The TRANSFORMING WAREHOUSE OPERATIONS FOR SUSTAINABLE GROWTH: EFFICIENCY AND EMISSIONS REDUCTION THROUGH INNOVATION

TRANSFORMING WAREHOUSE OPERATIONS FOR SUSTAINABLE GROWTH: EFFICIENCY AND EMISSIONS REDUCTION THROUGH INNOVATION

Abstrak

Transforming Warehouse Operations for Sustainable Growth: Efficiency and Emissions Reduction through Innovation

Helmi Yusuf

Student of Master Degree of Management Technology, Faculty of Business, President University   PresidentOrganization/Affiliation^1,2,3 

Jl. Sunan Muria 2 Cikarang Barat, Bekasi, Indonesia

Correspondence Email: helmi.yusuf@global.komatsu

ABSTRACT

This project case study was conducted at Indonesian company, named KUI, a company specializing in undercarriage components for hydraulic excavators (PC200–PC4000) and bulldozers (D39–D475), such as track links, rollers, idlers, sprockets, and segment teeth. KUI operates two production facilities: the Forging Plant and the Assembly Plant. However, capacity constraints in the Assembly Plant have impacted process cycle efficiency and CO₂ emissions management.

The study identified five types of waste: Waiting, Motion, Overprocessing, Defects, and Transportation. These issues caused delivery delays, high external warehouse costs, limited storage space, high forklift energy consumption, and increased CO₂ emissions.

As a solution, the project implemented Vertical Warehousing, RFID, and AGV. Using Sustainable Value Stream Mapping and Process Activity Mapping, the first phase showed improvements: process efficiency increased from 52% to 58%, warehouse capacity rose by 9.6%, costs decreased by 23.2%, and CO₂ emissions were reduced by 0.96 tons per year. In the second phase, focused on the roller area, CO₂ emissions dropped by 2.43 tons annually, with an additional 1.47 tons reduced each year. Productivity reached 60%. Safety risks were also addressed using HIRARC and REBA.

Keywords: Warehouse Management, 7 Waste, Sustainable Value Stream Mapping, Process Activity Mapping, Vertical Warehouse, RFID, AGV