Warehousing Process Flow Analysis Using Lean Warehousing Approach For Waste Minimization At PT XYZ

  • Salma Putria Nabila UPN Veteran Jatim
  • Sumiati Sumiati UPN "Veteran" Jawa Timur, Indonesia
Keywords: 5S, Lean Warehousing, PAM, Seven Waste, VSM

Abstract

This research aims to identify and minimize waste in the warehousing process at PT XYZ using the lean warehousing approach. The problems faced are non-value added activities such as waiting time, repetitive movements, and inappropriate material placement. The methods used include observation, interviews, data collection, and analysis using Value Stream Mapping (VSM) and Process Activity Mapping (PAM). The results showed five main wastes, namely waiting time, defects, unnecessary motion, and excess inventory with the highest weights of 3.75 to 3.25. Implementation of improvements reduced six NVA activities, decreased the number of activities from 31 to 25, and saved activity time from 338 minutes to 243 minutes. In addition, Process Cycle Efficiency (PCE) increased by 25.36% from 46.74% to 72.1%. This research is expected to improve warehouse operational efficiency and become a reference for the application of lean warehousing in the electricity sector.

Downloads

Download data is not yet available.

References

D. A. Dhika, A. Witonohadi, and A. D. Akbari, “The Proposed Warehouse Improvement Using Lean Approach to Eliminate Waste at the Main Warehouse of PT. XYZ,” J. USakti, vol. 16, no. 1, p. 94, 2023, doi: https://doi.org/10.31315/opsi.v16i1.7310.

B. P. Bestari and E. Fatma, “Penerapan Lean Warehousing Untuk Meningkatkan Kinerja Aktivitas Gudang Pada Perusahaan Percetakan Buku,” Pros. Ind. Res. Work. Natl. Semin., vol. 1, pp. 160–169, 2020.

F. Dzulkifli and D. Ernawati, “Analisa Penerapan Lean Warehousing Serta 5S Pada Pergudangan Pt. Sier Untuk Meminimasi Pemborosan,” Juminten J. Manaj. Ind. dan Teknol., vol. 2, no. 3, pp. 35–46, 2021, doi: https://doi.org/10.33005/juminten.v2i3.243.

L. Cannava, F. D. Javan, B. Najafi, and S. Perotti, “Green warehousing practices: Assessing the impact of PV self-consumption enhancement strategies in a logistics warehouse,” Sustain. Energy Technol. Assessments, vol. 72, p. 104054, Dec. 2024, doi: https://doi.org/10.1016/j.seta.2024.104054.

C. R. Pratama and S. A. Wibowo, “Optimalisasi Ruang Gudang dan Peningkatan Material Menggunakan Sistem OFO di PT XXX,” J. Logist., vol. 20, no. 20, pp. 7–14, 2022.

F. Fadhilah, R. Firdiansyah Suryawan, L. Suryaningsih, and L. Lestari, “Teori Gudang Digunakan Dalam Proses Pergudangan (Tinjauan Empat Aspek),” J. Transp. Logistik, dan Aviasi, vol. 1, no. 2, pp. 153–156, 2022, doi: https://doi.org/10.52909/jtla.v1i2.63.

B. B. Robertson and K. McCorkell, “Considerations Implementing Manufacturing Facilities in the Hospital Setting,” Cytotherapy, vol. 27, no. 5, p. S147, May 2025, doi: https://doi.org/10.1016/j.jcyt.2025.03.289.

A. M. Osman, Z. Ukundimana, F. B. Wamyil, A. A. Yusuf, and K. Telesphore, “Quantification and characterization of solid waste generated within Mulago national referral hospital, Uganda, East Africa,” Case Stud. Chem. Environ. Eng., vol. 7, p. 100334, Jun. 2023, doi: https://doi.org/10.1016/j.cscee.2023.100334.

T. Zhao et al., “Enhancing air traffic operational efficiency by reducing network scale,” Aerosp. Traffic Saf., vol. 1, no. 1, pp. 10–19, Mar. 2024, doi: https://doi.org/10.1016/j.aets.2024.06.001.

