapping (VSM), Process Activity Mapping, dan Gemba shikumi didapatkan 4 waste kritis yaitu barang menunggu diambil operator checking, operator checking memanggil operator picking karena terjadi kesalahan dalam picking barang, driver menukar faktur kepada driver lain, dan driver memindahkan barang untuk mencari barang sesuai dengan faktur yang telah dibagi. Dari 4 waste kritis tersebut dapat diberikan rekomendasi yaitu, Perubahan alur dengan menggabungkan stasiun untuk checking dan packing, Pembuatan pembatas rak, Pembuatan alat bantu pengambil keputusan untuk pengiriman ke pelanggan, dan Pembuatan pembagian area pada area outbound untuk setiap daerah. Dari rekomendasi alternatif perbaikan yang diusulkan diestimasikan waktu yang dapat direduksi adalah 8076 detik atau 21,6% dari waktu kondisi eksisting atau 37420 detik.
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PT XYZ is a Fast Moving Consumer Goods (FMCG) company in the cosmetics, perfume, personal care and skin care sectors. PT XYZ has 40 Distribution Centers (DC) to distribute its products to all stores and retailers throughout Indonesia with more than 75,000 stores serving stores. One of the Distribution Centers owned by PT XYZ is located in the city of Surabaya with a warehouse area of 1.5 hectares and can accommodate up to 1,457 SKUs (stock keeping units) with a total of 904,827 items stored. The company has several problems related to its warehousing process, namely there are quite a lot of picking errors, namely 268 wrong choices and 5 wrong delivery of goods to stores during January 2023, there is excessive goods in the checker area, and there are quite a lot of workers working overtime every day. This gives rise to indications of non-value-added activities and has an impact on the smooth production process and costs. To eliminate these problems, improvements can be made to the lean warehousing approach by integrating several tools, namely Value Stream Mapping (VSM), Process Activity Mapping, Gemba shikumi, Lean Matrix 2, 5 Ws Analysis, and Root Cause Analysis. By using Value Stream Mapping (VSM), Process Activity Mapping, and Gemba shikumi, 4 critical wastes are obtained, namely goods waiting to be picked up by checking operators, calling checking operators picking operators because there is an error in picking goods, drivers changing invoices to other drivers, and drivers moving goods to find items according to invoices that have been divided. Of the 4 critical wastes, recommendations can be given, namely, changing the flow by combining stations for checking and packing, making shelving boards, making decision-making tools for shipping to customers, and making distribution areas in the outbound area for each region. From the proposed alternative recommendations, it is estimated that the time that can be reduced is 8076 seconds or 21.6% of the existing condition time or 37420 seconds.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Gemba shikumi, Lean Assessment Matrix, Lean Warehouse, Root Cause Analysis
Subjects:	T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Al Farizi Wildan Sidqi
Date Deposited:	16 Aug 2023 07:34
Last Modified:	16 Aug 2023 07:34
URI:	http://repository.its.ac.id/id/eprint/101464

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