Perancangan Model Cycle Counting Berbasis Klasifikasi ABC-XYZ Pada Gudang Material Operasional PT X

Andhika, Yudha Koessala Puja (2026) Perancangan Model Cycle Counting Berbasis Klasifikasi ABC-XYZ Pada Gudang Material Operasional PT X. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Selama ini, pengelolaan persediaan pada Gudang Material Operasional PT X mengandalkan stock opname tahunan yang bersifat reaktif, sehingga selisih pencatatan baru terungkap setelah menumpuk selama satu tahun penuh dan sulit ditelusuri akar penyebabnya. Kondisi ini membuat manajemen kesulitan mengambil keputusan pengadaan dan pemeliharaan secara tepat waktu, karena data persediaan yang tersedia sepanjang tahun tidak dapat sepenuhnya diandalkan. Penelitian ini merancang model cycle counting berbasis klasifikasi ABC–XYZ sebagai alat kontrol persediaan yang awalnya bersifat "memeriksa sesekali dalam jumlah besar" menjadi kontrol yang "memeriksa berkelanjutan secara terarah", sehingga sumber daya gudang yang terbatas dapat difokuskan pada material yang paling berisiko dan paling berdampak terhadap keandalan operasi pembangkit, bukan disebar merata ke seluruh ribuan item tanpa prioritas. Secara manajerial, integrasi klasifikasi ABC dan XYZ memberikan peta risiko yang jelas bagi pengambil Keputusan. Material bernilai tinggi dengan pola pemakaian tidak stabil (kuadran AZ) memerlukan perhatian pengawasan berkala meski frekuensinya tidak setinggi item rutin, sementara temuan item deadstock bernilai tinggi pada kuadran CX memberi sinyal perlunya kajian penghapusan atau realokasi aset yang selama ini luput dari perhatian karena hanya terlihat sekali setahun. Implementasi model juga menunjukkan bahwa pengendalian berkelanjutan dapat dijalankan tanpa menghentikan operasional gudang dan tanpa menambah beban kerja berlebih pada petugas, sehingga dapat diadopsi sebagai aktivitas rutin operasional gudang, bukan proyek insidentil. Lebih jauh, mayoritas selisih yang ditemukan bersumber dari kelemahan disiplin administratif lintas fungsi (keterlambatan pencatatan transaksi antara gudang, user, dan procurement), sehingga cycle counting berfungsi ganda sebagai alat deteksi selisih fisik sekaligus alat audit proses bisnis yang mendorong akuntabilitas dan koordinasi antar unit kerja. Dari sisi kelayakan penerapan, model ini tidak membutuhkan tambahan sumber daya di luar kapasitas tim gudang yang ada, sehingga keputusan adopsinya tidak terkendala investasi besar, melainkan lebih pada komitmen manajemen terhadap konsistensi jadwal dan penguatan budaya kepatuhan pencatatan. Dengan demikian, penelitian ini merekomendasikan cycle counting berbasis ABC–XYZ sebagai kebijakan pengendalian persediaan berkelanjutan yang dapat direplikasi pada gudang serupa di lingkungan perusahaan.
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For a long time, inventory management at PT X's Operational Material Warehouse relied on a reactive annual physical inventory, meaning that recording discrepancies only came to light after accumulating for a full year and were difficult to trace back to their root cause. This condition made it difficult for management to make timely procurement and maintenance decisions, as the inventory data available throughout the year could not be fully relied upon. This research designs a cycle counting model based on ABC–XYZ classification as an inventory control tool that shifts from "infrequent, large-scale inspection" to "continuous, targeted inspection," allowing the warehouse's limited resources to be focused on the materials that carry the highest risk and the greatest impact on power plant operational reliability, rather than being spread evenly across thousands of items without prioritization. From a managerial perspective, the integration of ABC and XYZ classification provides decision-makers with a clear risk map. High-value items with unstable usage patterns (quadrant AZ) require regular monitoring attention, even though their counting frequency is not as high as routine items, while the discovery of high-value deadstock items in quadrant CX signals the need for a write-off or asset reallocation review, a condition that had previously gone unnoticed as it was only visible once a year. Implementation of the model also demonstrates that continuous control can be carried out without halting warehouse operations and without adding excessive workload to staff, making it feasible to adopt as a routine warehouse operational activity rather than a one-off project. Furthermore, the majority of discrepancies found originated from weaknesses in cross-functional administrative discipline (delays in recording transactions between the warehouse, users, and procurement), positioning cycle counting as serving a dual function: a tool for detecting physical discrepancies and a tool for auditing business processes that encourages accountability and coordination among work units. In terms of implementation feasibility, this model does not require additional resources beyond the existing capacity of the warehouse team, so the decision to adopt it is not constrained by large investment, but rather depends more on management's commitment to schedule consistency and strengthening a culture of recording compliance. Accordingly, this research recommends ABC–XYZ-based cycle counting as a sustainable inventory control policy that can be replicated in similar warehouses across the company.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Gudang, Akurasi Persediaan, ABC-XYZ, Cycle Counting, Manajemen Persediaan, Warehouse, Inventory Accuracy, Inventory Management
Subjects:	T Technology > TS Manufactures > TS161 Materials management.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Yudha Koessala Puja Andhika
Date Deposited:	07 Aug 2026 03:08
Last Modified:	07 Aug 2026 03:12
URI:	http://repository.its.ac.id/id/eprint/144200

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