Proposed Improvement Warehouse Layout At PT. Dwi Sumber Rejeki Using
Shared Storage Methods
Trie Finala
Teknik Industri
Universitas Mercu Buana - Jakarta
Email : trie.finala@gmail.com
ABSTRACT
PT. Dwi Sumber Rejeki is a company engaged in the plastics industry, which produces plastic pellets
and plastic bag (polybag). The problem faced by the PT. Dwi Sumber Rejeki today is an irregularity in the
preparation of the product, it will hamper the delivery processing time, some of the aisle that size does not
correspond to the size of the material handling making it difficult for employees in the process of making a
finished product in the warehouse. Other conditions are also present in the product placement in an area
which is less precise, where the goods should have the highest frequency of delivery and who often come and
go in the hold to the exit. Things like this that often cause further material handling and less effective. The
purpose of this study is to provide a proposed improvement warehouse layout finished products according to
the needs of storage space and space allowances so that the removal of material handling products to
become more effective. The method used in the management of shared storage warehousing is an approach
in which products have the highest frequency of delivery and are often out of brought closer to the entrance
to minimize the displacement distance of material handling. Tests were conducted on the proposed layout
produces material handling mileage on average per month of 3.511,6 m per month. While in the initial
layout mileage per month for 6.232 m per month.
Keywords: Warehouse, Method of Shared Storage, Warehouse Layout Design
I. INTRODUCTION
Background Research
PT. Dwi Sumber Rejeki is a company engaged in the plastics industry, which produces plastic pellets
and plastic bag (polybag) whereby in operation the company has five storage warehouse of finished products
called Finish Product Warehouse / FPWH consisting of 1 warehouse for grain products PE plastic types, one
warehouse for plastic resin product types HD / PP, 1 warehouse for plastic resin types of HDPE original and
one warehouse for plastic bags products. Based on the observations that have been made in the activities of
placement and preparation of finished products in the warehouse is still not organized and less tidy, causing
the ineffectiveness of work in the process of transfer of the finished product. The problem faced by the PT.
Dwi Sumber Rejeki today is an irregularity in the preparation of the product, it will hamper the delivery
processing time, some of the gang that size does not correspond to the size of the material handling making it
difficult for employees in the process of making a finished product in the warehouse. Other conditions are
also present in the product placement in an area which is less precise, where the goods should have the
highest frequency of delivery and who often come and go in the hold to the exit. Things like this that often
cause further material handling and less effective. Shared storage method is one method of storage of the
products in the warehouse. The method of storage apply one type of product is not placed in a special place,
but can share a place with a variety of other types of products, when the storage area is empty, it can be used
for storage of different products [1]. In the allocation of products in the warehouse, this method does not put
the product at random, but rather can be controlled laying on storage. The first thing that goes is placed close
to the point of I / O [2]
Then from some of these problems is necessary to redesign the layout of the warehouse of finished
products are more regular and better so as to obtain a displacement of material handling distance is shorter.
Formulation Of The Problem
From the description of the background of the above problems can be formulated problems
experienced in PT. Dwi Sumber Rejeki is how the layout of the warehouse of finished products based on the
needs of storage space and space allowances so that the removal of material handling products with more
effective use of shared storage methods.
Research Purposes
Based on the formulation of the problem, it can be described the purpose of the study is to provide a
proposed improvement warehouse layout finished products according to the needs of storage space and space
allowances so that the removal of material handling products with more effective use of shared storage
methods.
Scope Of Problem
In the final project, entitled Proposed Layout Improvement Warehouse at PT. Dwi Sumber Rejeki
Using Shared Storage Methods is the problem limited to:
1. The analysis is performed only for the layout of the finished product store space in finished goods
warehouse kinds of PE plastic ore products at PT. Dwi Sumber Rejeki.
2. Do not take into account the cost of planning the layout of the new warehouse.
3. The only observation made on finished goods warehouse at. PT. Dwi Sumber Rejeki.
While the assumptions used in this study are:
1. The condition of the company does not change during the study period.
2. Type of product stored in FPWH (Finish Product Warehouse) unchanged during the study was conducted.
II. LITERATURE STUDY
Definition Warehouse
Warehouses can be defined as a facility that serves to store the goods that will be used in the
production or sale. So the warehouse is a place that is used to store the goods either in the form of raw
materials, goods work in process or finished goods. [3]
Layout Design of Warehouse
The essence of a design procedure is a series of methods that thorough and linked to one another to
get the design that suits your needs. Needs can be identified from the company, especially plant managers
know all too well the role of warehouses in supporting production activities.
Several major part in the design of the warehouse.
