PROCESS IMPROVEMENT OF THE WAREHOUSE TO REDUCE RECORDING ERRORS

Abstract

A warehouse is a part of an industrial facility to keep and manage the material; therefore, good data accuracy is important for supporting this process. However, at one of the 3PL (third party logistics) companies located in Cikarang, problems related to data inaccuracy often occur. These problems were caused by many things, one of which was an error during the recording process. The recording process in this company warehouse was carried out manually. Due to the manual process, the actual item data recorded by the operator often differs from what it should be, whether it's the item's unique code, the amount, or the location. These can lead to idle time on the production floor. In July 2021, idle time was recorded as approximately 5 hours, so the company was penalized for Rp. 72,000,000. This research intends to improve the recording process, especially in the KD small part area in the company's warehouse. The method used in this research is PDCA Cycle. The improvement process began by analyzing the company's current system and developing a new design system. This study uses Swimlane Diagrams to help analyze the current system and make system improvements. The new system designed to solve the main problem uses a Barcode recording system and Google Spreadsheets. From these improvements, recording errors in the inbound process, put-away DLOC process, and inbound TROF/OF process of the KD Small Part Area, initially 3.47%, 3.59%, and 15.15%, respectively, could be decreased to 0%, 0.998%, and 0%. And the recording time for the DLOC put-away process, which was initially 23.67 seconds/transaction, can be accelerated to 5.94 seconds/transaction.