Analisis Inventory Record Inaccuracy (IRI) Dan Pengembangan Prosedur Untuk Meningkatkan Akurasi Inventaris Pada Perusahaan MRO

Putra, Rizki Yuniar (2026) Analisis Inventory Record Inaccuracy (IRI) Dan Pengembangan Prosedur Untuk Meningkatkan Akurasi Inventaris Pada Perusahaan MRO. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Kegiatan line maintenance di industri penerbangan menuntut ketersediaan material yang cepat dan tepat waktu untuk mendukung proses perawatan pesawat. Namun, ketidakakuratan catatan inventaris (Inventory Record Inaccuracy atau IRI) dapat menyebabkan perbedaan antara stok fisik dan stok sistem yang berujung pada stockout maupun overstock, sehingga mengganggu operasional dan meningkatkan biaya. Penelitian ini bertujuan mengukur tingkat dan pola IRI, mengidentifikasi penyebabnya, merancang prosedur perbaikan, serta mengevaluasi efektivitas prosedur tersebut dalam meningkatkan akurasi inventaris. Penelitian ini dilakukan pada 94 SKU material expendable dan consumable pendukung line maintenance pesawat Boeing 737-NG di gudang PT XYZ. Metode Fuzzy Failure Mode and Effects Analysis (Fuzzy FMEA) dan 5-Whys digunakan untuk mengidentifikasi akar penyebab IRI, sedangkan simulasi Monte Carlo digunakan untuk mengevaluasi efektivitas prosedur perbaikan. Hasil penelitian menunjukkan bahwa IRI awal mencapai 23,40% (akurasi 76,60%) dan didominasi oleh negative discrepancy akibat keterlambatan pencatatan transaksi. Analisis Fuzzy FMEA dan 5-Whys mengidentifikasi tiga penyebab utama, yaitu keterlambatan posting penerimaan material (RPN 659), keterlambatan posting pengembalian material (RPN 634), dan frekuensi cycle count yang tidak memadai (RPN 632). Implementasi tiga prosedur perbaikan berhasil menurunkan rata-rata IRI menjadi 3,13% dan meningkatkan akurasi inventaris menjadi 96,87%. Hasil tersebut kemudian divalidasi melalui simulasi Monte Carlo (10.000 iterasi) yang memproyeksikan rata-rata IRI jangka panjang sebesar 4,13% dengan probabilitas 79,74% untuk mempertahankan IRI di bawah 5%. Penelitian ini menunjukkan bahwa integrasi Fuzzy FMEA dan simulasi Monte Carlo dapat mendukung pengambilan keputusan berbasis risiko dalam pengelolaan inventaris MRO serta menghasilkan rekomendasi perbaikan yang efektif untuk meningkatkan akurasi inventaris dan keandalan operasi logistik.
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Line maintenance activities in the aviation industry require the timely and accurate availability of materials to ensure the efficient execution of aircraft maintenance operations. However, Inventory Record Inaccuracy (IRI) can result in discrepancies between physical inventory and system records, leading to stockouts or overstock situations that adversely affect operational performance and increase inventory-related costs. This study aims to measure the level and patterns of IRI, identify its root causes, develop improvement procedures, and evaluate the effectiveness of these procedures in enhancing inventory accuracy. The study was conducted on 94 stock-keeping units (SKUs) of expendable and consumable materials supporting Boeing 737-NG line maintenance operations at PT XYZ’s warehouse. Fuzzy Failure Mode and Effects Analysis (Fuzzy FMEA) and the 5-Whys technique were employed to identify and prioritize the root causes of IRI, while Monte Carlo simulation was utilized to assess the effectiveness and long-term sustainability of the proposed improvement procedures. The findings reveal that the baseline IRI level was 23.40%, corresponding to an inventory accuracy rate of 76.60%, and was predominantly characterized by negative discrepancies resulting from delayed transaction recording. The Fuzzy FMEA and 5-Whys analyses identified three critical root causes: delayed receipt posting (RPN = 659), delayed material return posting (RPN = 634), and inadequate cycle count frequency (RPN = 632). Based on these findings, three improvement procedures were developed and implemented, resulting in a reduction of the average IRI from 23.88% to 3.13% and an increase in inventory accuracy from 76.12% to 96.87%. Furthermore, Monte Carlo simulation with 10,000 iterations projected a long-term average IRI of 4.13% and a 79.74% probability of maintaining IRI below the 5% threshold. This study contributes to the advancement of inventory management practices in the aviation MRO industry through the integration of Fuzzy FMEA and Monte Carlo simulation. The proposed approach provides a systematic and risk-based framework for identifying inventory inaccuracies and evaluating corrective actions, thereby improving inventory accuracy and enhancing the reliability and efficiency of logistics operations.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Inventory Record Inaccuracy, Failure Mode and Effects Analysis, Simulasi Monte Carlo, MRO, Akurasi Inventaris. Inventory Record Inaccuracy, Failure Mode and Effect Analysis, Monte Carlo Simulation, MRO, Inventory Accuracy.
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD55 Inventory control H Social Sciences > HE Transportation and Communications > HE9787.5 Airplanes--Ground handling T Technology > TL Motor vehicles. Aeronautics. Astronautics > TL671.9 Airplanes--Maintenance and Repair T Technology > TS Manufactures > TS161 Materials management.
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Rizki Yuniar Putra
Date Deposited:	24 Jul 2026 03:42
Last Modified:	24 Jul 2026 03:42
URI:	http://repository.its.ac.id/id/eprint/136883

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