Process Improvement in A Spare Parts Warehouse Using Value Stream Mapping and Cost-Benefit Analysis

Asyarafi, Claudia Juwita (2024) Process Improvement in A Spare Parts Warehouse Using Value Stream Mapping and Cost-Benefit Analysis. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

The spare parts industry has witnessed significant growth, especially in the Asia-Pacific region, as it plays a crucial role in businesses, necessitating a well-organized logistics process to prevent disruptions and ensure operational efficiency and customer satisfaction, especially in managing high-service-level operation for mission-critical orders, requiring accurate and swift performance despite operational challenges. Examining the operational dynamics within a spare parts multi-user warehouse operated by a multinational 3PL company in Indonesia with a specific focus on Customer A reveals significant disparities: Customer A has a 33.6% lower pick rate and a 17.8% lower throughput processing rate than Customer B. These differences raise concerns about potential inefficiencies in Customer A's warehouse process. This research employs Value Stream Mapping (VSM), a lean manufacturing tool used to gain insights into the current and future states of a process for comparative analysis. This method identified 1,498 minutes of idle time per day in the overall Customer A's warehouse process. Based on these findings, improvements such as creating a skill matrix and implementing a Daily-In-Life-Of-Operation (DILO) analysis were made. These implementations reduced the total available time equivalent to two staff members and increased the throughput processing rate by 28.6%. Additionally, the throughput processing rate improved to 5.64% higher than Customer B's. The improvement impact is further analyzed with Cost Reduction Analysis, which revealed a 22.2% reduction in staff costs and a 22.8% decrease in staff cost per order compared to the pre-improvement state. ==============================================================Industri suku cadang telah mengalami pertumbuhan yang signifikan, terutama di wilayah Asia-Pasifik. Memainkan peran penting dalam bisnis, proses logistik harus terorganisasi dengan baik untuk mencegah gangguan dan memastikan efisiensi operasional serta kepuasan pelanggan, terutama dalam mengelola operasi tingkat layanan tinggi, berkinerja yang akurat dan cepat meskipun menghadapi tantangan operasional. Mengamati dinamika operasional dalam gudang multi-pengguna suku cadang yang dioperasikan oleh sebuah perusahaan 3PL multinasional di Indonesia dengan fokus khusus pada Pelanggan A mengungkapkan perbedaan signifikan: Pelanggan A memiliki pick rate yang 33,6% lebih rendah dan throughput processing rate yang 17,8% lebih rendah dibandingkan dengan Pelanggan B. Perbedaan ini menimbulkan kekhawatiran tentang potensi ketidakefisienan dalam proses gudang Pelanggan A. Penelitian ini menggunakan Value Stream Mapping (VSM), sebuah metode lean manufacturing yang digunakan untuk mendapatkan wawasan tentang keadaan proses saat ini dan masa depan untuk analisis komparatif. Metode ini mengidentifikasi 1.498 menit idle time per hari dalam keseluruhan proses gudang Pelanggan A. Berdasarkan temuan ini, perbaikan seperti pembuatan skill matrix dan pelaksanaan analisis Daily-In-Life-Of-Operation (DILO) dilakukan. Implementasi ini mengurangi waktu tersedia total yang setara dengan dua pegawai dan meningkatkan throughput processing rate sebesar 28,6%. Selain itu, throughput processing rate meningkat menjadi 5,64% lebih tinggi dibandingkan Pelanggan B. Dampak perbaikan ini dianalisis lebih lanjut dengan Cost-Benefit Analysis, yang mengungkapkan pengurangan biaya pegawai sebesar 22,2% dan penurunan biaya pegawai per pesanan sebesar 22,8% dibandingkan dengan keadaan sebelum perbaikan.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Third-party logistics, warehouse process, improvement, Value Stream Mapping, Cost Reduction Analysis, Logistik pihak ketiga, proses gudang, peningkatan, Value Stream Mapping, Cost-Benefit Analysis.
Subjects:	T Technology > TS Manufactures > TS167 Costs, Industrial
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Claudia Juwita Asyarafi
Date Deposited:	05 Aug 2024 03:28
Last Modified:	03 Sep 2024 03:58
URI:	http://repository.its.ac.id/id/eprint/113148

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