Perancangan Area Incoming Material Berbasis 5S Untuk Mengurangi Waste of Motion pada PT XYZ

Abstract

PT XYZ is a manufacturing company engaged in the fabrication and integration of electrical systems with a Make to Order (MTO) production system. Currently, the company's incoming material area does not have a standardized arrangement system, so electrical components are placed without clear classification and labeling. An evaluation of existing conditions was carried out using a 5S audit and observation of material search time for 25 actual working days. The audit results showed a 5S achievement percentage of 20.8%, with the Seiton element as the most critical at 6.3%, Meanwhile, the average time spent searching for materials, based on 42 observed samples, was recorded at 5.83 minutes per visit, resulting in a waste of 69.96 minutes per day—or 16.7% of total effective working hours. Based on these results, improvements are proposed through the design of floor marking with a division of three zones and a configuration of 10 vertical storage rack units with a total surface capacity of 24.00 m², equipped with a labeling system per slot. Based on the trial results, the implementation of both proposed improvements is projected to reduce material search time by up to 60%, resulting in a savings of 42.00 minutes per day or an equivalent of 10.0% of the daily effective working hours that can be diverted to productive activities.