<![CDATA[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]]>
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