ANALISIS KASUS OVERSTOCK DAN OUTSTANDING MATERIAL MENGGUNAKAN ROOT CAUSES ANALYSIS (STUDI KASUS: PT SHOWA INDONESIA MANUFACTURING)

Abstract

Arina Shafa Fauziyyah, Analisis Kasus Overstock dan Outstanding Material Menggunakan Root Causes Analysis (Studi Kasus: PT Showa Indonesia Manufacturing). PT. Showa Indonesia Manufacturing merupakan perusahaan manufaktur yang memproduksi shock absorber untuk roda dua dan roda empat. Materialnya sendiri didatangkan dari supplier, baik lokal maupun luar negeri. Material yang didatangkan dari luar negeri membutuhkan perencanaan dan kalkulasi yang matang mengingat lead time yang lama untuk material sampai tiba ke perusahaan. Dalam merespon demand customernya, PT. Showa Indonesia Manufacturing menggunakan mix system, yaitu make to order dan make to stock. Sistem kanban didasarkan dari Purchase Order customer dan forecasting digunakan untuk mengkalkulasi material yang didatangkan dari supplier luar negeri. Melalui studi lapangan diketahui bahwa perusahaan masih sering mengalami overstock dan outstanding material. Dengan menggunakan metode Root Causes Analysis, diketahui penyebab dari outstanding material adalah keterlambatan supplier dan planning yang tidak sesuai realitas. Sedangkan penyebab dari overstock material adalah Purchase Order yang kurang dari 5% forecast. Berdasarkan hasil analisis, kasus outstanding material dapat diminimasi dengan penggunaan level stock sedangkan kasus overstock material dapat diminimasi dengan pendekatan Dynamic Inventory untuk mengurangi nilai Days on Hand pada material CKD.

Abstract

Arina Shafa Fauziyyah, Analysing the Case of Overstock and Outstanding Material Using Root Causes Analysis (Case Study: PT Showa Indonesia Manufacturing). PT Showa Indonesia Manufacturing is a company that produces shock absorber for two wheels and four wheels. The material is imported from suppliers both local and abroad. Material imported from abroad require careful planning and calculation considering the long lead time for materials to arrive at the company. In responding to customer demand, PT Showa Indonesia Manufacturing uses mix system, those are make to order and make to stock. The kanban system is based on the purchase order of the customer and the forecasting is used to calculate material imported from overseas suppliers. Through field study, it is known that the company still often experience overstock and outstanding material. By using Root Causes Analysis method, it is known that the cause of the outstanding material is the delay of suppliers and the planning that does not match with reality. While the cause of overstock material is purchase order that is less than 5% of forecasting result. Based on the analysis. The case of the outstanding material can be minimized by using stock level while overstock material case can be minimized by using dynamis inventory approach to reduce days on hand value on CKD material.