Improving The X OHP Warehouse System Using The Plan, Do, Check, Action (PDCA) Method to Increase Warehouse Efficiency and Minimize Differences in Stock Opname

Abstract

PT XYZ is an automotive manufacturing company that produces precision spare parts for two- and four-wheeled vehicles in Indonesia. Out House Parts (OHP) is a production type involving activities outside the company. The Z-OHP is a product produced using OHP material with     PT Z as the customer. This research uses unstructured interviews, field observations, and company data. This research aims to determine the results of improvements to increase warehouse efficiency and minimize differences in Z-OHP stock opname, using the Plan-Do-Check-Action (PDCA) method with 8 steps and 7 tools. Using the PDCA method, an improvement plan was obtained by applying the 5S concept, layout and SOP, increasing the 5S audit score of the Z-OHP warehouse from 43 to 81 points in the May-June 2023 period and making warehouse storage efficient. The application of min-max stock and shutter rack increases the efficiency of Z-OHP material storage; the material is well controlled, FIFO runs, and there is no material shortage. Implementing a Kanban system can minimize differences in stock opname and material supply efficiency to the assembly line.