Guidelines for Reducing Storage Losses in a Warehouse: A Case Study of a Glass Packaging Company in Pathum Thani Province
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Abstract
This research investigated the causes of product damage in a glass packaging warehouse in Pathum Thani Province, Thailand, using an applied case study approach to develop targeted improvements for minimizing losses. Quality management tools, including Pareto Analysis, Why–Why Analysis, and the Plan–Do–Check–Act (PDCA) cycle, were systematically applied. Data were sourced from damage reports, internal documents, on-site observations, and semi-structured interviews with three forklift supervisors. Pareto Analysis identified bottle collapse as the primary cause, accounting for 52% of total monetary loss. Why–Why Analysis revealed root causes: improper product placement, uneven and subsided flooring, and inadequate lighting. Interventions via PDCA included redesigning storage layouts with zoning and marking, upgrading lighting with bi-weekly inspections, and implementing standardized procedures through staff training and reinforcement. Post-implementation, damage losses dropped from 98,281.60 Baht in 2024 (January–December) to 0 Baht in 2025 (January–September), achieving a 100% reduction. These results demonstrate the efficacy of quality tools in attaining zero-defect operations. The framework offers a replicable model for similar warehouses handling fragile goods, emphasizing root-cause analysis and continuous improvement for enhanced efficiency and sustainability.
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