Y. Triuntoro and F. W. Abdul, “Perbaikan Warehouse Business Process Dengan Metode Lean Six Sigma Di PT. XYZ,” J. Manaj. Logistik, vol. 1, no. 1, pp. 53–60, 2021.

D. L. Trenggonowati, A. Umyati, R. Patradhiani, A. Sonda, and F. P. Sari, “Analisis Penerapan Lean Six Sigma untuk Mengurangi Turn Around Time (TAT) C-CHECK pada Jasa Perawatan Pesawat,” Integr. J. Ilm. Tek. Ind., vol. 6, no. 2, p. 70, 2021, doi: https://doi.org/10.32502/js.v6i2.3989.

A. Adeodu, R. Maladzhi, M. G. Kana-Kana Katumba, and I. Daniyan, “Development of an improvement framework for warehouse processes using lean six sigma (DMAIC) approach. A case of third party logistics (3PL) services,” Heliyon, vol. 9, no. 4, p. e14915, Apr. 2023, doi: https://doi.org/10.1016/j.heliyon.2023.e14915.

A. A. Hafiz, “Analisis Pemborosan Pada Aliran Produksi Tablet Effervescent Dengan Tool Value Stream Mapping Pada PT XYZ (Studi Kasus : PT. XYZ),” Ind. Eng. Online J., vol. 8, no. November, pp. 1–9, 2020.

N. G. Ibrahim and Y. Prasetyawan, “Evaluasi Pergudangan dengan Pendekatan Lean Warehousing dan Linear Programming (Studi Kasus PT. X),” J. Tek. ITS, vol. 9, no. 2, pp. 278–283, 2021, doi: https://doi.org/10.12962/j23373539.v9i2.55529.

K. Kusnadi, A. E. Nugraha, and W. Wahyudin, “Analisa Penerapan Lean Warehouse Dan 5S+Safety Di Gudang Pt. Nichirin Indonesia,” J. Media Tek. dan Sist. Ind., vol. 2, no. 1, p. 1, 2020, doi: 10.35194/jmtsi.v2i1.270.

A. Purnomo, “Analisis Penerapan Lean warehouse untuk Minimasi Waste pada Warehouse Cakung PT Pos Logistik Indonesia,” vol. 10, no. 2, pp. 4–16, 2021.

I. Komariah, “Penerapan Lean Manufacturing Untuk Mengidentifikasi Pemborosan (Waste) Pada Produksi Wajan Menggunakan Value Stream Mapping (Vsm) Pada Perusahaan Primajaya Alumunium Industri Di Ciamis,” J. Media Teknol., vol. 8, no. 2, pp. 109–118, 2022, doi: https://doi.org/10.25157/jmt.v8i2.2668.

M. N. Adjietama and N. Rahmawati, “Penerapan Konsep Lean Warehousing untuk Minimasi Pemborosan Gudang Suku Cadang dengan Metode VSM Pada PT ABC,” vol. X, no. 1, pp. 12335–12347, 2025.

R. A. Mahen, H. Batubara, and D. Wijayanto, “Identifikasi Waste Melalui Proces Activity Mapping Dan Pendekatan Lean Manufacturing Pada Cv. Kreatifika Harapan Terbang Abadi,” Integr. Ind. Eng. Manag. Syst., vol. 7, no. 2, pp. 114–121, 2023.

M. Reza and H. H. Azwir, “Penerapan 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) Pada Area Kerja Sebagai Upaya Peningkatan Produktivitas Kerja (Studi Kasus Di CV Widjaya Presisi),” JIE Sci. J. Res. Appl. Ind. Syst., vol. 4, no. 2, pp. 72–81, 2020, doi: https://doi.org/10.33021/jie.v4i2.892.

Published
2025-06-12
How to Cite
Nabila, S., & Sumiati, S. (2025). Warehousing Process Flow Analysis Using Lean Warehousing Approach For Waste Minimization At PT XYZ. ITEJ (Information Technology Engineering Journals), 10(1), 39 - 53. https://doi.org/10.24235/itej.v10i1.230
Section
Articles