Implementation of Lean Warehousing to Improve Warehouse Performance of A Plastic Packaging Company

Simanjuntak, Alfia Khairani (2019) Implementation of Lean Warehousing to Improve Warehouse Performance of A Plastic Packaging Company. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Aktivitas gudang mempengaruhi operasi dalam proses bisnis di industri kemasan plastik kosmetik terutama lantai produksi karena kegiatan telah saling terhubung. Perusahaan memiliki masalah dalam memaksimalkan ruang penyimpanan dan menghilangkan stok di lantai karena ketidakakuratan pengolahan data stok gudang dan penempatan stok yang tidak tepat. Sehingga terjadi beberapa jenis pemborosan dalam fungsi gudang dari proses receiving, menyimpan, dan pengambilan barang. Melalui penerapan lean warehousing, efisiensi dapat ditingkatkan dengan mengurangi pemborosan yang ada. Data yang dikumpulkan dari penyimpanan bahan baku, penyimpanan WIP dan penyimpanan barang jadi akan divisualisasikan menggunakan value stream mapping (VSM) dan process activity mapping (PAM). Kemudian, kinerja gudang diukur. Dari VSM, PAM dan performansi gudang, pemborosan dapat diidentifikasi. Pemborosan dalam penyimpanan bahan baku adalah produksi berlebih, inventaris, cacat, transportasi, menunggu, pemrosesan berlebih, dan gerak. Pemborosan dalam gudang WIP dan penyimpanan barang jadi adalah persediaan, cacat, transportasi, menunggu, pemrosesan berlebih, dan limbah gerak. Rencana perbaikan yang direkomendasikan adalah mengalokasikan stok khusus, subleveling stok, pemetaan gudang berdasarkan klasifikasi FSN (Fast moving, Slow moving, dan Non-moving), membuat peraturan gudang dan memperbaiki metode perpindahan petugas transfer. Kinerja gudang setelah peningkatan menunjukkan bahwa indikator keuangan dan waktu siklus menurun sementara indikator pemanfaatan, kualitas dan produktivitas meningkat. Dengan menggunakan teknik lean, akurasi persediaan dapat ditingkatkan, kesalahan pemilihan pesanan dapat dikurangi, waktu pemrosesan dapat dikurangi, dan ruang gudang dapat diefisiensikan. ===================================================================================================================================
Warehouse activities affect the operations in the business process of a cosmetic plastic packaging company especially the production floor since the activities have connected each other. The company has problems in maximizing the storage space and eliminating the floor stock because of inaccuracy of warehouse stock data processing and inappropriate stock placement. So that, there are several types of waste in the warehouse activities from receiving, put away, storing, and order/material picking. The problem will be solved by using lean warehousing. The collected data of raw material storage, WIP storage and finished goods storage will be visualized using value stream mapping (VSM) and process activity mapping (PAM). Then, the warehouse performance is measured. From the VSM, PAM and performance measure, the waste can be identified. The wastes in the raw material storage are overproduction, inventory, defect, transportation, waiting, excess processing and motion. Wastes in WIP and finished goods storage are inventory, defect, transportation, waiting, excess processing, and motion waste. The improvement plans are to allocate the special stocks, subleveling the small quantity items, warehouse mapping based on FSN (Fast moving, Slow moving, and Nonmoving) classification, creating warehouse regulation and improving transfer officer movement. The warehouse performance after improvement shows that the financial and cycle time indicators decrease while utilization, quality and productivity indicators increase. By using lean techniques, inventory accuracy can be increased, order picking errors can be reduced, processing time can be reduced, and warehouse space can be streamlined.

Item Type:	Thesis (Other)
Additional Information:	RSI 658.785 Sim i-1 2019 3100020084135
Uncontrolled Keywords:	FSN Analysis, Lean Warehousing, Process Activity Mapping, Value Stream Mapping
Subjects:	T Technology > TS Manufactures > TS167 Costs, Industrial T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Alfia Khairani Simanjuntak
Date Deposited:	07 Nov 2025 03:42
Last Modified:	07 Nov 2025 03:42
URI:	http://repository.its.ac.id/id/eprint/65160

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