MINIMASI KASUS OVERTONNAGE PADA AKTIVITAS OUTBOUND MELALUI PENDEKATAN DMAIC (STUDI KASUS: WDC-UNILEVER)

Abstract

As a leading FMCG company in Indonesia, Unilever faces challenges in efficiently managing product inventory and ensuring product availability in the market. One of the problems encountered by Unilever in its outbound activities at the West Distribution Center is overtonnage. Overtonnage happens when the total weight or total volume of the products being handled exceeds what it actually is planned, causing inefficienty. The purpose of this study is to analyze the impact of overtonnage, to determine the contributing factors, and to find solutions to reduce overtonnage cases. Using the Define, Measure, Analyze, Improve and Control (DMAIC) approach from Six Sigma, this study assisted Unilever Indonesia to find the root causes of the overtonnage problem and to provide a systematic solution. The results revealed that overtonnage’s negative impacts include double handling costs, potential lost sales, and decreased warehouse productivity. While the factors causing overtonnage include Stock Keeping Unit (SKU) mix, layout of goods on trucks (planogram),different truck size that is used in distribution, the lack of update in master data, as well as some issues in the stage of planning. The proposed solution involves updating the master data regularly based on the actual dimensions, changing the dimensional check procedure, and updating the reporting system of overtonnage cases