OPTIMASI TATA LETAK UNIT GUDANG PACKAGING DI RAW MATERIAL WAREHOUSE PT XYZ

Abstract

PT XYZ merupakan perusahaan manufaktur yang menghadapi permasalahan pada Raw Material Warehouse berupa perpindahan material yang berlebihan, aktivitas menunggu yang tinggi, serta tata letak yang kurang mendukung kelancaran aliran material. Kondisi ini menyebabkan proses pergudangan menjadi kurang efisien dan meningkatkan biaya material handling. Penelitian ini bertujuan menganalisis serta mengoptimalkan tata letak gudang menggunakan metode Value Stream Mapping (VSM), Process Activity Mapping (PAM), klasifikasi Fast–Slow–Non Moving (FSN), dan analisis material handling. Hasil analisis menunjukkan adanya aktivitas non-value added yang dominan pada proses quality control, transportasi, dan administrasi. Usulan perbaikan dilakukan melalui penataan ulang area penyimpanan berdasarkan klasifikasi FSN sehingga material dengan frekuensi pergerakan tinggi ditempatkan lebih dekat ke area operasional. Perbaikan juga didukung oleh penerapan inline quality control dan sistem kerja yang lebih efisien. Hasil rancangan tata letak usulan mampu memperlancar aliran material, mengurangi jarak perpindahan, menurunkan lead time proses, serta menghasilkan penghematan biaya material handling sebesar Rp23.550.000 per tahun.

PT XYZ is a manufacturing company experiencing inefficiencies in its Raw Material Warehouse due to excessive material movement, high waiting time, and a warehouse layout that does not adequately support material flow. These conditions increase material handling costs and reduce operational efficiency. This study aims to analyze and optimize the warehouse layout using Value Stream Mapping (VSM), Process Activity Mapping (PAM), Fast–Slow–Non Moving (FSN) classification, and material handling analysis. The results indicate that non-value-added activities are mainly associated with quality control, transportation, and administrative processes. Improvement proposals include reorganizing storage locations based on FSN classification, ensuring that fast-moving materials are placed closer to operational areas. The proposed layout is further supported by inline quality control and more efficient work procedures. The optimized warehouse layout improves material flow, reduces travel distance and lead time, and generates material handling cost savings of IDR 23,550,000 per year, demonstrating its effectiveness in enhancing warehouse operational performance.