Penerapan Lean Warehouse Guna Memperbaiki Sistem Operasi Pergudangan (Studi Kasus: Gudang Bahan Baku Di PT X)

Rahmatindar, Princesia Olivia Prelita (2022) Penerapan Lean Warehouse Guna Memperbaiki Sistem Operasi Pergudangan (Studi Kasus: Gudang Bahan Baku Di PT X). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT X merupakan salah satu perusahaan manufaktur yang berlokasi di Sidoarjo, Jawa Timur. PT X bergerak di bidang otomotif dengan memproduksi baterai (aki) untuk beragam jenis kendaraan. Mayoritas aktivitas bisnis pada PT X dilakukan secara make-to-order sesuai dengan spesifikasi permintaan dari pelanggan. Gudang merupakan bagian penting dalam sebuah perusahaan manufaktur. Perusahaan mengalami beberapa masalah terkait gudang yaitu perbedaan antara jumlah barang di gudang dengan sistem, deadstock, dan peletakkan barang pada area di luar gudang. Keadaan ini menyebabkan kesulitan untuk mencari dan menemukan lokasi barang baik untuk barang yang baru datang dan juga menentukan jumlah barang untuk pembelian. Hal ini menimbulkan indikasi kegiatan yang tidak bernilai tambah dan berdampak pada kelancaran proses produksi dan biaya. Perbaikan proses gudang dengan menggunakan pendekatan Lean Warehouse dengan mengintegrasikan beberapa tools yaitu Value Stream Mapping (VSM), Process Activity Mapping, Gemba Shikumi, Lean Matrix 2, 5 Ws Analysis, dan Root Cause Analysi diusulkan untuk membantu perusahaan. Berdasarkan hasil pada Gemba Shikumi diperoleh 4 waste kritis yaitu, adanya perbedaan informasi stok dalam sistem dengan kondisi eksisting (defect), terdapat dead stock yang memenuhi area gudang (inventory), menunggu konfirmasi selesai dari proses penyimpanan barang (waiting), dan mencari lokasi rak penyimpanan barang dengan menyusuri keseluruhan rak (transportation). Pada Lean Matrix 2 diperoleh rekomendasi perbaikan terpilih berdasarkan tiga peringkat tertinggi dari rank of priority yang feasible untuk diterapkan oleh perusahaan saat ini, yaitu penerapan kanban card, penambahan beam, dan penerapan shared storage policy. Rekomendasi perbaikan terpilih diestimasikan dapat mereduksi waktu selama 900 detik sehingga cycle time menjadi 10.674 detik.
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PT X is a manufacturing company located in Sidoarjo, East Java. PT X is operating in the automotive sector by producing batteries for various types of vehicles. The majority of business activities at PT X are carried out on a make-to-order basis in accordance with customer specifications. Warehouse is an important part in a manufacturing company. The company experienced several problems related to warehouses, such as the difference between the number of goods in the warehouse with the system, deadstock, and placing goods in areas outside the warehouse. This situation causes difficulties in finding and locating goods both for newly arrived goods and also determining the number of goods for purchase. This situation indicates non value added activities and have an impact on the smooth production process and costs. Improvement of the warehouse process using the Lean Warehouse 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 are proposed to help companies. Based on the results of Gemba Shikumi, there are 4 critical wastes include in the form of observed problem such as, there are differences in stock information in the system with existing conditions (defect), there is dead stock in the warehouse area (inventory), waiting for confirmation of completion of the material storage process (waiting), and find the location of the shelf for storing goods for a long time by observing the whole warehouse shelves (transportation). In Lean Matrix 2, selected improvement recommendations are obtained based on the three highest rankings of rank of priority that are feasible to be implemented by the company at this time, such as the application of kanban cards, the addition of beams, and the application of shared storage policies. The selected improvement recommendations are estimated to be able to reduce the time for 900 seconds so that the cycle time becomes 10.674 seconds.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Ws Analysis, Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Root Cause Analysis, Ws Analysis, Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Root Cause Analysis
Subjects:	T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	09 Feb 2026 01:35
Last Modified:	09 Feb 2026 01:35
URI:	http://repository.its.ac.id/id/eprint/132261

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