VALUE STREAM MAPPING OF OCEAN IMPORT CONTAINERS: A PROCESS CYCLE EFFICIENCY PERSPECTIVE

International cargo transportation is majorly dependent on marine transport, which moves 80% of the international cargo. With the increase in vessel size and the same yard area available for container transportation, it is important to study the processes and understand the efficiency of the container operations process. This research paper aims to review the import container transportation process and understand the process cycle efficiency through lean six sigma concepts. The process is evaluated from the operations process perspective and documentation process at one of the ports of India. The research has been designed by conducting an industry expert review on the process of container transportation from vessel berthing to gate out for import containers, utilising lean six sigma principles such as value stream mapping (VSM) and process cycle efficiency. The results have contributed to the existing knowledge in identifying the waste in the container handling process and demonstrated the inefficiency in the system from the perspective of waiting time of containers due to customs examination, scanning, and inter-terminal handling and movement. The process cycle efficiency of 40% is calculated by analysing the detailed time of handling containers from vessel berthing to gate out. A new future value stream mapping is proposed considering the process cycle efficiency. Future studies will focus on studying this process for export containers and benchmarking the results with the top-performing ocean ports globally.

Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry

Purpose: This study aims to improve Process Cycle Efficiency (PCE) by reducing waste in the assembly production line. This research is a case study conducted in a four-wheel vehicle manufacturing company to create a Lean production system. Methodology/Approach: This study uses the Waste Assessment Model (WAM) and Lean Automation integration methods carried out by 5 expert judgements in the selected four-wheeled vehicle industry. Findings: Based on the WAM method, this study found the biggest waste on the assembly line, namely transportation with a percentage of 20.44%. Improvements made with Lean Automation can increase the value of PCE from 56.76% to 63.62%. Research Limitation/Implication: This research is limited to one model, namely Multi Purpose Vehicle (MPV). This research provides benefits for companies related to waste reduction. For similar companies, this research can be input for manufacturing practitioners in improving manufacturing performance to compete in the global market. This Lean production can reduce manpower which has an impact on saving production costs. Originality/Value of paper: This paper provides added value related to the application of Lean terminology which aims to improve industrial automation-based manufacturing companies.

Energy Analysis of Steam Cycle Efficiency with Feed Water Heater Modification (Case Study: PT. Pertamina EP Asset 1 Field Lirik)

The increasing energy efficiency program will decrease the consumption of energy. If these improvements are carried out together, it will certainly ensure energy reliability for a sustainable and better future. The aim of this paper was to investigate the possibility of increasing efficiency in the crude oil heating system at PT. Pertamina EP Asset 1 Lirik Field. The research method was done by modification the steam cycle using the close and open Feed Water Heater (FWH). As result, the efficiency of steam cycle of close FWH increased 2.53% and 2.78% for open FWH. While the efficiency of the steam cycle in the initial conditions was 36.74%.

Assessment of Organic Rankine Cycle Part-Load Performance as Gas Turbine Bottoming Cycle with Variable Area Nozzle Turbine Technology

Power cycles on offshore oil and gas installations are expected to operate more at varied load conditions, especially when rapid growth in renewable energies puts them in a load-following operation. Part-load efficiency enhancement is advantageous since heat to power cycles suffer poor efficiency at part loads. The overall purpose of this article is to improve part-load efficiency in offshore combined cycles. Here, the organic Rankine bottoming cycle with a control strategy based on variable geometry turbine technology is studied to boost part-load efficiency. The Variable Area Nozzle turbine is selected to control cycle mass flow rate and pressure ratio independently. The design and performance of the proposed working strategy are assessed by an in-house developed tool. With the suggested solution, the part-load organic Rankine cycle efficiency is kept close to design value outperforming the other control strategies with sliding pressure, partial admission turbine, and throttling valve control operation. The combined cycle efficiency showed a clear improvement compared to the other strategies, resulting in 2.5 kilotons of annual carbon dioxide emission reduction per gas turbine unit. Compactness, autonomous operation, and acceptable technology readiness level for variable area nozzle turbines facilitate their application in offshore oil and gas installations.

