Implementation of Jolly Box and Inventory Classification Analysis for Inventory Loss Prevention at PT DSV Solutions Indonesia, Margomulyo Surabaya Site

Analisis Penerapan Jolly Box dan Classification Inventory Analysis terhadap Pencegahan Loss Inventory PT DSV Solutions Indonesia Site Margomulyo Surabaya

Abstract

Effective storage system management is a crucial aspect in supporting smooth operational activities and maintaining accurate inventory data in the warehouse environment. At the warehouse of PT DSV Solutions Indonesia Site Margomulyo Surabaya, the goods picking process still faces several obstacles, including the use of conventional cardboard that does not support storage order, difficulties in differentiating products with similar characteristics in high-moving SKUs (Stock Keeping Units), and daily demand fluctuations that increase the potential for picking errors, stock discrepancies, and inventory loss. These problems have an impact on decreasing the Overall Warehouse Efficiency (OWE) value. This study aims to analyze the effect of implementing a Jolly Box system integrated with stock classification on increasing OWE and reducing the risk of inventory loss. The study results showed improvements in all OWE indicators, including availability through reduced operational downtime due to sudden reorganizations, performance through zoning of product lines based on movement levels, and quality through reduced risk of picking errors. Furthermore, the system implementation was able to reduce lean waste in the form of defects and unnecessary motion by up to 68% of the total factors causing inventory loss. To ensure the sustainability of the achieved results, regular monitoring of transaction data, routine cycle count implementation, and adjustment of container capacity are required according to the development of managed SKUs.