Top Coat, Putty, Construction Chemicals, Primer and Sealer are main products that produced in PT. XYZ. One of manufacturing industries focused on producing paint and construction chemical. In order to store those products, the warehouse is used in the company as a temporary storage area. Currently, it is designed floor stack and used dedicated storage policy. Around 62066 SKU’s were not found in the warehouse from the data order picking activity. In addition, manual searching activity is the waste that occurs in the warehouse and it can cause delay time. This research is conducted to minimize delay time, especially for searching activity.
Big Picture Mapping using Value Stream Mapping and Detail Mapping were used to get the process time and the value of each activity. Moreover, the proposed future of product storage policy was used class-based storage policy using FSN Analysis, then the zoning and slotting were determined for storing product in put away activity. Furthermore, the routing method for picking activity is simulated under Genetic Algorithm. The results of the research, future condition show to decrease the processing time from 3465,35 seconds to 2767,37 seconds. In addition, the value added time is increase 22%.