OPTIMASI PENGENDALIAN PENYIMPANAN DI GUDANG BAHAN BAKU BISKUIT MENGGUNAKAN DEDICATED STORAGE DAN POKA YOKE DENGAN PENDEKATAN FAILURE MODE AND EFFECT ANALYSIS (FMEA) DAN HUMAN RELIABILITY ANALYSIS (HRA)

Abstract

Abstract: A total of 41 picking error incidents were recorded at PT XYZ’s biscuit raw material warehouse between January and June, with operator inaccuracy identified as the primary cause (43.9%). These errors were driven by a wide variety of raw materials, similarities in physical product characteristics, and the absence of a structured error-prevention mechanism. This study integrates Failure Mode and Effects Analysis (FMEA), Human Reliability Analysis (HRA) using the HEART method, Dedicated Storage, and Poka-Yoke to identify, quantify, and mitigate picking error risks. FMEA was used to prioritize risks based on the Risk Priority Number (RPN), while HRA-HEART was employed to measure the Human Error Probability (HEP). FMEA results revealed four high-priority failure modes: retrieving expired materials (RPN 400), placing materials in incorrect locations (RPN 392), selecting the wrong raw materials (RPN 392), and non-compliance with FIFO procedures (RPN 378). HRA results indicated the highest HEP values ​​in the tasks of issuing materials to production (72.8%), raw material retrieval (65.9%), and material placement (53.8%). Improvements were implemented using Dedicated Storage—based on the throughput-to-space requirement ratio—and Poka-Yoke measures, including barcode verification, a FIFO physical lock system, and a color-coded visual management system. These improvements reduced the RPN of all high-priority failure modes to below 100 and lowered the raw material retrieval HEP from 65.9% to 13.2%. Thus, the integration of FMEA, HRA, Dedicated Storage, and Poka-Yoke proved effective in mitigating picking error risks and enhancing warehouse operational reliability.

Keyword: Picking error, FMEA, HRA, Dedicated Storage, Poka Yoke.

Abstrak: Kesalahan pengambilan barang (picking error) di gudang bahan baku biskuit PT XYZ tercatat sebanyak 41 kejadian selama Januari–Juni, dengan ketidaktelitian operator sebagai penyebab dominan sebesar 43,9%. Kondisi tersebut dipengaruhi oleh tingginya variasi bahan baku, kemiripan karakteristik fisik produk, serta belum adanya mekanisme pencegahan kesalahan yang terstruktur. Penelitian ini mengintegrasikan Failure Mode and Effects Analysis (FMEA), Human Reliability Analysis (HRA) dengan metode HEART, Dedicated Storage, dan Poka Yoke untuk mengidentifikasi, mengukur, dan mengurangi risiko picking error. FMEA digunakan untuk menentukan prioritas risiko berdasarkan Risk Priority Number (RPN), sedangkan HRA-HEART digunakan untuk mengukur Human Error Probability (HEP). Hasil FMEA menunjukkan empat failure mode prioritas tinggi, yaitu pengambilan bahan kedaluwarsa (RPN 400), penempatan bahan tidak sesuai lokasi (RPN 392), salah pengambilan bahan baku (RPN 392), dan ketidaktaatan FIFO (RPN 378). Hasil HRA menunjukkan HEP tertinggi pada tugas pengeluaran bahan ke produksi sebesar 72,8%, pengambilan bahan baku 65,9%, dan penempatan bahan 53,8%. Perbaikan dilakukan melalui Dedicated Storage berdasarkan rasio throughput/kebutuhan ruang dan Poka Yoke berupa verifikasi barcode, FIFO Physical Lock System, serta Visual Management System berbasis kode warna. Hasil perbaikan menurunkan seluruh failure mode prioritas tinggi menjadi RPN <100 dan menurunkan HEP pengambilan bahan baku dari 65,9% menjadi 13,2%. Dengan demikian, integrasi FMEA, HRA, Dedicated Storage, dan Poka Yoke efektif dalam mengurangi risiko picking error dan meningkatkan keandalan operasional gudang.

Kata kunci: picking error, FMEA, HRA, dedicated storage, poka yoke