1. Determine the maximum inventory level of each item.
2. Establish a warehouse area allocation for each category of goods.
3. Establish a standard size storage location.
4. Melilih method appropriate layout. [3]
Layout Goods
In doing the layout of goods in the warehouse, there are several things that must be considered. It
should be considered in setting the layout of the barn is a good measurement system speed and good control
system. Speed measurement system will see the flow velocity based on the classification of goods flow of
goods where the goods will be divided into three kinds, namely slow moving, moving medium, and fast
moving. By looking at the above three kinds of goods we are able to control things well. [4]
For a slow-moving items should be placed at the warehouse of the most difficult to reach, on the
grounds that this item is very rare to experience the movement of goods. As for fast moving goods are
usually placed fairly open section so as to facilitate the conduct of making goods. By doing such stuff laying
on top of the control in making pickup will be easier, so the efficiency of the warehouse will be high.
Principles Road Running (aisle)
This principle is applied in the function key area warehouse. Area function is the function of
reception, transport, opening, sorting, counting, storage, order pick, selection, packing, and shipping. Ideal
aisle greatly affect the movement of goods. Which is too wide aisle space to give effect to save the fewer
goods, while too narrow resulting in savings and packing process becomes longer and provide risk goods
dropped or damaged.
Determination wide alley that is required is based on the longest dimension is that of the diagonal
removal equipment materials used when carrying material formula used is:
diagonal = √(𝑙𝑜𝑛𝑔)2 + (𝑤𝑖𝑑𝑡ℎ)2 [5]
Method of Shared Storage
Shared storage is a method of preparation of storage areas based on the condition of the floor area of
the warehouse, then sorted the area closest to the area farthest from the doorway I / O so that the placement
of goods that will be sent is placed on the area closest and so on. Shared storage can be considered as a
system of moving goods quickly to a product, if each pallet warehouse filled in different areas from time to
time. Depending on the number of products in the warehouse at the time of delivery comes, it will be
possible that the 5 pallets are filled in the space will be saved only 1 day. While 5 other pallets in the same
shipment would be in a warehouse for 20 days. [6]
III. RESEARCH METHODOLOGY
The stages in this study with the flow as follows:
Figure 1. Flowchart of Research Implementation Phase
Stages of data collection is an important step to support the achievement of the purposes of research.
Here is the data that is required in this study:
a.
Primary data
Primary data is data obtained from direct observations and research in the field. Primary data
collection was done by observing directly the activities that occur in the finished goods warehouse,
especially in warehouse of finished products (FPWH) PT. Dwi Sumber Rejeki. The data required are:
1. Size of finished product warehouse (FPWH).
2. The shape and size of the finished product warehouse (FPWH).
3. The size of the dimensions of the trolley.
b.
Secondary data
Secondary data is data obtained from secondary sources instead of direct observation, for example
from company documents relating to the issues discussed, the following secondary data are needed:
1. Delivery data in October, November, December 2014.
2. The volume of production.
3. Data types of products.
The data have been collected, then processed based on the method used, in this study the method
used is the shared storage. The following step in processing the data:
Figure 2. Flowchart of Shared Storage Method
IV. RESULTS AND ANALYSIS
Result
From the results of the processing of data obtained obtained data below:
Table 1. Mileage Average Material Handling Proposed Layout
No
(1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Type of
Product
Delivery Area
Mileage At
Delivery (m)
Mileage Total
(m)
(2)
(3)
(4)
(5)
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUSU
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE NOBLEN
