IMPROVING WAREHOUSE PERFORMANCE OF A SEAWEED SNACK MANUFACTURING AND PACKAGING COMPANY USING SYSTEMATIC LAYOUT PLANNING (SLP)

Abstract

This research focuses on PT. XYZ, a seaweed snack manufacturing company, that has an issue of a limited finished goods warehouse capacity. By utilizing a general workflow of DMAIC (Define, Measure, Analyze, Improve, Control), followed by a thorough analysis using Systematic Layout Planning (SLP), the warehouse capacity is increased and layout alternatives were developed for both the Main and Partial Finished Goods Warehouses. The layouts were evaluated based on warehouse static capacity (WSC), storage utilization, and cost-benefit analysis. Discrete-event simulations in AnyLogic were used to model and test each alternative’s operational efficiency. Results show that the usage 3-level racks significantly increase capacity, with the Partial FG Warehouse achieving the highest WSC of 88,200 cartons. However, considering implementation costs and practicality, Alternative Layout 1 is recommended for the Main FG Warehouse in the short term and Alternative Layout 2 for Partial FG Warehouse. This research provides a replicable methodology for small to medium enterprises to improve warehouse capacity without major infrastructure changes.