Jurnal Logistik Indonesia Vol. , No. , April 2018, pp.

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Analysis of Issue Master Data by Measuring Outer Case

Dimensions Actually in Over Tonnage Cases Using the
DMAIC Method at PT Unilever Indonesia, Tbk.
Alief Yudhistira Firmansyah a,1
a
Telkom University, Jl. Telekomunikasi. 1, Bojongsoang, Bandung, 40257, Indonesia
1
yudhistiraalief26@gmail.com

*Alief Yuhdistira Firmansyah

ARTICLE INFO ABSTRACT (10PT)

Unilever Indonesia is one of the FMCG (Fast Moving Consumer

Article history Goods) companies in Indonesia. WDC Unilever is one of the many
Received warehouse that Unilever have in Indonesia. In WDC has happened over
Revised tonnage or over dimension cases. Over tonnage is a condition when a
Accepted truck cannot load an order according to the shipment plan. Over tonnage
or over dimension cause loss like potencial loss sales, double handling
cost, and waste time when load the order. Over tonnage or over
Keywords
dimension caused by master data issue, planner issue, mix SKU,
Over Tonnage
planogram, and the truck size didn’t same as shipment plan. In this
Master Data Issue
project will be focus on issue master data. Issue master data is a
DMAIC
condition when the outer case dimension in the system didn’t same as
the outer case dimention in actual. Their need to make an improvement
to solve this case.

1. Introduction
Unilever Indonesia is one of the FMCG (Fast Moving Consumer Goods) companies in
Indonesia. Unilever was serve Indonesian people since 5 December 1933 with name “Lever
Zeepfabrieken N.V”. Unilever Indonesia has many warehouse in Indonesia, WDC Unilever is one of
the many warehouse that Unilever has it. In WDC has happened over tonnage atau over dimension
cases. Over tonnage or over dimension was caused by mix SKU, master data issue, planogram,
planner issue, and the truck size is not same as shipment plan. Over tonnage or over dimension make
company gain some loss like potencial loss sales, double handling cost, and waste time when load
the order. In this project will be focus on master data issue. Master data issue is a condition when the
outer case dimension in system didn’t same as actual condition it cause an over tonnage or over
dimension. This research was conducted in business operation division. Business operation division
main task is to improve the quality of the process to gain more benefits. To make an improvement
we used DMAIC method.

2. The Proposed Method (bold, 11 pt)

2.1. DMAIC
DMAIC is sub method from lean six sigma frame work. DMAIC consist of define, measure,
analyze, improve, and control. Step define is used to identify the problem and explained it. Step
measure is used to collecting data and make a measurement. Analyze step is used to analysis the root
cause. Improve step is used make an improvement from the analyze step. And the last step is control
is used to controlling the improvement so it can be sustain. DMAIC aims at quality upgrade until
achieve six sigma target level (Nasution).

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3. Method
The method used in this research is DMAIC. DMAIC stands for define, measure, anlayze,
improve, and control.

3.1. Equations
3.1. 1. Define
Over tonnage or over dimension is a condition when the order cannot be load as the shipment
plan. Over tonnage or over dimension caused by master data issue, planner issue, mix SKU,
planogram, and the truck size was different not same as shipment plan when it came to WDC.
In this project will be focus on master data issue. Master data issue is a condition when data
outer case dimension didn’t same with the actual condition. Over tonnage or over dimension
caused loss for company like potential loss sales, double handling cost, and waste time when load
the order.
3.1. 2. Measure
Measure step is collecting data and do a measurement.there is two way to collect data, first
asked to another employee in WDC Unilever MM2100, second is taking walk in the warehouse and
do a direct measurement to all reguler, promo, and new SKU.

Table 1. Progress Outer Case Dimension Checking

3.1. 3. Analyze
Analyze step is to do an anlysis and to find the root cause. Fishbone diagram will help to
find the root cause.

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Figure 1. Fishbone Diagram

3.1. 4. Improve
Improve step is the fouth step. There is 2 improvement, short term and long term.
Short term :
1. Sweeping all reguler, promo, and new SKU. Straight down to the warehouse to find SKU –
SKU that has different outer case dimension between system and actual.
2. Make daily report. Reporting SKU that has different outer case dimension between system
and actual condition to warehouse and planner division.
3. Monitoring outer case dimension changing progress. Monitoring changing progress to all
SKU that has been report to warehouse and planner division until the SKU has change in
the system according to actual outer case dimension.
Long term :
1. Planner make sure every outer case dimension is same as actual condition before request to
MDM to input it.
2. RND, do a cross check to every outer case dimension before their give the data to planner.
And make sure planner give a correct data as actual condition to MDM.
3.1. 5. Control
Control was the last step in DMAIC method. To make the improvement sustainable company need
a good controlling system. So there is proposal to do an alignment and refreshment on the current
checking SOP at receiving section.
Red square as a bookmark for additions procedure in new alignment and refreshment checking
SOP.

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Figure 2. Alignment and Refreshment Checking SOP

Based on the picture above, there is addition procedure on planner/RND ULI, checker, and admin
receiving to check and make sure that all promo and new product has same outer case dimension
berween actual and system.

4. Results and Discussion

Based on the measurement result and data processing. Over tonnage/ over dimension case still
exist because the proposed SKU for changing outer case dimension still on process to request
approval from planner.

5. Conclusion
The conclusion is there was no information from planner to 3PL warehouse inventory about new
and promo product like when it will arrive at WDC, production date, and many more. From 1239
SKU has been checked and measured, there is 184 SKU need to change the outer case dimension in
the system according to actual condition. From 184 SKU there is 90 SKU has done changed in
system according actual condition, it meant there’s half of 184 SKU that not changed until right now
that affected over tonnage/over dimension case right now.
Operatinal division must consider the proposed alignment and refreshment checking SOP as a
preventive action at receiving section.

References
Heizer, Render, J. &., & Barry. (2015). Manajemen Operasi: Manajemen
Keberlangsungan dan Rantai Pasokan. (H. Kurnia, R. Saraswati, & D. Wijaya,
Translator.) Jakarta: Salemba Empat.
Li, X. (2014). Operations Management of Logistics and Supply Chain: Issues and
Direction Review.
M.Nur, N. (2015). Manajemen Mutu Terpadu. Jakarta: Ghalia Indonesia.

First Author et.al (Title of paper shortly)

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Martono, R. (2015). Manajemen Logistik Terintegrasi. PPM Manajemen, 343.

Salim, Z. (2015). Kesiapan Indonesia Menuju Pasar Tunggal dan Berbasis Produksi
ASEAN : Sektor Jasa Logistik. LIPI Press. Jakarta.
Siahaya, W. (2013). Sukses Supply Chain Management Akses Demand Chain
Management. Jakarta: In Media.

Supplementary Material
Supplementary material that may be helpful in the review process should be prepared and
provided as a separate electronic file. That file can then be transformed into PDF format and
submitted along with the manuscript and graphic files to the appropriate editorial office.

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