Perbaikan Sistem Manajemen Gudang Distribution Center Dengan Menggunakan Gemba Shikumi Dan Lean Matrix

Elma, Vici Syania (2021) Perbaikan Sistem Manajemen Gudang Distribution Center Dengan Menggunakan Gemba Shikumi Dan Lean Matrix. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. X adalah perusahaan distribusi yang beroperasi di Surabaya yang menghubungkan pabrik sebagai sebuah produsen dengan pelaku retail sebagai konsumen. Produk mi instan termasuk ke dalam kategori produk fast moving yang mengalami permasalahan tingginya angka retur dari toko yang berakibat pada terganggunya pencapaian service level termasuk lead time dan kerugian biaya yang harus ditanggung perusahaan. Hasil observasi awal mengindikasikan adanya aktivitas di Gudang yang tidak efisien dan berpotensi menimbulkan kerusakan pada produk mi instan. Penelitian ini bertujuan untuk memberikan rekomendasi untuk mengeliminasi waste pada proses aktivitas Gudang menggunakan pendekatan Lean Warehouse dengan Value Stream Mapping (VSM) dan Process Activity Mapping (PAM) untuk memetakan proses aktivitas pergudangan, Gemba Shikumi untuk mencari waste kritis, 5 Whys untuk menemukan akar penyebab waste, dan Lean Matrix 2 untuk menentukan prioritas rekomendasi perbaikan. Berdasarkan hasil pada Gemba Shikumi didapatkan waste kritis yaitu menyusuri keseluruhan rak gudang untuk mengetahui rak kosong (transportation), menurunkan produk dari atas truk angkutan ke lantai unloading area (transportation), menempatkan pallet yang telah terisi pada pinggir area gudang (transportation), dan godown keeper dan chief delivery menunggu picking slip & dispatch (waiting). Selanjutnya pada lean matrix 2 didapatkan rekomendasi perbaikan terpilih berdasarkan tiga peringkat teratas pada hasil rank of action priority, yaitu penerapan conveyor, penerapan sensor light dependent resistor, dan penerapan E-Kanban. Berdasarkan penyusunan future VSM didapatkan estimasi efisiensi pada cycle time sebesar 20% dari kondisi awal 22.351 detik menjadi 17.779 detik. ================================================================================================ PT. X is a distribution company operating in Surabaya, which plays a role as a factory that connects its products to retailers (as consumers). As a product categorized in the fast moving products, instant noodles have its own problem, which includes the high number of returns from retailers that cause disruption of the service level achievement including lead team and cost loss. The results of the initial observations indicate that there are inefficient activities at the warehouse and have the potential to cause damage to instant noodle products. This study aims to give recommendations on eliminating waste in the warehouse activity using Lean Warehouse with Value Stream Mapping (VSM) and Process Activity Mapping approaches, Gemba Shikumi to find critical waste, find the root causes of waste using 5Whys, and Lean Matrix 2 to determine the main priority for improvement. Based on the results of Gemba Shikumi, these waste crisis include in the form of activities, such as observing the whole warehouse shelves to find empty shelves (transportation), lowering the products from the loading truck to the unloading area (transportation), placing the filled pallet onto the edge of warehouse area (transportation), waiting for godown keeper & chief delivery to pick slip and dispatch (waiting). Furthermore, based on the results found in the Lean Matrix 2, it is shown that the best recommendations for improvements are built upon the top three rankings of action priority. These are conveyor application, censor application on light dependent resistor, and E-Kanban application. Efficiency estimation on the cycle time is resulted as 20% higher from the initial condition (from 22.351 seconds to 17.779 seconds) on the disposition for future VSM.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Perusahaan Distribusi, Value Stream Mapping (VSM). Distribution Company, Gemba Shikumi, Lean Assessment Matrix, Lean Warehouse, Value Stream Mapping (VSM).
Subjects: T Technology > T Technology (General)
T Technology > TS Manufactures
T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Z Bibliography. Library Science. Information Resources > Z665 Library Science. Information Science
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: Vici Syania Elma
Date Deposited: 14 Aug 2021 12:20
Last Modified: 14 Aug 2021 12:20
URI: https://repository.its.ac.id/id/eprint/86538

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