ANALISIS RISIKO KERUSAKAN BARANG SAAT PENYORTIRAN DAN PENANGANAN DI GUDANG DENGAN METODE DEFINE, MEASURE, ANALYZE, IMPROVE, CONTROL (DMAIC) (STUDI KASUS PT XYZ, CABANG KOBE)

Abstract

PT XYZ, as one of the major players in the Japanese logistics industry, is committed to the principle of Zero defects to achieve better operational performance. However, the Kobe Branch facility still faces problems related to goods damage during the sorting and handling processes. This study aims to systematically implement the DMAIC (Define, Measure, Analyze, Improve, Control) method to analyze, reduce, and control the risk of such damage. The analysis was conducted using damage and shipment data for three months, from November to January. In the Measure phase, it was found that although the process reliability Level was quite high (5.81 Sigma), the potential annual financial loss was estimated to reach JPY 1,680,000. The most frequent type of damage was "Contact Damage," which originated from two main processes: "Assortment" and "Loading." In the Analyze phase, a Fishbone diagram was used to identify the root causes. The results showed that the damage was not caused by a single error but was the result of the interaction of systemic factors, such as human (related to physical and cognitive conditions), machine (forklift vibrations and blind spots), method (complex procedural arrangements), environment (congested workplace traffic), materials (differences in packaging), and Measurement (KPI pressure). The Improve phase formulated holistic solutions, such as enhancing employee well-being, making ergonomic process adjustments, managing the work environment through visualization, and fostering a proactive safety culture. This research concludes that the DMAIC approach is highly effective in addressing complex problems in a high-level work environment. The recommendation is to implement these solutions through a pilot project to ensure sustainability