PE SUSU
PE SUPER
PE AI/A+
PE SUPER
PE NOBLEN
A1, A2 (70)
A3 (181)
A4, B1 (179)
B2, B3 (192)
A2 (170), B4 (140)
A3 (59), C1 (122)
B1 (61), C2, C3 (118)
B3 (48), C4, D1 (144)
B4 (100), D2 (210)
C1 (118), D3 (63)
C3 (122), D4, E1 (57)
D1 (96), E2, E3 (96)
D2 (30), E4, F1 (40)
A1 (181)
E1 (183), F2 (236)
E3 (144), F3, F4 (48)
A1 (59), A2 (122)
A4, B2 (70)
A3, B1 (179)
A2 (118), C1 (63)
B2 (170), B4 (140)
B1 (61), B3, C2 (118)
C1 (59), C4 (122)
B4 (100), D1 (210)
D4, E2 (192)
A1 (181)
C3, D1 (30), D2 (40)
C2 (122), E1, E4 (57)
A3, A4 (70)
E2 (48), E3, F3 (144)
11.5
8.45
19.2
24.2
19.2
24.2
44.95
52.65
34.2
39.2
67.65
74.95
79.95
5.75
56.5
95.35
11.5
19.2
19.2
21.5
24.2
39.95
34.2
34.2
49.2
5.75
59.95
69.95
16.9
87.65
23
16,9
38,4
48,4
38,4
48,4
89,9
105,3
68,4
78,4
135,3
149,9
159,9
11,5
113
190,7
23
38,4
38,4
43
48,4
79,9
68,4
68,4
98,4
11,5
119,9
139,9
33,8
175,3
Table 1. Mileage Average Material Handling Proposed Layout (extention)
(1)
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
(2)
(3)
(4)
(5)
PE SUSU
PE SUPER
PE SUSU
PE AI/A+
PE SUPER
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE SUPER
PE NOBLEN
PE SUPER
PE AI/A+
PE SUPER
PE SUSU
PE SUPER
PE NOBLEN
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE NOBLEN
PE SUSU
PE AI/A+
PE SUSU
A1 (59), A2 (122)
B1 , B2 (70)
A2 (118), B3 (63)
B4, C1 (179)
A4 (170), C2 (140)
C3, D1 (192)
A1, A3 (70)
B3 (177), C4 (4)
C1 (61), D2, D3 (118)
A2, A3 (70)
B1, B2 (192)
A4, B4 (70)
C1 (179), C2
A1, A3 (70)
B3 (181)
A2, A3 (70)
B1, B2 (192)
A3 (100), A4 (110)
B4, C1 (179)
A1 (181)
A3 (70), A4 (130)
B2 (68), B3, C2 (42)
A1 (59), A2 (122)
B1, C1 (61), C3 (118)
A1 (181)
11.5
21.5
19.2
29.2
24.2
39.2
14.2
31.9
59.95
14.2
21.5
21.9
31.5
14.2
13.45
14.2
21.5
16.9
29.2
5.75
16.9
39.95
11.5
44.95
5.75
23
43
38,4
58,4
48,4
78,4
28,4
63,8
119,9
28,4
43
43,8
63
28,4
26,9
28,4
43
33,8
58,4
11,5
33,8
79,9
23
89,9
11,5
56
PE SUPER
A3 (170), A4 (110), B4 (30)
30.35
60,7
TOTAL
3.511,6
Table 2. Mileage Material Handling Beginning Layout
No
(1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Type of
Product
Delivery Area
Mileage At
Delivery (m)
Mileage Total
(m)
(2)
(3)
(4)
(5)
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE NOBLEN
PE SUSU
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE NOBLEN
PE SUSU
PE SUPER
PE AI/A+
A1, A2 (70)
A3 (181)
A4, B1 (179)
B2, B3 (192)
A2 (170), B4 (140)
A3 (59), C1 (122)
B1 (61), C2, C3 (118)
B3 (48), C4, D1 (144)
B4 (100), D2 (210)
C1 (118), D3 (63)
C3 (122), D4, E1 (57)
D1 (96), E2, E3 (96)
D2 (30), E4, F1 (40)
A1 (181)
E1 (183), F2 (236)
E3 (144), F3, F4 (48)
A1 (59), A2 (122)
A4, B2 (70)
A3, B1 (179)
A2 (118), C1 (63)
B2 (170), B4 (140)
B1 (61), B3, C2 (118)
C1 (59), C4 (122)
B4 (100), D1 (210)
D4, E2 (192)
A1 (181)
C3, D1 (30), D2 (40)
C2 (122), E1, E4 (57)
64,2
30,75
62,9
53,5
60,2
56,2
74,95
73,65
48,2
44,2
61,65
50,95
49,65
33,45
28,2
38,95
64,2
60,2
60,2
56,2
56,2
78,95
50,9
50,9
36,2
33,45
62,95
57,65
128,4
61,5
125,8
107
120,4
112,4
149,9
147,3
96,4
88,4
123,3
101,9
99,3
66,9
56,4
77,9
128,4
120,4
120,4
112,4
112,4
157,9
101,8
101,8
72,4
66,9
125,9
115,3
Table 2. Mileage Material Handling Beginning Layout (extention)
(1)
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
(2)
(3)
(4)
(5)
PE SUPER
PE NOBLEN
PE SUSU
PE SUPER
PE SUSU
PE AI/A+
PE SUPER
PE NOBLEN
PE SUPER
PE SUSU
PE AI/A+
PE SUPER
PE NOBLEN
PE SUPER
PE AI/A+
PE SUPER
PE SUSU
PE SUPER
PE NOBLEN
PE SUPER
PE AI/A+
PE SUSU
PE SUPER
PE NOBLEN
PE SUSU
PE AI/A+
PE SUSU
PE SUPER
A3, A4 (70)
E2 (48), E3, F3 (144)
A1 (59), A2 (122)
B1 , B2 (70)
A2 (118), B3 (63)
B4, C1 (179)
A4 (170), C2 (140)
C3, D1 (192)
A1, A3 (70)
B3 (177), C4 (4)
C1 (61), D2, D3 (118)
A2, A3 (70)
B1, B2 (192)
A4, B4 (70)
C1 (179), C2
A1, A3 (70)
B3 (181)
A2, A3 (70)
B1, B2 (192)
A3 (100), A4 (110)
B4, C1 (179)
A1 (181)
A3 (70), A4 (130)
B2 (68), B3, C2 (42)
A1 (59), A2 (122)
B1, C1 (61), C3 (118)
A1 (181)
A3 (170), A4 (110), B4 (30)
TOTAL
64,2
40,25
64,2
56,2
57,5
54,9
56,2
44,2
64,2
52,2
62,95
61,5
56,2
62,9
48,2
64,2
26,75
61,5
56,2
64,2
54,9
33,45
64,2
76,25
64,2
77,65
33,45
93,65
128,4
80,5
128,4
112,4
115
109,8
112,4
88,4
128,4
104,4
125,9
123
112,4
125,8
96,4
128,4
53,5
123
112,4
128,4
109,8
66,9
128,4
152,5
128,4
155,3
