Reducing Dwelling Time Non-Conformance in Outbound Vehicle Logistics: A Toyota Business Practice Approach to Transit-Out Process Diagnosis

Abstract

Abstract—This study addresses the transport-logistical problem of dwelling-time non-conformance in the transit-out area of outbound vehicle distribution logistics at an automotive National Distribution Centre (NDC) in the Bandung area of Indonesia. The study aims to diagnose the internal process segments and root causes driving the corridor's ETA performance gap and to propose evidence-based countermeasures using the Toyota Business Practice (TBP) framework. The corridor's ETA punctuality was only 88% against a 98% target, with Dwelling Time Transit Out (DWT/O) identified as the highest internally controllable factor. Data were collected through event-log analytics of 1,477 validated delivery transactions extracted from the company's Logistics System and analysed within the TBP eight-step framework. Process capability analysis established that DWT/O is statistically incapable (PPU = 0.33; PPM ≈ 116,452) against a six-hour upper specification limit. Root causes were identified through a problem-tree analysis triangulated across the three data sources, revealing three causal domains unit-swapping disruption, irregular Car Carrier arrival, and unmonitored post-loading idle time. A set of structured countermeasures is proposed, including a time-based swap penalty scheme. The proposed interventions are expected to raise DWT/O process capability toward PPU ≥ 1.0 and reduce the non-conformance rate from approximately 10% to below 2%.

Keywords—Dwelling Time, Vehicle Distribution Logistics, Toyota Business Practice, Process Capability, Event-Log Analytics