Penerapan Lean Warehousing untuk Meningkatkan Efisiensi Gudang Menggunakan Metode Value Stream Mapping pada PT. DSV Solutions Indonesia

Abstract

The effectiveness and efficiency of warehouse operational activities are crucial in enhancing a company's productivity, particularly in the logistics industry. PT. XYZ is a Third Party Logistics (3PL) provider offering logistics, warehousing, and transportation services. The company faces challenges such as long lead times and inefficiencies in inbound and outbound processes, which result in low achievement of the Key Performance Indicators (KPI) for Dock to Stock Time and On Time Dispatch (OTD). Data indicates that there are periods when these KPIs do not meet the company's minimum targets, adversely affecting company performance and customer satisfaction. The purpose of this study is to reduce lead times in inbound and outbound processes and to improve the KPIs for Dock to Stock Time and On Time Dispatch (OTD) in subsequent periods. This is achieved by reducing non-value-added activities in warehouse operations, particularly in inbound and outbound activities, through the application of lean warehousing concepts using the Value Stream Mapping (VSM) method and process improvement tools such as Kaizen 5S. Based on an end-to-end analysis of each warehouse operational activity and process mapping using VSM at PT. XYZ, a lead time of 549.17 minutes was identified, consisting of 28 value-added (VA) activities at 63.76%, 12 non-value-added (NVA) activities at 15.72%, and 24 necessary but nonvalue- added (NNVA) activities at 20.52%. Critical wastes identified in the operational process include inappropriate processing, waiting, and transportation waste. Subsequent process improvements and simplifications targeted these identified wastes. The results showed a reduction in lead time to 455.28 minutes, comprising 29 value-added (VA) activities at 89.32%, 1 non-value-added (NVA) activity at 3.54%, and 21 necessary but non-value-added (NNVA) activities at 7.14%. These findings indicate that the implementation of lean warehousing significantly reduces lead time and improves the efficiency and effectiveness of inbound and outbound warehouse processes at PT. XYZ.