ANALISIS WASTE PADA PROSES PEMBONGKARAN PETI KEMAS DENGAN PENDEKATAN LEAN SERVICE DI PT PELINDO I CABANG LHOKSEUMAWE

PT Pelindo I Cabang Lhokseumawe merupakan pelabuhan yang menyediakan pelayanan dermaga dan fasilitas lain untuk bertambat, bongkar muat peti kemas, curah cair dan curah kering. Dalam prakteknya, terdapat beberapa jenis pemborosan pada proses pembongkaran peti kemas yang dapat menurunkan produktivitas perusahaan. Permasalahan dalam penelitian ini adalah waktu proses pembongkaran peti kemas tidak sesuai dengan standar yang di tetapkan oleh perusahaan yaitu 20 container/jam sedangkan di lapangan hanya dapat membongkar 9 container/jam. Hal ini disebabkan oleh aktivitas yang tidak memiliki nilai tambah yang berdampak pada waktu transportasi dan waktu menunggu yang lama. Tujuan dari penelitian ini adalah mengidentifikasi waste yang terdapat pada aliran proses pembongkaran peti kemas dan mengusulkan perbaikan guna mengeliminasi waste. Metode yang digunakan adalah lean service dan Value Stream Mapping. Berdasarkan hasil perhitungan data diketahui bahwa jenis pemborosan yang paling berpengaruh adalah transportasi sebesar 45,60% dan waiting sebesar 29,47%. Oleh karena itu, usulan perbaikan adalah perlunya penjadwalan dan pengalokasian waktu bongkar muat, penyediaan crane dengan kondisi yang sesuai, pelatihan bagi operator dan pembuatan SOP slot penyusunan peti kemas. Hasil perhitungan usulan perbaikan setelah penerapan lean service menunjukkan jumlah container mengalami peningkatan dari 9 container/jam menjadi 12 container/jam, penurunan waktu lead time dari 413,03 detik menjadi 300,06 dan peningkatan Process Cycle Efficiency dari 34,04% menjadi 58,75%, hal ini bermakna bahwa adanya peningkatan produktivitas perusahaan setelah penerapan lean service.

Surface Treatment of Glass Vials for Lyophilization: Implications for Vacuum-Induced Surface Freezing

Freeze-drying is commonly used to increase the shelf-life of pharmaceuticals and biopharmaceuticals. Freezing represents a crucial phase in the freeze-drying process, as it determines both cycle efficiency and product quality. For this reason, different strategies have been developed to allow for a better control of freezing, among them, the so-called vacuum-induced surface freezing (VISF), which makes it possible to trigger nucleation at the same time in all the vials being processed. We studied the effect of different vial types, characterized by the presence of hydrophilic (sulfate treatment) or hydrophobic (siliconization and TopLyo Si–O–C–H layer) inner coatings, on the application of VISF. We observed that hydrophobic coatings promoted boiling and blow-up phenomena, resulting in unacceptable aesthetic defects in the final product. In contrast, hydrophilic coatings increased the risk of fogging (i.e., the undesired creeping of the product upward along the inner vial surface). We also found that the addition of a surfactant (Tween 80) to the formulation suppressed boiling in hydrophobic-coated vials, but it enhanced the formation of bubbles. This undesired bubbling events induced by the surfactant could, however, be eliminated by a degassing step prior to the application of VISF. Overall, the combination of degasification and surfactant addition seems to be a promising strategy for the successful induction of nucleation by VISF in hydrophobic vials.

Optimization of Low Pressure Steam Heating Technology of Thermoelectric Joint Production

In order to reduce the loss of heat saving in the thermal engine, improve energy utilization efficiency. This paper uses EBSILON simulation software to establish models and perform changes to the working condition, and the comparison of design values on the thermal balance graph. The results show that this method is applicable to the calculation of the thermoelectric gauge. At different heat supply and exhaust flow and the ambient temperature, the heat transfer characteristics of the unit is constantly changed. When the ambient temperature is less than 15∘C, the combined circulation thermal consumption rate is negative and the ambient temperature is negative, and the ambient temperature is higher than 15∘C time is positively correlated. When the heating capacity is greater than 300 gj/h, the combined cycle efficiency of the unit at the same heating rate is higher than the 100% load rate. Conclusion: the EBSILON simulation software is reliable.

VORTEX TRACKING OF PURGE-MAINSTREAM INTERACTIONS IN A ROTATING TURBINE STAGE

The use of purge flow in gas turbines allows for high turbine entry temperatures, which are essential to produce high cycle efficiency. Purge air is bled from the compressor and reintroduced in the turbine to cool vulnerable components. Wheel-spaces are formed between adjacent rotating and stationary discs, with purge air supplied at low radius before exiting into the mainstream gas-path through a rim-seal at the disc periphery. An aerodynamic penalty is incurred as the purge flow egress interacts with the mainstream. This study presents unparalleled three-dimensional velocity data from a single-stage turbine test rig, specifically designed to investigate egressmainstream interaction using optical measurement techniques. Volumetric Velocimetry is applied to the rotating environment with phase-locked measurements used to identify and track the vortical secondary flow features through the blade passage. A baseline case without purge flow is compared to experiments with a 1.7% purge mass fraction; the latter was chosen to ensure a fully sealed wheel-space. A non-localised vortex tracking function is applied to the data to identify the position of the core centroids. The strength of the secondary-flow vortices was determined by using a circulation criterion on rotated planes aligned to the vortex filaments........[abridged]