Improvement of Green Bean Warehouse Operations of Koperasi Kopi Wonosalam Using Lean Warehousing Approach

Akbari, Talitha Rahma (2024) Improvement of Green Bean Warehouse Operations of Koperasi Kopi Wonosalam Using Lean Warehousing Approach. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Koperasi Kopi Wonosalam merupakan sebuah organisasi yang berada dibawah naungan Asosiasi Kopi Wonosalam yang terletak pada daerah kecamatan Wonosalam, kabupaten Jombang, provinsi Jawa Timur. Koperasi Kopi Wonosalam merupakan salah satu sentra penghasil kopi di Indonesia, yang dimana memiliki aktivitas bisnis yang dilakukan secara make-to-order dan make-to-stock. Koperasi Kopi Wonosalam mengalami beberapa permasalahan gudang, yaitu penyimpanan pada gudang masih bercampur dengan benda yang tidak berelasi dengan produk kopi, kemasan yang rusak, merapikan stok yang rusak dan berserakan, dan melakukan pemrosesan ulang stok yang rusak. Sehingga permasalahan pada gudang ini berdampak pada efektivitas penggunaan ruangan, kerugian karena stok yang rusak harus dibuang, dan pemrosesan yang berlebihan untuk membersihkan stok yang rusak dan mengolah kembali stok yang rusak. Keadaan ini dapat menyebabkan timbulnya aktivitas yang tidak bernilai dan berdampak untuk sistem operasional gudang. Perbaikan pada proses gudang dapat dilakukan dengan menggunakan pendekatan Lean Warehousing dengan menggunakan beberapa tools yang ada didalamnya, yaitu Value Stream Mapping (VSM), Process Activity Mapping (PAM), Genba Shikumi, 5 Why’s Analysis, dan Lean Assessment Matrix. Berdasarkan hasil analisis pada Genba Shikumi, didapatkan 4 waste kritis yang terdiri atas operator gudang harus memindahkan stok lama menuju pallet paling depan (transportation), kerusakan pada kemasan (defect), merapikan stok yang robek dan berceceran (over processing), dan operator gudang harus mencari tempat penyimpanan karena kurangnya informasi (transportation). Dengan menggunakan tools Lean Matrix 2, dapat diperoleh rekomendasi perbaikan yaitu berupa penerapan penggunaan kebijakan dedicated storage pallet, penerapan metode pest control, penggunaan pallet covers, dan penerapan kartu Kanban. Berdasarkan rekomendasi perbaikan yang diberikan, dapat diestimasikan pengurangan waktu dalam 1 kali aktivitas pergudangan untuk menyimpan stok green bean sebanyak 200 kg yang dilakukan 1 kali pada setiap bulannya diestimasikan pengurangan sebanyak 4290 detik untuk gudang 1 sehingga cycle time awal sebesar 17535 detik menjadi 12615 detik dan untuk gudang 2 berkurang sebesar 5100 detik sehingga cycle time awal sebesar 24455 detik menjadi 19355 detik.
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Koperasi Kopi Wonosalam is an organization under the Wonosalam Coffee Association that located in Wonosalam sub-district, Jombang regency, East Java province. Koperasi Kopi Wonosala is one of the coffee production centers in Indonesia, which conduct business activities both make-to-order and make-to-stock basis. Koperasi Kopi Wonosalam facing several warehouse problems, including storage in the warehouse is still mixed with objects that are not related to coffee products, damaged packaging, tidying up torn and scattered stock, and reprocessing damaged stock. The problems in this warehouse impact the effectiveness of space usage, losses due to discarded damaged stock, and excessive processing to clean and reprocess damaged stock. This condition can cause activities that are not valuable and have an impact on the warehouse operational system. Improvements to the warehouse process can be done using the Lean Warehousing approach using several tools in it, namely Value Stream Mapping (VSM), Process Activity Mapping (PAM), Genba Shikumi, 5 Why's Analysis, and Lean Assessment Matrix. Based on the analysis results on Genba Shikumi, 4 critical wastes were obtained consisting of warehouse operators having to move old stock to the front pallet (transportation), damage to packaging (defect), tidying up torn and scattered stock (over processing), and warehouse operators having to find a storage place due to lack of information (transportation). By using the Lean Matrix 2 tools, recommendations for improvement can be obtained, namely the implementation of dedicated storage pallet, the implementation of pest control methods, the use of pallet covers, and the implementation of Kanban cards. Based on the improvement recommendations, it can be estimated that the reduction time in 1 warehousing activity to store 200 kg of green bean stock which is carried out once every month is estimated to be a reduction of 4290 seconds for warehouse 1, reducing the initial cycle time from 17535 seconds to 12615 seconds, and 5100 seconds cycle time reduction for warehouse 2, reducing the initial cycle time from 24455 seconds to 19355 seconds.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Warehousing, Genba Shikumi, 5 Why’s Analysis, Lean Assessment Matrix
Subjects:	T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Talitha Rahma Akbari
Date Deposited:	07 Aug 2024 07:09
Last Modified:	07 Aug 2024 07:14
URI:	http://repository.its.ac.id/id/eprint/111620

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