Estimation of Buffer Warehouse Capacity Requirement in A Fertilizer Company : A Simulation Study

Viviansyah, Salsabila Faradina Fairuz (2019) Estimation of Buffer Warehouse Capacity Requirement in A Fertilizer Company : A Simulation Study. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

A fertilizer company utilizes buffer warehouse in delivering subsidized product to its customers. The problem occurs due to gap existence between fertilizers’ production and seasonal demand. During the dry season (April-September) the buildup of fertilizers in the Gresik warehouse occurs due to low demand. But during the planting season (October-March), the fertilizers demand is high and can even cause stockout. Therefore, there are stacking fertilizers outside the multi-purpose warehouse or called open storage. On the other hand, buffer warehouses have sufficient capacity to accommodate fertilizer stored on open storage. However, these available remaining capacities can’t be occupied freely. Each buffer warehouses storage area has been divided into and are only allowed to be occupied by certain types of fertilizers. The complexity adds up as the company has to follow government’s coverage days regulation. Hence, the evaluation warehouse capacity will be done to set the estimation capacity needed for buffer warehouse. The evaluation is done by assessing the delivery rule in terms of quantity and types of product, and also assessing the coverage days using Discrete Event Simulation (DES) with service level, buffer warehouse utility, total cost, and maximum daily on-hand inventory as the parameter output.
This research proposed a better scenario of buffer warehouse capacity by changing the coverage days and product placement regulation. By implementing the proposes coverage days regulation, the estimation of buffer warehouse capacity requirement was reduced and reduced to 81.5% on average from the current capacity. While by changing the product placement and coverage days regulation resulted to the highest reduced buffer warehouse capacity around 67% on average from the current capacity.
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Perusahaan pupuk menggunakan gudang penyangga dalam mengirimkan pupuk subsidi. Masalah terjadi dikarenakan adanya gap antara produksi pupuk dan permintaan pupuk yang bersifat musiman. Saat musim kemarau (April-September), penumpukan pupuk di gudang Gresik terjadi dikarenakan permintaan yang sedikit. Sedangkan saat musim hujan (Oktober-Maret), permintaan pupuk tinggi dan dapat menyebabkan stockout. Sehingga perusahaan menumpuk stok pupuk diluar, atau gudang open storage. Meskipun sisa kapasitas di gudang penyangga masih cukup untuk menyimpan stok. Aturan kapasitas di gudang penyangga sudah dibagi untuk setiap produk, sehingga sisa kapasitas tidak bisa ditempati secara sembarangan. Masalah semakin kompleks dikarenakan perusahaan harus mengikuti aturan pemerintah mengenai jumlah hari ketersediaan stok. Sehingga diperlukan evaluasi kapasitas gudang benyangga untuk estimasi kapasitas gudang penyangga yang dibutuhkan. Evaluasi yang dilakukan meliputi aturan kuantitas dan produk pengiriman, dan aturan jumlah hari ketersediaan stok menggunakan Discrete Event Simulation (DES) dengan parameter yaitu service level, utilitas gudang penyangga, total biaya, dan maksimum stok yang disimpan.
Penilitian ini mengusulkan skenario perbaikan kapasitas gudang penyangga dengan mengganti aturan jumlah hari ketersediaan stok dan penempatan produk di gudang penyangga. Penerapan aturan jumlah hari ketersediaan stok yang baru, estimasi kebutuhan kapasitas gudang penyangga berkurang rata-rata 81.5% dari kapasitas sekarang. Sedangkan dengan menerapkan aturan jumlah hari ketersediaan stok baru dan aturan penempatan produk di gudang penyangga baru menghasilkan estimasi kebutuhan kapasitas gudang penyangga berkurang rata-rata 67% dari kapasitas sekarang.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Discrete Event Simulation, Warehouse Capacity, Product Clustering, Coverage Days.
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD30.28 Planning. Business planning. Strategic planning. H Social Sciences > HD Industries. Land use. Labor > HD55 Inventory control
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Salsabila Faradina Fairuz Viviansyah
Date Deposited:	21 Jul 2026 13:54
Last Modified:	21 Jul 2026 13:54
URI:	http://repository.its.ac.id/id/eprint/65547

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