INTEGRATION OF LEAN WAREHOUSING AND LINE BALANCING APPROACHES IN OPTIMIZING LOGISTICS PERFORMANCE TO REDUCE WASTE AND INCREASE EFFICIENCY OF INBOUND-OUTBOUND COIL PROCESSES IN HRC WAREHOUSE SYSTEM
DOI:
https://doi.org/10.53067/ijomral.v4i3.322Keywords:
Lean Warehousing, Line Balancing, Root Cause Analysis, HRC Coil. Total Revenue, Authorized Capital and Corporate InventoriesAbstract
This study aims to optimize the performance of warehousing logistics in inbound and outbound HRC coil activities at PT. XYZ through the integration of Lean Warehousing and Line Balancing approaches. The main problems faced are distribution delays due to operational bottlenecks, imbalance in workload between processes, and the absence of an effective distribution flow management system. The methods used include observation, case studies, brainstorming, and the Root Cause Analysis (RCA) approach supported by Fishbone Diagrams, Pareto Charts, and 5 Whys analysis. The data analyzed includes total warehousing profits from January to October 2024, factors causing delays, and standard time measurements for each work activity. The RCA results identified six dominant factors contributing to 80.44% of delays. Based on these findings, a solution was designed using the 5W + 1H method, including a loading and unloading slot booking system, development of outbound coil buffer areas, standard time measurements, forklift preventive checklists, and line balancing of work activities. The design implementation increased inbound efficiency from 29% to 74% and outbound from 34% to 62%. Inbound idle time decreased from 14,059.21 seconds to 1,988.85 seconds (savings of 201 minutes), while outbound decreased from 15,504.01 seconds to 4,907.28 seconds (savings of 176 minutes). Inbound balance delay decreased from 71% to 26%, outbound from 66% to 38%, and the smoothing index showed a more even workload distribution. These findings prove that integrating Lean Warehousing and Line Balancing reduces waste, accelerates distribution flows, and increases HRC coil warehousing productivity.
Downloads
References
Arif, R., & Gunawan, A. (2023). Pareto Diagram and Fishbone Diagram: Causes Affecting Delays in Procurement of Goods at the Petrochemicals Company in Cilegon for 2020-2022. Tirtayasa Business and Management Research Journal (JRBMT), 7(1), 1–10. https://jurnal.untirta.ac.id/index.php/JRBM/article/view/23411%0Ahttps://jurnal.untirta.ac.id/index.php/JRBM
Astuti, R. D., & Edy purwanto, H. S. A. (2019). Line Balancing Improvement of Xyz Tablet Packing Process Using the Ranked Positional Weight Method at PT. Y. Performa: Industrial Engineering Scientific Media, 18(1), 46–57. https://doi.org/10.20961/performa.18.1.32360
Dzulkifli, F., & Ernawati, D. (2021). Analysis of Lean Warehousing and 5S Implementation in the Warehousing of PT. Sier to Minimise Waste. Juminten, 2(3), 35–46. https://doi.org/10.33005/juminten.v2i3.243
Efendi, M. Y., & Aryanny, E. (2024). Analysis of Waste in the Warehousing Flow Process With Lean Warehousing Method At PT. Xyz. Tekmapro, 19(2). https://doi.org/10.33005/tekmapro.v19i2.398
Firdaus, M. F. S., & Kusuma, T. Y. T. (2019). Determination of Optimal Number of Workers to Increase Work Productivity (Case Study of UD. Rekayasa Wangdi). Integrated Lab Journal, 07(02), 26–36.
Haekal, J. (2021). Improving Work Efficiency and Productivity with Line Balancing and TPS Approach and Promodel Simulation on Brush Sub Assy Line in Automotive Companies. International Journal Of Scientific Advances, 2(3), 387–397. https://doi.org/10.51542/ijscia.v2i3.24
Mega Astuti DR, Uwes Anis Chaeruman, & Mulyadi. (2019). Application of Root Cause Analysis to Decrease in Employee Performance. Journal of Innovative Learning, 2(2), 133–143. https://doi.org/10.21009/jpi.022.07
Mujahidulloh, M. F., & Bakhtiar, A. (2021). Line Balancing Analysis for the Balance of the Antimo Tablet Production Process at PT. Phapros Semarang. Industrial Engineering Online Journal, 10(4).
