Penerapan Konsep Lean untuk Meningkatkan Operasi Warehouse di Industri Manufaktur

M Syahri Nur Afif, Soemarsono Sudarto

Abstract


This paper discusses the application of lean methods in warehouse operations in the manufacturing industry. To meet customer demand, product storage and product delivery activities are the main things to support customer satisfaction. This paper highlights efforts to improve warehouse operations by eliminating waste using value flow mapping (VSM). This study aims to improve all warehouse operations by analyzing and minimizing waste. The current state of VSM represents a waste of the existing system. The proposed improvement to minimize warehouse operational time is by using the lean concept. The observations through current state value stream mapping obtained a total lead time of 550 minutes. After analyzing the waste and planning improvements, it is expected to reduce the lead time to 525 minutes or 4.5%. The value-added time is reduced from 120 minutes to 90 minutes or 25% through mapping the future value flow of warehouse operations.


Keywords


lean warehouse; warehouse management; value stream mapping; non-value added activity; value added

Full Text:

PDF

References


Abideen, A. Z., & Mohamad, F. B. (2020). Supply chain lead time reduction in a pharmaceutical production warehouse – a case study. International Journal of Pharmaceutical and Healthcare Marketing, 14(1), 61–88. https://doi.org/10.1108/IJPHM-02-2019-0005

Affydah, D., Rose, A., Rashid, M. A., & Mohamed, N. N. (2021). Review of Lean Manufacturing with IR4.0 in Automotive Industry. Journal of Physics: Conference Series, 1874(1), 012050. https://doi.org/10.1088/1742-6596/1874/1/012050

Baby, B., Prasanth, N., & Selwyn Jebadurai, D. (2018). Implementation of Lean Principles To Improve the Operations of. International Journal of Technology, 1, 46–54.

Bait, S., Pietro, A. Di, & Schiraldi, M. M. (2020). Waste Reduction in Production Processes through Simulation and VSM. Sustainability 2020, Vol. 12, Page 3291, 12(8), 3291. https://doi.org/10.3390/SU12083291

Barros, T. R. (2015). Applying value stream mapping as promotion of lean manufacturing in a warehouse of automotive replacement parts in the search for greater competitiveness. International Journal of Business Performance and Supply Chain Modelling, 7(2), 109–121. https://doi.org/10.1504/IJBPSCM.2015.069907

Caridade, R., Pereira, T., Pinto Ferreira, L., & Silva, F. J. G. (2017). Analysis and optimisation of a logistic warehouse in the automotive industry. Procedia Manufacturing, 13, 1096–1103. https://doi.org/10.1016/J.PROMFG.2017.09.170

Czifra, G., Szabó, P., Mĺkva, M., & Vaňová, J. (2019). Lean principles application in the automotive industry. Acta Polytechnica Hungarica, 16(5), 43–62. https://doi.org/10.12700/APH.16.5.2019.5.3

Dotoli, M., Epicoco, N., Falagario, M., Costantino, N., & Turchiano, B. (2015). An integrated approach for warehouse analysis and optimization: A case study. Computers in Industry, 70(1), 56–69. https://doi.org/10.1016/J.COMPIND.2014.12.004

Ebrahimi, M., Baboli, A., & Rother, E. (2019). The evolution of world class manufacturing toward Industry 4.0: A case study in the automotive industry. IFAC-PapersOnLine, 52(10), 188–194. https://doi.org/10.1016/J.IFACOL.2019.10.021

El Kihel, Y., Amrani, A., Ducq, Y., & Amegouz, D. (2019). Implementation of Lean through VSM modeling on the distribution chain: Automotive case. International Colloquium on Logistics and Supply Chain Management, LOGISTIQUA 2019. https://doi.org/10.1109/LOGISTIQUA.2019.8907282

Hartanti, R. S., & Singgih, M. L. (2020). Management of redpack shipping logistics services to reduce waste: PT. PELNI case study). Operations Excellence: Journal of Applied Industrial Engineering, 12(3), 283–296. https://doi.org/10.22441/oe.2020.v12.i3.002

Irfan, M. (2018). Penyelesaian Travelling Salesman Problem (TSP) Menggunakan Algoritma Hill Climbing dan MATLAB. Matematika, 17(1), 13–20. https://doi.org/10.29313/jmtm.v17i1.3090

Liker, J. K., & Meier, D. (2006). The Toyota Way Fieldbook (1st ed.). McGraw-Hill Education.

