DOUBLE CYCLING

A study on the effects of double cycling for PT. Terminal Petikemas Surabaya.

By: Robin Memelink

1. CURRENT SITUATION

Vessel Wharf / QC Truck Yard

Single Cycling

Vessel Wharf / 1th QC Empty Truck Wharf / 2nd QC Loaded Truck Yard

Multi-crane Double Cycling

2. WHAT IS THE DOUBLE CYCLING METHOD

Focus on minimization of empty movements

Simultaneous unloading & loading

2 Stages both QC and Truck Single Cycling Double Cycling

.  

Loading Unloading Loading/Unloading

3. PROS & CONS

  

 Simultaneous loading and unloading by QC

Skillful operator required

 

Decrease vessel

turnaround time

Lower costs per container

moved

Fewer head-trucks + drivers

required

Increase QC

productivity

 

Increase risk

 

Impact vessel

stability

Difficult planning

Increase difficulty

crane operations

Reduce empty

movements

Fewer required cycles

Reduction in fuel usage

 

Intensify Communica

-tion

Complicatesshore

operations 

 

Longer QC

Cycles

 

2 stagesTruck and

QC 

4. AVERAGE VESSELSBay view Chiloe Island

Bay view Marindo Baru

21 BOX

130 BOX

  Chiloe Island Marindo Baru

INTERNATIONAL DOMESTIC

Capacity (TEUS)

2,824 424

Bays 13 Feu / 24 TEU 6 FEU / 12 TEU

Rows12 above deck / 10

below deck7 above deck / 5 below

deck

Tiers 12 6

Year Made 2000 1983

Feeder / Direct

FEEDER FEEDER

Horse Power 35.000 -

Gross Ton 28,911.00 5,020.00

Death Weight 39,228.00 5,223.00

Length (m) 222 120

Principal MAERSK LINE SALAM PACIFIC IND. L

  Chiloe Island Marindo Baru

INTERNATIONAL DOMESTIC

Amount TEUS %

Amount TEUS %

Total capacity 2824 100 424 100

Capacity below deck

1026 36.12 168 39.62

Capacity above deck

1798 63.88 256 60.38

Capacity applicable for double cycling

923 32.68 151 35.61

4. EXTRA TIME CYCLES

Extra time cycles in seconds

Minimum(First row

from quay)Average

Maximum(Last row

from quay)International

vessels40 60 80

Domestic vessels

35 48 60 *Predicted by means of observations

4. PRODUCTIVITY - GRAPHS

Double cycling is only applicable to below deck container slots

Vessels berthing at TPS hold between 57% and 70% of the total containers below deck.

For example: when a vessel carries 60% of its containers below deck.

Single cycling would require 112.91 QC hoursDouble cycling would require 94.25 QC hours

57%

58%

59%

60%

61%

62%

63%

64%

65%

66%

67%

68%

69%

70%

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

Chiloe Island QC Hours

QC Hours with double cycleQC hours without double cycleExtra time because of longer cycles avr: 60 sec

% Below deck storage of total

Hours

4. PRODUCTIVITY - TABLE

Benefits per % below deck Double Cycling

  Double cycle savings

  % boxes below deck

DC100% 90% 80% 70% 60% 50%

40%

30%

20% 10% 0%

Chiloe Island

Cycles saved - 757 673 589 505 421 337 252 168 84 0

QC hours reduced

-17.6

715.7

113.7

411.7

89.82

7.85

5.89

3.93 1.96 0

Marindo Baru

Cycles saved - 124 110 96 83 69 55 41 28 14 0

QC hours reduced

- 6.10 5.42 4.74 4.06 3.392.71

2.03

1.35 0.68 0

4. PRODUCTIVITY - TABLE

Ultimate results, with 100% usage of container slots

  Chiloe IslandMarindo

BaruTotal boxes on vessel 2316 348

Total boxes Below Deck 841 138Cycles without double

cycling4632 695

Cycles with double cycling 3875 572Saved cycles 757 124

% Reduction in cycles -16.34% -17.81%QC hours without double

cycling185.28 43.47

QC hours with double cycling

155.00 35.73

Extra Time Cycles 12.62 1.65Reduction in QC hours 17.67 6.10

4. PRODUCTIVITY

Time and Containers saved per cyclewhile double cycling International2.4 – 0.60 = 1.8 minutes1.8/0.024 = 0.75 container

Domestic3.75-0.48 = 3.27 minutes3.27/0.0375 = 0.872 container

Cycles per hour while Double CyclingInternational 60/(2.4+0.60) = 20 Cycles

Domestic60/(3.75+0.48) = 14 Cycles

5. FUEL USAGE

Quay Crane fuel consumption per hour

  Distance in KM

Liters of Fuel

Domestic Distance 1.9 1.22

International

Shortest Distance 2.2 1.41

Average Distance 3.9 2.5

Longest Distance 6.4 4.1

Truck fuel consumption per distance

Type QC nmbr Consumption

Average

Domestic Ihi QC 11 - 12 49.64 L/H 49.64 L/H

International

Kone QC 1 - 4 39.59 L/H

43.8 L/HHitachi QC 5 42.25 L/H

Impsa QC 6 - 10 49.56 L/H

5. QC FUEL SAVED

Quay Crane fuel saved per % double cycled

Example: when double cycling 60%, savings are: 516L and 202L

TEUS below deck

% below deck TEUS double cycled 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

QC hours reduced

Chiloe Island 17.67 17.67 15.71 13.74 11.78 9.82 7.85 5.89 3.93 1.96 0.00

Marindo Baru 6.10 6.10 5.42 4.74 4.06 3.39 2.71 2.03 1.35 0.68 0.00

QC Fuel liters saved

Chiloe Island 774 774 688 602 516 430 344 258 172 86 0.00

Marindo Baru 303 303 269 235 202 168 135 101 67 34 0.00

5. TRUCK FUEL SAVED Truck fuel saved per amount of slots double cycled below deck

- multi-crane double cycling

Marindo Baru% below deck boxes double cycled

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

Cycles saved below deck 124 124 110 96 83 69 55 41 28 14 0.0

Truck Fuel saved Marindo Baru 82 82 73 64 55 45 36 27 18 9 0.0

Chiloe Island% below deck boxes double cycled

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

Cycles saved below deck 757 757 673 589 505 421 337 252 168 84 0.0

Truck Fuel saved Chiloe Island 1022 1022 909 795 682 568 454 341 227 114 0.0

5. FUEL REDUCTION OF TOTAL

Sustainability- Green Port

Savings of QC fuel usage =

International: (773.96/8115.26)*100 = 9.54%

Domestic: (302.65/2157.85)*100 = 14.03%

(QC fuel saved/Total QC usage)*100

Savings of truck fuel usage =

International: (1022/11580)*100 = 8.83%.

Domestic: (81.7/847.8)*100 = 9.64% 

(Fuel saved /Total truck fuel usage)*100