Order Picking Improvement Through Storage Assignment Optimization And Human Error Identification: A Case Study Of Automobile Seat Manufacturer

Adiwidya, Muhammad Andhika (2021) Order Picking Improvement Through Storage Assignment Optimization And Human Error Identification: A Case Study Of Automobile Seat Manufacturer. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Order Picking (OP) adalah salah satu proses yang paling signifikan di seluruh operasi gudang. Rata-rata, biaya OP mengkonsumsi 55% dari total biaya gudang. Untuk mencapai proses OP yang ideal, ada dua hal yang perlu diperhatikan, yaitu efisiensi dan akurasi. Penelitian ini menggunakan studi kasus produsen jok mobil. Saat ini perusahaan mengalami beberapa kendala dalam operasional gudangnya, seperti kelebihan kapasitas dan kesalahan pencatatan barang dalam proses penerimaan bahan baku. Untuk mengatasi masalah ini, dua pendekatan diterapkan. Untuk meningkatkan efisiensi proses OP, analisis keputusan kapasitas dan metode optimasi menggunakan program linier digunakan untuk melakukan tugas penyimpanan bahan baku di gudang. Model perbaikan human error tersebut kemudian digunakan sebagai metode untuk mengurangi human error yang terjadi pada proses OP dan meningkatkan akurasinya. Tujuan dari pekerjaan ini adalah untuk mengurangi waktu yang dibutuhkan untuk melakukan proses OP serta untuk mendapatkan saran untuk tindakan korektif yang memiliki dampak terbesar dalam mengurangi kesalahan manusia. Hasil perhitungan kapasitas menunjukkan bahwa dibutuhkan ruang tambahan sebesar 46, 55 m2. Tiga skenario penugasan penyimpanan menghasilkan total waktu OP selama satu bulan pada skenario 1, skenario 2, dan skenario 3 berturut-turut adalah 417, 9 jam, 288,6 jam, dan 255,5 jam. Tindakan perbaikan yang memiliki rasio efektivitas terhadap kesulitan tertinggi adalah melakukan pelatihan spreadsheet untuk keperluan perekaman data, menerapkan sistem kartu FIFO dengan garis rak yang berbeda untuk barang baru dan barang lama setelah penambahan kapasitas, dan membuat peta besar penempatan bahan baku barang di gudang.
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Order Picking (OP) is one of the most significant processes in the entire warehouse operation. On average, the cost of the OP consumes 55% of the total warehouse cost. To achieve the ideal OP process, two things need to be considered, which are efficiency and accuracy. This study uses a case study of an automobile seat manufacturer. Currently, the company is experiencing several problems in its warehouse operations, such as overcapacity and wrong item record in raw material receiving processes. To solve this problem, two approaches are implemented. To improve efficiency of OP process, capacity decision analysis and an optimization method using linear programming is used to perform storage assignments of raw material in the warehouse. The human error improvement model is then used as a method to reduce human error that occurs in the OP process and increase its accuracy. The purpose of this work is to reduce the time required to perform the OP processes as well as to obtain suggestions for corrective actions that have the greatest impact on reducing human errors. The results of the capacity calculation show that there are 46.55 m2 additional space required. The three scenarios of storage assignment results the total OP time for one month in scenario 1, scenario 2, and scenario 3 is 417.9 hours, 288.6 hours, and 255.5 hours respectively. Improvement actions that has the highest effectiveness to difficulty ratio were conducting spreadsheet training for data recording purposes, implementing a FIFO card system with different shelf lines for new goods and old goods after the addition of capacity, and making a large map of item raw material placement in the warehouse.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Order Picking, Storage Assignment, Optimization, Human Error
Subjects: H Social Sciences > HD Industries. Land use. Labor
H Social Sciences > HD Industries. Land use. Labor > HD38.5 Business logistics--Cost effectiveness. Supply chain management. ERP
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: Muhammad Andhika Adiwidya
Date Deposited: 16 Aug 2021 16:22
Last Modified: 12 Jan 2022 05:02
URI: http://repository.its.ac.id/id/eprint/87236

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