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All Journal Journal of Industrial Engineering and Operation Management (JIEOM) Academia Open
Gairwyn, Shannon Viona
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Decision Sciences, Operations Research & Management Industrial & Manufacturing Engineering Medicine & Pharmacology Public Health

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ANALISIS PERSEDIAAN SPARE PARTS PADA STOCK MANAGEMENT MENGGUNAKAN METODE PDCA DAN KAIZEN DI PT X Gairwyn, Shannon Viona; Suryadi, Akmal
Journal of Industrial Engineering and Operation Management (JIEOM) Vol 8, No 1 (2025)
Publisher : Universitas Islam Kalimantan Muhammad Arsyad Al Banjari Banjarmasin

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31602/jieom.v8i1.17473

Abstract

Manajemen stok yang efektif di warehouse PT X menjadi kunci dalam menjaga ketersediaan spare parts, mendukung operasional perusahaan dan kepuasan pelanggan. Penelitian ini bertujuan untuk mengidentifikasi penyebab utama ketidaksesuaian tersebut serta mengusulkan strategi perbaikan menggunakan pendekatan PDCA dan metode Kaizen yaitu analisis 5M checklist dan implementasi 5S movement. Penelitian ini dilakukan selama Pra Stock Opname Tahunan melalui pengamatan langsung, wawancara, analisis variansi data, dan evaluasi operasional. Hasil menunjukkan ketidaksesuaian stok disebabkan oleh kesalahan manusia, gangguan teknis, dan kurangnya standar operasional untuk barang khusus. Implementasi strategi perbaikan pada Stock Opname Tahunan 2024 meningkatkan akurasi data sehingga bernilai 99,97% dan mengurangi pencatatan manual. Gerakan 5S mempercepat pencarian barang hingga 30% dengan lingkungan kerja yang lebih terorganisasi. Penelitian ini membuktikan efektivitas pendekatan PDCA dan Kaizen dalam meningkatkan efisiensi manajemen stok.Kata Kunci:  Kaizen, Manajemen Stok, PDCA, Pergudangan.
HDPE Bag Production Waste Fell After Integrated Lean Analysis Gairwyn, Shannon Viona; SZS, Joumil Aidil
Academia Open Vol. 11 No. 1 (2026): June
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/acopen.11.2026.13994

Abstract

General Background: Production efficiency is essential for manufacturing competitiveness, yet many systems remain dominated by non value added activities and seven waste categories. Specific Background: In HDPE plastic bag production, a defect rate of 7.02% exceeds the 3% standard and is accompanied by waiting, motion, and process inefficiencies. Knowledge Gap: Limited studies integrate Lean Manufacturing with Failure Mode and Effect Analysis in HDPE bag production contexts. Aims: This study aims to identify dominant waste and formulate improvement strategies using an integrated Lean approach. Results: Seven waste types were identified, with defects (RPN 441) and waiting (RPN 336) as priorities; improvements reduced activities from 39 to 31, decreased lead time from 214.94 to 151.14 minutes, and increased process cycle efficiency from 45.42% to 64.59%. Novelty: This study integrates Value Stream Mapping, Process Activity Mapping, fishbone diagram, and FMEA within a single framework tailored to HDPE bag production. Implications: The findings demonstrate that systematic waste identification and elimination of non value added activities improve production flow, quality, and operational efficiency while supporting structured maintenance and pull-based systems. Highlights: Defect and waiting categories ranked as highest priority based on risk evaluation. Process restructuring reduced total operational steps and shortened processing duration. Integrated mapping and risk assessment enabled systematic identification of root causes. Keywords: Lean Manufacturing, FMEA, HDPE Plastic Bags, Waste, Production Process.
Co-Authors Akmal Suryadi SZS, Joumil Aidil