Implementasi Lean Warehousing untuk Meningkatkan Efisiensi Operasional Pergudangan: Studi Kasus Gudang Bahan Baku di Sebuah Perusahaan Manufaktur Kereta Api

Bimantara, Alvin (2024) Implementasi Lean Warehousing untuk Meningkatkan Efisiensi Operasional Pergudangan: Studi Kasus Gudang Bahan Baku di Sebuah Perusahaan Manufaktur Kereta Api. Other thesis, Intitut Teknologi Sepuluh Nopember.

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Abstract

PT Industri Kereta Api (Persero) atau yang biasa disingkat menjadi PT INKA (Persero) merupakan perusahaan manufaktur kereta api terintegrasi pertama di Asia Tenggara. Untuk menunjang proses produksi yang dilakukan, PT INKA memiliki 3 jenis gudang bahan baku yaitu gudang bahan baku komponen, gudang gas, dan gudang open storage. Pada penelitian ini berfokus pada gudang open storage. Pada gudang open storage, terdapat beberapa permasalahan terkait dengan aktivitas pergudangan yang dilakukan yaitu penumpukan material di inbound area. Hal ini mengindikasikan adanya aktivitas pergudangan kurang efisien di dalam proses pergudangan yang mengganggu kelancaran dari operasional pergudangan. Untuk mengatasi permasalahan tersebut dapat dilakukan dengan mengeliminasi kegiatan yang tidak memberikan nilai tambah dengan metode lean warehousing dengan menggunakan beberapa tools yaitu Value Stream Mapping (VSM), Process Activity Mapping (PAM), Gemba Shikumi, Lean Matrix 2, dan Root Cause Analysis dengan Fishbone Diagram. Melalui identifikasi menggunakan Value Stream Mapping (VSM), Process Activity Mapping (PAM), dan Gemba Shikumi didapatkan 3 waste kritis yaitu penyimpanan yang melebihi kapasitas gudang (penyimpanan di luar gudang), operator gudang memindahkan material lama dari alamat penyimpanan ke area kosong sekitar alamat untuk menerapkan sistem penyusunan material secara FIFO, dan operator gudang memindahkan material yang berada di bagian depan terlebih dahulu karena penyusunan material dilakukan secara horizontal. Dari waste kritis tersebut diusulkan perbaikan yaitu pembuatan rak material, peningkatan awareness operator gudang tentang continuous improvement dalam operasional pergudangan, pembuatan SOP penerapan first in first out (FIFO) di gudang, dan pembuatan parameter kinerja pergudangan berkaitan dengan aktivitas pergudangan. Dari usulan perbaikan tersebut diestimasikan reduksi waktu dari keseluruhan aktivitas pergudangan sebesar 448 detik atau 34,65% dari kondisi eksisting 1293 detik menjadi 845 detik.
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PT Industri Kereta Api (Persero) or commonly abbreviated as PT INKA (Persero) is the first integrated railway manufacturing company in Southeast Asia. To support the production process, PT INKA has 3 types of raw material warehouses, namely component raw material warehouses, gas warehouses, and open storage warehouses. This research focuses on the open storage warehouse. In the open storage warehouse, there are several problems related to warehousing activities carried out, namely the accumulation of materials in the inbound area. This indicates that there are inefficient warehousing activities in the warehousing process that interfere with the smooth running of warehousing operations. To overcome these problems, it can be done by eliminating activities that do not provide added value with the lean warehousing method using several tools, namely Value Stream Mapping (VSM), Process Activity Mapping (PAM), Gemba Shikumi, Lean Matrix 2, and Root Cause Analysis with Fishbone Diagram. Through identification using Value Stream Mapping (VSM), Process Activity Mapping (PAM), and Gemba Shikumi, 3 critical wastes were obtained, namely storage that exceeds warehouse capacity (storage outside the warehouse), warehouse operators moving old materials from the storage address to an empty area around the address to implement a FIFO material arrangement system, and warehouse operators moving materials at the front first because the material arrangement is done horizontally. From these critical wastes, improvements are proposed, namely the construction of material racks, increasing warehouse operators' awareness of continuous improvement in warehousing operations, making SOPs for implementing first in first out (FIFO) in the warehouse, and creating warehousing performance parameters related to warehousing activities. From the proposed improvements, it is estimated that the time reduction of all warehousing activities is 448 seconds or 34,65% of the existing condition of 1293 seconds

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Root Cause Analysis, Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Root Cause Analysis
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management H Social Sciences > HD Industries. Land use. Labor > HD56.25 Industrial efficiency--Measurement. Industrial productivity--Measurement.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Alvin Bimantara
Date Deposited:	19 Jul 2024 08:54
Last Modified:	19 Jul 2024 08:54
URI:	http://repository.its.ac.id/id/eprint/108526

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