Distribution Performance Improvement Using DMAIC Methodology (Case Study: A Bottled Water Company)

Triyanti, Komang Desira (2022) Distribution Performance Improvement Using DMAIC Methodology (Case Study: A Bottled Water Company). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Demand for bottled water has greatly increased since the COVID-19 pandemic outbreak by nearly 700% in Kaori Mineral Water company. Kaori Mineral Water is a brand owner of Kaori bottled water who is responsible as distributor with gallon water as their main sales product. Along with the increase in demand, bottled water business competition nowadays is getting tougher, faster, more complex, and difficult to predict. Thus, the company faced a problem where they could not fulfill all the orders perfectly or called low Perfect Order Fulfillment (POF) rate. The process defect is around 5000 gallons per month. This is proven by the KPI measurement on Perfect Order Fulfillment is only 79% while the target was 90%. It is not easy to solve the problem because it involves interrelated supply chain elements. There is an urgency to use a structural and detailed method to help the company to improve the POF process. Due to its detailed phase and ease to understand, the company prefers to use Six Sigma methodology to ideate process solutions and problem-solving approaches by using five stages of DMAIC (Define-Measure-Analyze-Improve-Control). This research is expected to acknowledge the process sigma level and be used as a reference in making the supply chain process improvement. The current Sigma level for the POF process is 3.3 while the target was sigma level 4. By using the Pareto diagram, it is known that the significant critical to quality is the lead time for 2 days (CTQ 1), on schedule (CTQ 3), and exact quantity (CTQ 4). There are also root causes of POF process defects which are inadequate production capacity from the factory, stoppage of suppliers, and lack of maintenance of the transport fleet. There are 9 priority improvements selected using Analytical Hierarchy Process (AHP) which are to sign manufacturing contract with other makloon factory, implement multiple sourcing strategies, schedule preventive maintenance, increase safety stock, require regular driver reports, add qualified human resources with various cultures, partial shipment warning to factory, hold monthly meetings, and ensure supplier capability.
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Permintaan Air Minum Dalam Kemasan (AMDK) meningkat pesat hingga 700% pada perusahaan Kaori Mineral Water sejak pandemi COVID-19. Kaori Mineral Water adalah pemilik merek air minum Kaori yang bertanggung jawab sebagai distributor dengan air galon sebagai produk utama penjualan. Seiring dengan peningkatan permintaan, persaingan bisnis AMDK saat ini semakin ketat, cepat, kompleks, dan sulit diprediksi. Perusahaan menghadapi masalah tidak dapat memenuhi semua pesanan dengan sempurna atau disebut tingkat Perfect Order Fulfillment (POF) rendah. Cacat proses terjadi pada sekitar 5.000 galon per bulan. Hal ini dibuktikan dengan pengukuran KPI Perfect Order Fulfillment yang hanya 79% dengan target 90%. Tidak mudah untuk menyelesaikan masalah tersebut karena melibatkan keterkaitan elemen rantai pasok. Terdapat urgensi untuk menggunakan metode struktural dan rinci untuk membantu perusahaan meningkatkan proses POF. Mempetimbangkan kemudahan dan tahapan yang detail, perusahaan memilih Six Sigma untuk mencari solusi proses dan pendekatan pemecahan masalah DMAIC (Define-Measure-Analyze-Improve-Control). Penelitian ini diharapkan dapat mengetahui tingkat sigma proses dan dapat digunakan sebagai acuan dalam melakukan perbaikan proses rantai pasok. Level Sigma saat ini untuk proses POF adalah 3.3 dengan target yaitu sigma level 4. Dengan menggunakan Diagram Pareto diketahui bahwa Critical to Quality signifikan yang harus diperhatikan adalah lead time selama 2 hari (CTQ 1), tepat waktu (CTQ 3), dan tepat kuantitas (CTQ 4). Adapula akar penyebab cacat proses POF adalah kapasitas produksi yang tidak memadai dari pabrik, pemberhentian supplier, dan kurangnya perawatan armada angkut. Terdapat 9 perbaikan prioritas yang dipilih menggunakan Analytical Hierarchy Process (AHP) yang secara berurutan adalah kerjasama dengan pabrik makloon lain, menerapkan strategi multiple sourcing, menjadwalkan perawatan preventif, meningkatkan safety stock, mewajibkan laporan reguler bagi supir, menambah keragaman sumber daya manusia, memberikan peringatan untuk pengiriman parsial, menggelar rapat bulanan, dan menjamin kemampuan supplier.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Analytical Hierarchy Process (AHP), Bottled Water Industry, Perfect Order Fulfillment (POF), Six Sigma DMAIC, Supply Chain Performance, Air Minum Dalam Kemasan (AMDK), Analytical Hierarchy Process (AHP), DMAIC, Performansi Rantai Pasokan
Subjects:	T Technology > TD Environmental technology. Sanitary engineering > TD481 Water distribution systems
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	18 Feb 2026 02:21
Last Modified:	18 Feb 2026 02:21
URI:	http://repository.its.ac.id/id/eprint/132484

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