ANALISIS KINERJA PERGUDANGAN BAHAN BAKU BATU BARA DENGAN PENDEKATAN LEAN WAREHOUSING MENGGUNAKAN PROCESS ACTIVITY MAPPING DAN 5 WHYS ANALYSIS UNTUK MEMINIMASI WASTE PADA STOCKPILE PT. XYZ

Abstract

Abstrak

Lean Warehousing merupakan upaya untuk mengurangi atau menghilangkan pemborosan dalam gudang. Penelitian ini bertujuan untuk menganalisis kinerja pergudangan bahan baku batu bara di PT. XYZ dengan menggunakan pendekatan Lean Warehousing, khususnya melalui metode Process Activity Mapping (PAM) dan analisis 5 Whys untuk meminimalkan waste pada stockpile. Data dikumpulkan melalui observasi lapangan dan wawancara selama satu bulan, dengan total 35 kali pengamatan dari kedatangan bahan baku hingga penyimpanan di gudang. Hasil penelitian menunjukkan bahwa 34% dari total waktu aktivitas adalah Value Added (VA), 58% Non-Value Added (NVA), dan 7% Necessary but Non-Value Added (NNVA). Mayoritas waste terjadi dalam bentuk keterlambatan (delay). Analisis Process Activity Mapping mengidentifikasi empat aktivitas utama yang memakan waktu lama, yaitu pemindahan batu bara ke truk, pembongkaran batu bara dari kapal tongkang, persiapan tempat sandar dan peralatan bongkar muat, serta penyiapan dokumentasi penerimaan. Analisis 5 Whys juga mengidentifikasi akar penyebab waste, termasuk kurangnya sensor suhu, lingkungan kerja yang tidak ideal, kurangnya pelatihan, serta metode dan material yang tidak sesuai. Implementasi Lean Warehousing dengan fokus pada peningkatan pengawasan keselamatan, pelatihan rutin, dan pengelolaan lingkungan serta peralatan yang lebih baik diharapkan dapat meningkatkan efisiensi operasional dan mengurangi waste.

Kata kunci: Lean Warehousing, Process Activity Mapping, 5 Whys Analysis, waste

Abstract

Lean Warehousing is an effort to reduce or eliminate waste in the warehouse. This study aims to analyse the warehousing performance of coal raw materials at PT XYZ using the Lean Warehousing approach, specifically through the Process Activity Mapping (PAM) method and 5 Whys analysis to minimise waste in the stockpile. Data was collected through field observations and interviews for one month, with a total of 35 observations from the arrival of raw materials to storage in the warehouse. The results showed that 34% of the total activity time was Value Added (VA), 58% Non-Value Added (NVA), and 7% Necessary but Non- Value Added (NNVA). The majority of waste occurs in the form of delay. Process Activity Mapping analysis identified four main activities that took a long time, namely transferring coal to trucks, unloading coal from barges, preparing berths and loading and unloading equipment, and preparing receiving documentation. The 5 Whys analysis also identified the root causes of waste, including lack of temperature sensors, non- ideal working environment, lack of training, and inappropriate methods and materials. The implementation of Lean Warehousing with a focus on increased safety supervision, regular training, and better management of the environment and equipment is expected to improve operational efficiency and reduce waste.

Keywords: Lean Warehousing, Process Activity Mapping, 5 Whys Analysis, waste