Analysis of Material Unavailability in the Beside Table Production Process Using Root Cause Analysis (RCA) and 5S Methods in A Furniture Company

Abstract

Furniture manufacturing company, producing products such as tenban, beside cabinet, beside table. In carrying out its production, furniture companies often occur conditions of material unavailability when the production process is in progress and there is a difference between the amount of material inventory stock in the information system (computer) and the stock of materials in the warehouse. This research will identify the factors that cause material unavailability during production using the Root cause analysis (RCA) method. Several factors cause material unavailability, namely, errors in inputting material stock data, not doing physical stock-taking regularly, material moving to other parts of the shelf, material storage is not neat because there are few storage shelves and material identity labels are not yet valid, recording stock-taking is still manual, material or spare parts are lost, return material (defects) from users is placed on the same shelf as OK material and narrow warehouse space and limited storage shelves. To overcome these problems, this research provides a sustainable improvement proposal by implementing the lean thinking concept with the 5S principle in the company. It is expected that with the application of the 5S concept in this company so that the material inventory system in the warehouse is controlled optimally so that it can increase the productivity of employee performance in the company and a better change for the company.