Optimasi Tata Letak Produk Pada Gudang Bahan Baku untuk Meminimalisasi Waktu Order Picking Menggunakan Metode Integer Linear Programming

Rachma, Azzahra Aulia (2023) Optimasi Tata Letak Produk Pada Gudang Bahan Baku untuk Meminimalisasi Waktu Order Picking Menggunakan Metode Integer Linear Programming. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Gudang merupakan salah satu komponen penting dalam rantai pasok, karena berperan sebagai penyangga aliran material guna mengakomodasi variabilitas yang disebabkan oleh produk musiman dan konsep batching pada proses produksi maupun transportasi. Tiga proses utama dalam operasional gudang adalah perpindahan, penyimpanan, dan transfer informasi. Perpindahan terdiri dari beberapa aktivitas seperti receiving, put-away, order picking, cross-docking dan shipping. Aktivitas order picking sendiri mampu merepresentasikan 55-60% dari total biaya operasional. Tata letak produk memiliki pengaruh yang besar terhadap waktu order picking sehingga perlu diperhatikan oleh perusahaan supaya dapat meningkatkan efisiensi. Penelitian ini dilakukan terhadap perusahaan 3PL yang berfokus pada aktivitas pergudangan yang menangani bahan baku dari tiga perusahaan manufaktur di bidang otomotif. Dengan jumlah pesanan harian yang dapat mencapai ribuan SKU dan lokasi penyimpanan yang berjumlah lebih dari 7000 lokasi palet, akan sangat banyak pergerakan yang terjadi, khususnya pada proses order picking. Selain itu, kebijakan penyimpanan yang berlaku di gudang saat ini adalah class-based storage policy, dimana fast-moving product disimpan pada fix location yang diletakkan pada rak level 1 dan 2 yang menyebar di seluruh lokasi penyimpanan. Hal ini menyebabkan picker harus menempuh perjalanan yang jauh untuk memenuhi pesanan yang diterima. Oleh karena itu, penelitian ini dilakukan dengan tujuan untuk menentukan tata letak penyimpanan produk di gudang sehingga mampu meminimalisasi waktu order picking. Optimasi dilakukan dengan merancang model matematis integer linear programming untuk storage assignment dengan pendekatan clustering. Setelah menjalankan percobaan menggunakan dua skenario perbaikan, skenario 1 dipilih karena menghasilkan waktu order picking sebesar 287.03 jam untuk memenuhi order ketiga customer dalam satu bulan atau setara dengan pengurangan waktu sebesar 144.79 jam per bulan jika dibandingkan dengan kondisi eksisting.
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A warehouse is one of the important components in the supply chain, as it serves as a buffer for material flow to accommodate variability caused by seasonal products and batching concepts in production or transportation processes. The three main processes in warehouse operations are movement, storage, and information transfer. Movement consists of several activities such as receiving, put-away, order picking, cross-docking, and shipping. The order picking activity alone can represent 55-60% of the total operational cost. The layout of products has a significant influence on order picking time and needs to be considered by companies to improve efficiency. This research was conducted on a 3PL company that focuses on warehousing activities, handling raw materials from three manufacturing companies in the automotive industry. With a daily order volume that can reach thousands of SKUs and storage locations totaling more than 7000 pallet locations, there will be a significant amount of movement, especially in the order picking process. Furthermore, the current storage policy in the warehouse is a class-based storage policy, where fast-moving products are stored in fixed locations placed on shelves at levels 1 and 2 distributed throughout the storage area. This causes pickers to travel long distances to fulfill incoming orders. Therefore, this research was conducted with the aim of determining the storage layout of products in the warehouse in order to minimize order picking time. The optimization was carried out by designing a mathematical model of integer linear programming for storage assignment using a clustering approach. After conducting experiments using two improvement scenarios, scenario 1 was chosen as it resulted in an order picking time of 287.03 hours to fulfill the orders of the third customer in one month, or equivalently, a reduction of 144.79 hours per month compared to the existing condition.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Optimization, Order Picking, Product Clustering, Product Layout, Storage Warehouse,Gudang Penyimpanan, Optimasi, Order Picking, Pengelompokkan Produk, Tata Letak Produk
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD38.5 Business logistics--Cost effectiveness. Supply chain management. ERP
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Azzahra Aulia Rachma
Date Deposited:	23 Aug 2023 05:24
Last Modified:	23 Aug 2023 05:24
URI:	http://repository.its.ac.id/id/eprint/101583

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