Nabila, Ike Jihan (2026) Optimalisasi Kinerja Operasional Gudang dengan Mengurangi Bottleneck Menggunakan Theory of Constraints (TOC) dan Discrete Event Simulation (DES) (Studi Kasus: PT PLN (Persero) UP3 Madura). Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
PT PLN (Persero) UP3 Madura is a State-Owned Enterprise (SOE) operating in the electrical energy sector and is responsible for ensuring the availability of national electricity supply. As a center for the storage and distribution of electrical materials, the warehouse operations of PT PLN (Persero) UP3 Madura have not yet been optimally implemented due to the presence of bottleneck activities. This study aims to optimize the operational performance of the warehouse at PT PLN (Persero) UP3 Madura by identifying and reducing bottlenecks in the process flow using the Theory of Constraints (TOC) method and proposing improvements through a Discrete Event Simulation (DES)-based simulation model. The results of the TOC analysis indicate that the activity of preparing delivery orders at Activity 4 – Workstation 2 (outbound) is the main bottleneck, as it has the highest standard processing time and the greatest resource utilization. This condition leads to queue formation and extends the system cycle time. Based on TOC calculations using the Drum Buffer-Rope (DBR) approach, the addition of seven operators results in a per-operator utilization rate of 87.7%, which is below the critical utilization threshold of 90%, indicating a safe and stable operating condition. Utilization values within this range suggest that operators are working optimally. A DES simulation model using ProModel was developed based on actual operating conditions and has undergone verification and validation processes, enabling it to accurately simulate system performance. Three improvement scenarios were tested through simulation: adding forklifts, extending working hours for the bottleneck administrative staff, and increasing the number of bottleneck administrative staff. The simulation results show that Scenario 3—the addition of seven administrative operators—provides the most optimal alternative, yielding the largest capacity increase, the most significant reduction in cycle time, and an improvement in throughput compared to all other scenarios. Therefore, this study concludes that the integration of TOC and DES methods is effective in identifying system constraints and evaluating improvement alternatives, and it recommends adding operators as the optimal solution to enhance overall warehouse operational efficiency. Keywords: Theory of Constraints, Discrete Event Simulation, ProModel, Bottleneck
| Item Type: | Thesis (Undergraduate) | ||||||||
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| Subjects: | T Technology > T Technology (General) > T55.4-60.8 Industrial engineering. Management engineering | ||||||||
| Divisions: | Faculty of Engineering > Departement of Industrial Engineering | ||||||||
| Depositing User: | Ike Jihan Nabila | ||||||||
| Date Deposited: | 27 Jan 2026 03:37 | ||||||||
| Last Modified: | 27 Jan 2026 03:37 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/49152 |
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