Analisis Pemborosan Aktivitas pada Gudang Produk Jadi Menggunakan Metode Lean Warehouse dan Usulan Perbaikan Berbasis 5S di PT XYZ

Abstract

The finished goods warehousing process at PT XYZ still experiences various forms of waste that result in inefficient operational activities, such as time spent locating storage spaces, waiting time, material handling, and unnecessary movements. This study aims to identify the waste occurring in the warehousing process and propose improvements using the 5S approach to enhance warehouse operational efficiency. The methods used include Big Picture Mapping, Value Stream Analysis Tools (VALSAT), Process Activity Mapping (PAM), and the Fishbone Diagram to identify waste and its root causes; improvement proposals were then formulated through Future Big Picture Mapping based on the 5S principles. The results of the study indicate that the most dominant form of waste is Searching Time, while the proposed improvements—including grouping products by type, implementing visual management, reorganizing the loading dock area, consistently updating product location data, and streamlining certain activities—were able to improve warehouse process efficiency. This is evidenced by an increase in the percentage of Value-Added (VA) activities from 24.19% to 31.71%, a decrease in Non Value-Added (NVA) activities from 22.33% to 4.27%, and an increase in Process Cycle Efficiency (PCE) from 24.19% to 31.71%, making the warehousing process more effective and efficient.