Productivity Improvement through Kaizen: Faster Crane Cycle Time

Situation

A container terminal observed significant variation in Ship-to-Shore (STS) crane performance during operations and between operators. This variation made it difficult to predict and control operations. Terminal leaders recognized that standardizing and improving STS crane cycle times could provide immediate gains in terminal capacity and reliability. To address this, they decided to organize a Kaizen event.

Approach

The Kaizen event was meticulously planned using the Standard Work lean methodology. A team comprising STS operators, supervisors, and Assent Maintenance functional experts was assembled. The event began with a short training session on the methodology, followed by detailed observations and measurements of cycle times for various container moves (on deck, below deck, portside, and seaside).

The team broke down the STS cycle into clear steps, each with critical points and safety guidelines. Extensive measurements and analysis of best practices were conducted, resulting in the creation of visual instructions for both discharge and load moves. By the end of the five-day event, the team documented the new process and developed a comprehensive roll-out plan.

Results

The Kaizen event delivered remarkable improvements:

• Cycle Time Reduction: Training and coaching an average STS operator on the new process led to an 10-15% improvement in cycle time, increasing terminal capacity and productivity.

• Enhanced Engagement: STS driver engagement significantly improved as they contributed to the best practice process creation. They found the performance measurement based on cycle time to be more accurate and fairer.

• Standardization: Standardizing cycle steps and times provided immediate gains in terminal capacity and reliability.

The Power of Kaizen

This example underscores the transformative power of the Kaizen approach. By leveraging the collective knowledge and expertise of team members, the terminal achieved substantial gains in efficiency and reliability. The Kaizen methodology not only improved operational performance but also fostered a collaborative and engaged workforce. Leadership involvement and change management are also key for the success.