66,9
187,3
6.232
Analysis
Analysis Method of Shared Storage
Shared storage is a method of setting the layout of the warehouse space by using the principle of
FIFO (First In First Out) where soonest delivered goods placed on the storage area closest to the doorway (I /
O).
This method would be better spent on the type of company that has the same size or product
dimensions are not much different, because different products can occupy the same storage area based on
production time and date of delivery of such products, although only one product occupies the area when the
area filled.
Space Needs Analysis
In determining the need for warehouse space needed is to determine the length of the types of
products in the warehouse (lead time) by the length of time between the order of the date of delivery.
Many need the space required for storage by multiplying the production capacity (720 per day) with most
long lead time (7 days) is 5040 products in the warehouse.
To facilitate the preparation of the products to the storage area and also the utilization of space, the
area contained 240 sacks, with the preparation of 8 + 12, which consists of 12 levels with an area of 372 m2
available. So broad one storage area is:
Storage Area Size= (4)long product x [(2)long product + (2)width product]
Storage Area Size= (4)0,75 m x [(2)0,75 m + (2)0,5 m] = 7,5 m2
The amount of required storage area is:
Storage Area Requirement =
Total Products
Number of Products In 1 Area
Storage Area Needs =
5.040
= 21 area
240
Space needs for 21 area = 21 x 7.5 m2 = 157.5 m2
Then the need for space for movement of material handling (trolley) is the longest dimension of the
trolley when bringing a product that is diagonal (2 m). Then the required aisle width of 2 m to the movement
of the trolley.
Preparation of Warehouse Layout with Shared Storage Method
Further arranged with such arrangement layout storage area, warehouse layout images proposal can
be seen in Figure 3.
Here is the procedure of product placement, the procedure is intended that preparation of the product
being organized and unloading process becomes easier as follows:
1. The first area consists of 240 products (12 levels).
2. Items placed first arrived at the empty storage area closest to the door (to the level of closest to
furthest is A, B, C then D).
3. There should not be two types of products in one or more storage areas.
4. Registration of the product in the warehouse using the warehouse card.
Figure 3. Proposed Storage Layout
With the warehouse layout as above proposals comprising 24 storage areas, the layout of the
proposed warehouse will be able to accommodate the number of 5.760 zak products, or 8 days of storage.
Mileage Material Handling Average Per Month
Calculation of mileage trolley tested in 4th period, which is the 4th period average data demand data
in October, November, December 2014 for each product, the average frequency of requests per month and
the average delivery time. In order to obtain the average mileage per month.
Mileage calculation method is to use rectlinier distance and the results obtained amounted to 3511.6 m.
Proposed Warehouse Layout Comparison with the Benginning Warehouse Layout
1. Mileage material handling on average per month for the warehouse layout proposals amounted to
3511.6 m whereas the distance for the initial warehouse layout is equal to 6,232 m.
2. By using the settings proposed warehouse layout you will get the ease of checking the goods in the
warehouse. By looking at the warehouse card, then setting the loading and unloading will be easier because it
is known which areas are vacant to occupied the product and the location of the product to be delivered
easily identified.
V. CONCLUSION
From the results, it can be concluded as follows:
1. The amount of storage area needs is as much as 21 area with the number of areas that could be set up as
many as 24 area.
2. One area consists of 240 products are stacked as many as 12 levels with a size of 3 m x 2,5 m so vast
space requirements for the product is 180 m2.
3. Aisle width required is 2 m, so the total space requirements for the alley is 180 m2.
4. Area of unused area is 12 m2.
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