The Problem of Irregular Storage System

Oct 13, 2025 by leolavanderia.com.br 69 views

Optimization of the Layout of the Finished Product Warehouse at PT. Gold Coin Indonesia: Increasing Efficiency with Storage and Retrieval Methods

Introduction

The warehouse is the operational heart of a company, especially for the manufacturing industry such as PT. Gold Coin Indonesia which is engaged in animal feed. Maintaining the availability of products and the efficiency of taking is the key to meeting market demand and minimizing operational costs. However, PT. Gold Coin Indonesia faces problems related to the layout of finished product warehouses that are less than optimal. An irregular storage system and less-based FIFO (First in, First Out) causes difficulties in finding products to be distributed. As a result, operators and conveyances must travel further distances and spend longer time to find the desired product. This has a negative impact on operational efficiency and logistics costs.

The Problem of Irregular Storage System

The current storage system at PT. Gold Coin Indonesia is characterized by an irregular layout, making it difficult for operators to find the desired product. This leads to longer search times and increased distances traveled by operators and conveyances. The lack of a systematic approach to storage and retrieval has resulted in a warehouse layout that is not optimized for efficiency. The consequences of this irregular storage system are:

Longer search times for operators, leading to decreased productivity and increased costs
Increased distances traveled by operators and conveyances, resulting in higher fuel consumption and wear and tear on equipment
Reduced customer satisfaction due to delayed product delivery
Increased risk of product damage during storage and collection

The Solution: Storage and Retrieval Method

To overcome these problems, this research applies the Storage and Retrieval method in designing the layout of the finished product warehouse. This method aims to optimize product placement based on the request cycle and the frequency of taking, thereby minimizing the distance and search time. The Storage and Retrieval method considers several factors, including:

*** Frequency of Product Demand: ** Products that are often asked to be placed in easily accessible locations. *** Dimensions and Weight Products: ** Large and heavy products are placed in locations that are easily accessed by transportation. *** Life Cycle Products: ** Products with short expiration periods are placed in a location closer to the collection area. *** Flow of goods: ** The direction of the flow of goods in the warehouse is designed to minimize cross movements and increase efficiency.

This method is usually applied with the help of warehouse simulation software to model various layout scenarios and identify optimal solutions.

Benefits of Application of Storage and Retrieval Methods

Application of Storage and Retrieval Method at PT. Gold Coin Indonesia not only has a positive impact on warehouse operational efficiency, but also provides other benefits, such as:

*** Increasing customer satisfaction: ** Faster and timely delivery of products will increase customer satisfaction. *** Reducing product damage: ** More efficient product handling can reduce the risk of product damage during storage and collection. *** Improving Occupational Safety: ** Optimal warehouse layout arrangements can increase occupational security for operators and workers. *** Increasing the efficiency of resource use: ** Space and time savings can optimize the use of company resources.

Case Study: PT. Gold Coin Indonesia

The results of this study showed that with the application of storage and retrieval methods, the layout of the finished product warehouse of PT. Gold Coin Indonesia has become more effective. The total mileage for product collection was successfully reduced up to ** 7194.79 m/day **, much lower than the current condition that reached ** 27542 m/day . In addition, this research also produces the efficiency of the use of storage space. The warehouse area that previously reached ** 1476.59 m2 ** can be reduced to ** 1146.73 m2 ** after planning the warehouse layout. This means PT. Gold Coin Indonesia can save the use of warehouse space up to ** 22.34%.

Conclusion

This study proves that the application of storage and retrieval methods can be an effective solution to optimize the layout of the finished product warehouse at PT. Gold Coin Indonesia. By minimizing the distance and search time, as well as optimizing the use of storage space, PT. Gold Coin Indonesia can improve operational efficiency and save logistics costs. The results of this study can be a reference for other companies to apply similar methods in optimizing their warehouse layout.

Recommendations

Based on the findings of this study, the following recommendations are made:

PT. Gold Coin Indonesia should continue to apply the Storage and Retrieval method in designing the layout of the finished product warehouse.
The company should also consider implementing warehouse simulation software to model various layout scenarios and identify optimal solutions.
The company should provide training to operators and workers on the new warehouse layout and the Storage and Retrieval method.
The company should monitor and evaluate the effectiveness of the new warehouse layout and the Storage and Retrieval method on a regular basis.

Future Research Directions

This study has several limitations, including:

The study only focused on the finished product warehouse of PT. Gold Coin Indonesia and did not consider other warehouses or facilities.
The study only considered the application of the Storage and Retrieval method and did not consider other warehouse design methods.
The study only considered the operational efficiency of the warehouse and did not consider other aspects, such as customer satisfaction and product damage.

Future research should aim to address these limitations and explore other warehouse design methods and their applications in various industries.
Frequently Asked Questions (FAQs) about Storage and Retrieval Methods

Q: What is a Storage and Retrieval method?

A: A Storage and Retrieval method is a systematic approach to designing warehouse layout by considering factors such as frequency of product demand, dimensions and weight of products, life cycle of products, and flow of goods.

Q: What are the benefits of using a Storage and Retrieval method?

A: The benefits of using a Storage and Retrieval method include:

Increased operational efficiency
Reduced search times for operators
Decreased distances traveled by operators and conveyances
Improved customer satisfaction
Reduced product damage
Improved occupational safety
Increased efficiency of resource use

Q: How does a Storage and Retrieval method work?

A: A Storage and Retrieval method works by optimizing product placement based on the request cycle and the frequency of taking. This is done by considering the following factors:

Q: What are the steps involved in implementing a Storage and Retrieval method?

A: The steps involved in implementing a Storage and Retrieval method include:

Conducting a warehouse analysis to identify the current layout and operational inefficiencies.
Developing a new warehouse layout design based on the Storage and Retrieval method.
Implementing the new warehouse layout design.
Training operators and workers on the new warehouse layout and the Storage and Retrieval method.
Monitoring and evaluating the effectiveness of the new warehouse layout and the Storage and Retrieval method.

Q: What are the tools and software used in implementing a Storage and Retrieval method?

A: The tools and software used in implementing a Storage and Retrieval method include:

Warehouse simulation software
Warehouse management software
Inventory management software
Supply chain management software
Barcode scanners and other data collection devices

Q: What are the challenges of implementing a Storage and Retrieval method?

A: The challenges of implementing a Storage and Retrieval method include:

Resistance to change from operators and workers
Limited budget and resources
Complexity of warehouse operations
Limited data and information on warehouse operations
Difficulty in implementing new technology and software

Q: How can I measure the effectiveness of a Storage and Retrieval method?

A: The effectiveness of a Storage and Retrieval method can be measured by:

Tracking operational efficiency metrics such as search times and distances traveled
Monitoring inventory levels and turnover rates
Evaluating customer satisfaction and feedback
Analyzing product damage and loss rates
Conducting regular audits and assessments of warehouse operations

Q: Can a Storage and Retrieval method be applied to other industries and warehouses?

A: Yes, a Storage and Retrieval method can be applied to other industries and warehouses. The method is flexible and can be adapted to different types of warehouses and operations.

Q: What are the future trends and developments in Storage and Retrieval methods?

A: The future trends and developments in Storage and Retrieval methods include:

Increased use of automation and robotics in warehouse operations
Development of new warehouse management software and systems
Increased use of data analytics and artificial intelligence in warehouse operations
Increased focus on sustainability and environmental impact of warehouse operations
Increased use of mobile devices and apps in warehouse operations