Optimizing Material Storage Areas with Kaizen Approach

Abstract

In the industrial world, the layout of a product is quite important, considering the cost of renting a warehouse for some companies. Therefore, the Company needs to make improvements to the warehouse layout in order to fix the problem. This research aims to improve the layout of the warehouse in order to maximize the number of "A-1" parts in the pallet. We use data from May 2025 to July 2025 with a monthly average of 190,050pcs per month and require at least 25 pallets. The method we use is Plan, Do, Check, Act (PDCA). The initial planning increased the initial capacity of part A-1 from 7,560pcs in one pallet to 10,080pcs per pallet. From the results of this study, we succeeded in optimizing the use of pallets from 25 pallets to 18, where previously we cleared 30.25 m2 of land to 21.78m2. Another research that we conducted, a well-organized warehouse layout can reduce the cost of renting a warehouse, which is Rp. 550,550 per month or Rp. 6,606,600 per year. This shows a significant cost when we can improve a good warehouse layout. This research is expected to provide practical solutions that can be directly applied to reduce warehouse rental costs, store parts more optimally, and the delivery process is easier and faster.