Bottleneck Analysis and Distribution Capacity Optimization in Used Goods Business Using Theory of Constraints: A Case Study of UD. DOA ABADI, Semarang

Fajriansyah Mahdy Tsani; Dewa Kusuma  Wijaya

doi:10.70716/reswara.v4i4.866

Authors

Fajriansyah Mahdy Tsani Industrial Engineering, Universitas Dian Nuswantoro, Semarang, Indonesia Author
Dewa Kusuma Wijaya Industrial Engineering, Universitas Dian Nuswantoro, Semarang, Indonesia Author

DOI:

https://doi.org/10.70716/reswara.v4i4.866

Keywords:

bottleneck, operational capacity, distribution lead time, reverse logistics, theory of constraints

Abstract

Operational capacity determines the ability of the distribution system to balance the supply in the reverse logistics-based second-hand goods business. This study aims to analyze operational capacity and identify bottlenecks in the UD distribution system. DOA ABADI, a second-hand goods trading business in Semarang City that handles iron, cardboard, paper, and plastic bottles. The study uses a descriptive quantitative approach with a single case study design based on operational data from June 2025–June 2026 and weekly data for 13 weeks of the third quarter of 2025, including fleet ritasize, vehicle capacity, loading/unloading time, lead time, demand, and stock. The analysis was carried out through inventory mass balance, fleet and labor utilization, and Theory of Constraints and Supply Chain Operations Reference (SCOR) approaches. The results showed that fleet utilization reached 91.7%, with an average real load of 2.73 tons per ritase from a capacity of 3.0 tons and a lead time of 4.8 hours. This condition is higher than the labor utilization of 81.0%, so the fleet is the main constraint. Demand is not met at an average of 0.25 tons per week, accompanied by an increase in stock from 21.5 tons to 29.4 tons and warehouse utilization from 42.2% to 57.6%. A comparison of three scenarios shows that the addition of weekly ritase without new fleet investment is the most financially feasible and multi-criteria alternative. This study confirms that capacity analysis based on operational data and cost-benefits is effective to identify bottlenecks and determine priorities for increasing distribution in circular economy businesses.

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