Improving Warehouse Efficiency through Lean Warehousing Principles at Operating Supply Warehouse of PT Semen Padang

Lestari, Regina Ayu (2025) Improving Warehouse Efficiency through Lean Warehousing Principles at Operating Supply Warehouse of PT Semen Padang. S1 thesis, Uiversitas Andalas.

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Abstract

Warehouses play a crucial role in supporting company operations by ensuring the smooth flow of goods, efficient storage, and timely order fulfillment. However, poor warehouse management can lead to various inefficiencies that reduce productivity and increase costs. This condition is evident in the OPS Cement Bag Warehouse of PT Semen Padang, which faces several l problems such as excessive material handling, unstructured storage, unclear item locations, and difficulties in applying FIFO principles, that resulting in increased operational costs and reduced productivity. These problems align with key lean waste categories, particularly transportation, motion, and inventory waste, highlighting the need for a systematic lean warehousing approach. This study adopts lean warehousing as the main framework to identify and eliminate waste in warehouse operations. Waste identification was carried out using two tools, the Warehouse Layout Criteria to evaluate compliance with good layout standards, and Big Picture Mapping to visually map warehouse flows and identify transportation, motion, and waiting waste. Root cause analysis was conducted using the Fishbone Diagram. For waste elimination, two methods were selected based on the identified problem, namely Frequency-Based Storage (FBS) to reduce travel distances by optimizing item placement, and the 5S methodology to improve operational discipline, organization, and efficiency in daily warehouse processes. Result shows a 49.8% reduction in average forklift travel distance, translating to measurable decreases in fuel consumption and operational costs. The optimized layout improved space utilization while enhancing FIFO compliance. Complementary 5S implementation can resolve identified operational wastes, particularly in item retrieval times and inspection accuracy. This approach proves effective for unit-load warehouses seeking to balance spatial efficiency with lean improvements.

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