Minimization of waiting time in coal loading and unloading processes to reduce demurrage using value stream mapping

Authors

  • Apriani Sarempa Department of Industrial Engineering, Faculty of Industrial Technology, Universitas Trisakti, Jakarta 11440, Indonesia
  • Pudji Astuti Department of Industrial Engineering, Faculty of Industrial Technology, Universitas Trisakti, Jakarta 11440, Indonesia
  • Dadang Surjasa Department of Industrial Engineering, Faculty of Industrial Technology, Universitas Trisakti, Jakarta 11440, Indonesia

DOI:

https://doi.org/10.31315/opsi.v19i1.14346

Keywords:

Coal transhipment , Demurrage , Lean supply chain , Value stream mapping, Waste identification

Abstract

Demurrage issues pose a significant challenge that affects operational efficiency in the coal transportation industry, particularly in the  coal transhipment process using mother vessel and barges. This study aims to identify and reduce waiting times that cause demurrage. Waste identification leading to demurrage was conducted through a structured Value Stream Mapping (VSM) approach consisting of current-state mapping, waste identification and analysis, process activity mapping, and future-state mapping to develop improvement recommendations for coal loading and unloading operations. The results from the Port of Loading (POL) showed a significant improvement in operational efficiency after the proposed improvements were incorporated into the future-state process. Before the improvements, value-added activities contributed 28.20% of the total time and increased to 84.97%. The total loading time was reduced from 10.04 days to 3.17 days. At the Port of Discharge (POD), value-added activities increased from 47.27% to 77.24%, and the unloading time decreased from 14.58 days to 4.89 days. This improvement was achieved through better coordination, equipment maintenance, and optimization of the loading and unloading process, which significantly enhanced overall efficiency and reduced demurrage costs. This study highlights the importance of process optimization in the coal shipping industry, offering valuable insights to reduce delays and improve profitability.

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2026-07-30

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Vol. 19 No. 1 (2026): OPSI - June 2026

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