Andriawan, Muhammad Nirwan (2019) Reduksi Waste Pada Operasi Warehouse Dengan Menerapkan Metode Lean Warehousing. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Persaingan antar perusahaan pemasok produk sweetener akhir-akhir ini
semakin ketat seiring dengan terus meningkatnya harga pasar komoditas tepung
tapioka dan tepung jagung yang merupakan bahan baku pembuatan produk
sweetener. Dengan meningkatnya harga bahan baku tersebut membuat perusahaan
harus dapat meningkatkan efisiensi dari keseluruhan rantai pasoknya agar dapat
terus bersaing. Masalah yang dihadapi oleh perusahaan saat ini yaitu tingginya
biaya operasional yang dikeluarkan pada salah satu rantai pasoknya yaitu area
warehouse bahan baku starch dan warehouse produk jadi powder, liquid.
Lean warehousing adalah metode yang digunakan untuk mengidentifikasi
waste yang terjadi serta digunakan untuk dapat mengurangi atau mengeliminasi
waste tersebut. Keuntungan menerapkan lean warehousing yaitu dapat
meningkatkan responsiveness terhadap permintaan pasar dan mengurangi biaya
total yang dikeluarkan dalam menjalankan operasional warehouse. Tahapan
penelitian yang dilakukan mengacu pada 5 prinsip lean thinking (Phogat, 2013)
yang erat kaitannya dengan lean warehousing yaitu identify value, map the value
stream, create flow, establish pull, seek perfection.
Lean tools digunakan untuk mengidentifikasi waste dengan melakukan
current state VSM (value stream mapping) dan PAM (process activity mapping)
sehingga didapat 4 waste teridentifikasi yaitu unnecessary inventory, unnecessary
motion, inappropriate process, dan excessive transportation. Metode 5 why
analysis digunakan untuk mendapatkan akar permasalahan dari waste tersebut yaitu
belum ada kebijakan yang mengatur optimum monthly stock cover, kontaminasi
bugs dari pabrik pakan ternak tetangga, kontaminasi debu dari area boiler.
Rekomendasi solusi ditentukan berdasarkan signal kaizen burst yang diidentifikasi pada VSM current state, untuk melakukan perbaikan terhadap aliran proses, implementasi pull system, mengurangi PLT (process lead time), TCT (total cycle time) dari value chain yang dipetakan pada VSM future state. Dengan melakukan rekomendasi solusi pada penelitian ini maka perusahaan dapat melakukan penghematan terhadap biaya operasional warehouse sebesar 27% atau sekitar 6,7 milyar rupiah mengacu pada aktual biaya yang dikeluarkan pada tahun 17/18. Dengan rincian biaya operasional yang dapat dihemat dari pengeluaran biaya sewa eksternal raw material starch warehouse, biaya penggunaan jumbo bag material serta biaya penggunaan manpower.
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The competition between companies supplying sweetener products lately is
getting tighter as the commodity market price of tapioca starch and corn starch
continues to increase, which is the raw material for making sweetener products.
With the increase in prices of raw materials, companies must be able to increase the
efficiency of the entire supply chain in order to continue to compete. The problem
faced by companies today is the high operational costs incurred in one of the supply
chains, namely the warehouse area for starch raw materials and powder, liquid
finished product warehouses.
Lean warehousing is a method used to identify waste that occurs and is used
to be able to reduce or eliminate the waste. The benefits of implementing lean
warehousing are increasing responsiveness to market demand and reducing the total
costs incurred in running warehouse operations. The stages of the research carried
out refer to the 5 lean thinking principles (Phogat, 2013) which are closely related
to lean warehousing namely identify value, map the value stream, create flow,
establish pull, seek perfection.
Lean tools are used to identify waste by conducting current state VSM
(value stream mapping) and PAM (process activity mapping) so that 4 identified
waste, namely unnecessary inventory, unnecessary motion, inappropriate process,
excessive transportation. The 5 why analysis method is used to get the main root
causes of waste, there is no policy that regulates the optimum monthly stock cover,
contamination of bugs from neighboring animal feed factories, and dust
contamination from the boiler area.
Solution recommendations are determined based on the kaizen burst signal
identified in the VSM current state, to make improvements to the process flow, pull
system implementation, reduce PLT (process lead time), TCT (total cycle time)
from the value chain mapped in the VSM future state. By making a solution
recommendation in this study, the company can make savings on warehouse
operational costs by 24% or around 6,7 billion rupiah refer to the actual cost in
17/18. With details of the operational costs that can be saved from the expenditure
of rental external raw material for starch warehouses, the cost of using jumbo bag
material and the cost of using manpower.
| Item Type: | Thesis (Masters) |
|---|---|
| Additional Information: | RTMT 658.785 And r-1 2018 |
| Uncontrolled Keywords: | Lean warehousing, 5 principle lean thinking, current & future state VSM, kaizen burst, process activity mapping, root cause analysis, dan pull system. |
| Subjects: | A General Works > AI Indexes (General) A General Works > AI Indexes (General) H Social Sciences > HF Commerce > HF5485 Warehouses--Management |
| Divisions: | Faculty of Creative Design and Digital Business (CREABIZ) > Technology Management > 61101-(S2) Master Thesis |
| Depositing User: | Muhammad Nirwan Andriawan |
| Date Deposited: | 17 Sep 2021 05:53 |
| Last Modified: | 01 Apr 2024 00:50 |
| URI: | http://repository.its.ac.id/id/eprint/60335 |
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