Analysis of warehouse management at PT XYZ warehouse using root cause analysis

Abstract

Warehouse management is an important aspect in supporting production and distribution processes in manufacturing companies. The TCXA Plant Warehouse at PT XYZ experiences several operational problems, including product accumulation, ineffective implementation of the first in first out (FIFO) method, irregular Warehouse layout, and inventory control discrepancies. This study aims to analyze the root causes of ineffective Warehouse management and provide improvement recommendations based on actual operational conditions. The research employed a qualitative descriptive approach through observation, semi-structured interviews, and documentation conducted from January to April 2026. Data analysis was carried out using the Root Cause Analysis (RCA) method with Fishbone Diagram and 5 Why Analysis approaches. The results showed that the main problems were caused by the suboptimal implementation of Standard Operating Procedures (SOP), inappropriate operational task distribution, damage to the robotic Filling system, and the absence of standardized Warehouse Zoning. These conditions resulted in material flow backtracking, accumulation of off-spec products, and operational inefficiencies within the Warehouse. Based on the analysis, several corrective actions were proposed, including adjustment of job descriptions, consistent SOP implementation, Warehouse capacity and inventory monitoring, and development of a digital-based monitoring dashboard. The implementation of these recommendations is expected to improve the effectiveness and sustainability of the Warehouse Management System at the TCXA Plant Warehouse of PT XYZ.