Musthofa, A., & Muhammad, K. (2024). Line balancing analysis in producing F2AD06-002AS products at PT XYZ (case study: Production Department). 4(4), 460–469.
Prasetyawan, Y., & Ibrahim, N. G. (2020). Warehouse Improvement Evaluation using Lean Warehousing Approach and Linear Programming. IOP Conference Series: Materials Science and Engineering, 847(1). https://doi.org/10.1088/1757-899X/847/1/012033
Pratiwi, A. L., & Widjajati, E. P. (2023). Analysis of Waste in the Warehouse Flow Process of PT. FLSmidth Indonesia with the Lean Warehousing Method. Journal of Mechanical, Industrial, Electrical and Informatics Engineering (JTMEI), 2(4), 124–135. https://doi.org/10.55606/jtmei.v2i4.2993
Putri, S. S., Okdinawati, L., & Pramudita, A. S. (2017). Supply chain risk analysis at PT Leschaco Logistic Indonesia using the house of risk (HOR) method. Journal of Business Logistics, 8(1), 54–63. https://ejurnal.poltekpos.ac.id/index.php/logistik/article/view/414
Redantan, D. (2021). Improving Line Efficiency (LE) by Repairing Bottlenecks with the Line Balancing Method at PT. RST. Sigma Teknika, 4(2), 267–270. https://doi.org/10.33373/sigmateknika.v4i2.3635
Rouf, A. N., & Muhammad, K. (2023). Analysis of Improvement in Writing List of Material Preservation Program Using Root Cause Analysis (Rca) Method. 4(4), 452–459.
Sarjono, J. S. (2021). Minimizing Waste in Oil Seal Manufacturing Process with Lean Manufacturing Approach (Case Study of Oil Seal Line Sim Production Process at PT. Nok Indonesia). Kocenin Conference Series, 4th National Expert Webinar, 1(1), 1–6.
Sasmito Muslim, S., Wibowo, N. A., & Nofandi, F. (2021). Analysis of the Application of Management Information Systems in Logistics Activities in Indonesia. Dinamika Bahari, 2(1), 6–12. https://doi.org/10.46484/db.v2i1.262
Subagio, H. (2024). Line balancing affects the efficiency and effectiveness of shoe production at PT Wangta Agung. JPPI (Jurnal Penelitian Pendidikan Indonesia), 10(2), 332. https://doi.org/10.29210/020242665
Tohir, M., Primadi, A., & Akmalia, S. P. (2023). Analysis of Infrastructure, Distribution and Warehousing on Logistics Systems in Indonesia. Jmpd, 1(2), 101–109. https://siberpublisher.org/https://creativecommons.org/licenses/by/4.0/
Udonsathian, T., & Worapun, W. (2024). Enhancing analytical thinking in grade 8 science education: Integrating 5E inquiry-based and 5W1H techniques. International Journal of Advanced and Applied Sciences, 11(5), 62–69. https://doi.org/10.21833/ijaas.2024.05.007
Wedha, B. Y., Dazki, E., & Indrajit, R. E. (2022). Enterprise Architecture for the Logistics Truck Industry in Indonesia. JATISI (Jurnal Teknik Informatika Dan Sistem Informasi), 9(2), 1137–1150. https://doi.org/10.35957/jatisi.v9i2.1255
Zaneta, S., Putri, A., & Laksono, P. W. (2023). Line Balancing Analysis with Ranked Positional Weight (RPW) Method on Sewing Line at PT XYZ. IDEC National Seminar and Conference, 97–106.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Ghani Bayu Pranaditya, Taufiq Immawan

This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.