Nallusamy, S., & Adil Ahamed, M. A. (2017). Implementation of lean tools in an automotive industry for productivity enhancement - A case study. International Journal of Engineering Research in Africa, 29(1), 175–185. https://doi.org/10.4028/www.scientific.net/JERA.29.175

Oey, E., & Nofrimurti, M. (2018). Lean implementation in traditional distributor warehouse - A case study in an FMCG company in Indonesia. International Journal of Process Management and Benchmarking, 8(1), 1–15. https://doi.org/10.1504/IJPMB.2018.088654

Pinto, G. F. L., Silva, F. J. G., Campilho, R. D. S. G., Casais, R. B., Fernandes, A. J., & Baptista, A. (2019). Continuous improvement in maintenance: a case study in the automotive industry involving Lean tools. Procedia Manufacturing, 38, 1582–1591. https://doi.org/10.1016/J.PROMFG.2020.01.127

Rifqi, H., Zamma, A., Souda, S. B., & Hansali, M. (2021). Lean Manufacturing Implementation through DMAIC Approach : A Case Study in the Automotive Industry. Quality Innovation Prosperity, 25(2), 54–77. https://doi.org/10.12776/QIP.V25I2.1576

Setiawan, I., & Hernadewita, H. (2022). Reducing production process lead time using Value Stream Mapping and Kaizen approaches : A case study in the musical instrument industry. AIP Conference Proceedings, April, 1–9. https://doi.org/10.1063/5.0080159

Setiawan, I., Tumanggor, O., & Purba, H. H. (2021). Value Stream Mapping: Literature Review and Implications for Service Industry. Jurnal Sistem Teknik Industri, 23(2), 155–166. https://doi.org/10.32734/jsti.v23i2.6038

Setiawan, Setiawan, I., Jaqin, C., Prabowo, H. A., & Purba, H. H. (2021). Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry. Quality Innovation Prosperity, 25(3), 48–64. https://doi.org/10.12776/qip.v25i3.1613

Shah, B., & Khanzode, V. (2015). A comprehensive review and proposed framework to design lean storage and handling systems. International Journal of Advanced Operations Management, 7(4), 274–299. https://doi.org/10.1504/IJAOM.2015.075025

Sugiyono. (2017). Metode Penelitian Kuantitatif, Kualitatif, dan R&D (1st ed.). CV Alfabeta.

Tahboub, K. K., & Salhieh, L. (2019). Warehouse Waste Reduction Level and Its Impact on Warehouse and Business Performance. Industrial and Systems Engineering Review, 7(2), 85–101. https://doi.org/10.37266/ISER.2019V7I2.PP85-101




DOI: http://dx.doi.org/10.22441/oe.2022.v14.i1.043

Refbacks



Copyright (c) 2022 Operations Excellence: Journal of Applied Industrial Engineering

Creative Commons License
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

Journal ISSN:

Portal ISSNPrint ISSN: 2085-4293
Online ISSN: 2654-5799

Tim Editorial Office
Operations Excellence: Journal of Applied Industrial Engineering
Magister Teknik Industri Universitas Mercu Buana
Jl. Raya Meruya Selatan No. 1 Kembangan Jakarta Barat
Email: [[email protected]]
Website: http://publikasi.mercubuana.ac.id/index.php/oe
Journal DOI: 10.22441/oe

The Journal is Indexed and Journal List Title by:

                 

 

 

Operations Excellence: Journal of Applied Industrial Engineering is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.