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All Journal Industrika : Jurnal Ilmiah Teknik Industri
Febrian Hiltono
Universitas Singaperbangsa Karawang
Control & Systems Engineering Decision Sciences, Operations Research & Management Economics, Econometrics & Finance Engineering Industrial & Manufacturing Engineering

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Penerapan Pendekatan DMAIC dalam Mengurangi Kelebihan Stok Barang di Area Warehouse Industri Otomotif Rafli Bagas Prayoga; Dene Herwanto; Febrian Hiltono
Industrika : Jurnal Ilmiah Teknik Industri Vol. 10 No. 4 (2026): Industrika: Jurnal Ilmiah Teknik Industri
Publisher : Fakultas Teknik Universitas Tulang Bawang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37090/s20qjy03

Abstract

The overflow problem in the automotive industry warehouse occurs due to a mismatch between the incoming material volume and the available storage capacity. Data shows that the total inbound materials over four months reached 72,235.68 pcs, exceeding the warehouse’s maximum capacity of 59,280 pcs, resulting in a 22% overcapacity. This condition leads to material accumulation outside designated storage areas, disrupts operational activities, and increases the risk of product damage. This study aims to analyze the root causes of overflow and develop corrective actions using the DMAIC (Define, Measure, Analyze, Improve, Control) approach. In the Define stage, the process scope is mapped using a SIPOC diagram. The Measure and Analyze stages involve evaluating historical inbound data, Pareto charts, fishbone diagrams, and 5 Whys analysis. The results show that material overstock accounts for 65.71% of the overflow causes, while inconsistent SOP implementation contributes 17.57%. The Improve stage proposes optimizing the ordering system, which has the potential to reduce excess supply by 25–30%, adjusting storage capacity to increase effective capacity by up to 18%, and revising SOPs to reduce process variation. The Control stage establishes routine monitoring and periodic audits to ensure long-term sustainability. The implementation of DMAIC significantly improves warehouse efficiency and reduces the risk of future overflow. Keywords: DMAIC, Goods Overflow, Inventory Management, Material Handling, Raw Material Warehouse, Stock Control
Analisis Perencanaan dan Pengendalian Persediaan Material Filter Menggunakan Metode Forecasting di PT ABC Putri Febriyani; Dene Herwanto; Febrian Hiltono
Industrika : Jurnal Ilmiah Teknik Industri Vol. 10 No. 4 (2026): Industrika: Jurnal Ilmiah Teknik Industri
Publisher : Fakultas Teknik Universitas Tulang Bawang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37090/1x77f490

Abstract

Effective inventory management is a crucial aspect in ensuring the continuity of production processes and fulfilling customer demand optimally, especially in a dynamic and fluctuating market environment. PT ABC, as a manufacturing company producing filter components, faces challenges related to demand fluctuations and additional Purchase Orders (PO) from customers, which impact material availability. This study aims to analyze the planning and control of filter inventory by applying forecasting methods, specifically Moving Average and Linear Regression methods. Historical demand data were used to forecast the requirements for filters with diameters Ø50 mm and Ø72 mm. The results indicate that Linear Regression produces lower forecasting errors compared to Moving Average for both filter sizes. For the Ø50 mm filter, Linear Regression yields an MSE of 3,524,583.3, MAD of 1,576, and MAPE of 0.4121, all of which are lower than the values produced by the Moving Average method. A similar pattern is observed for the Ø72 mm filter, where Linear Regression results in an MSE of 1,182,480.374, MAD of 817, and MAPE of 0.2667, which are also lower than those generated by Moving Average. Therefore, this study concludes that Linear Regression is the recommended forecasting method for planning filter requirements at PT ABC. Keywords: Filter, Forecasting, Linier Regression, Material, Moving Average
Pengendalian Kualitas Screen Assy dengan Metode Seven Tools Pada PT Industri Komponen Otomotif Febrian Hiltono; Dene Herwanto; Rafli Bagas Prayoga; Putri Febriyani
Industrika : Jurnal Ilmiah Teknik Industri Vol. 10 No. 4 (2026): Industrika: Jurnal Ilmiah Teknik Industri
Publisher : Fakultas Teknik Universitas Tulang Bawang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37090/zvwnzg25

Abstract

Quality problems persist in the production of the 14.08 mm Screen Assy at PT Industri Komponen Otomotif, where the observed defect rate surpasses the company’s quality standard. Production records from 2024 show an average defect rate of roughly 2%, well above the company’s tolerance of 0.2%, and Ami (wire mesh) defects are the most frequent type. Such defects can lower product quality and push up costs through rework and scrap, so a more structured approach to quality control is needed. This study applies the seven quality control tools (check sheet, histogram, Pareto chart, scatter diagram, cause-and-effect or fishbone diagram, control chart, and flowchart) in a quantitative approach to inspection reports collected from April 2024 to February 2025. Of the 268,584 units produced, 3,141 were defective, and Ami defects accounted for 1,093 units (32.3%). The fishbone analysis points to human factors as the leading cause, followed by machine and work-method factors. The process is generally statistically in control, although several points lie close to the upper control limit. The Seven Tools thus help trace the root causes of defects in an organized way and provide a basis for continuous improvement proposals. Keywords: Defect, Fishbone Diagram, Quality Control, Screen Assy, Seven Tools  
Co-Authors Dene Herwanto Putri Febriyani Rafli Bagas Prayoga