As the tank container industry in Asia continues to evolve, the need for efficient turnaround times becomes paramount. In this article, we explore strategic approaches to optimize the turnaround times for tank container, emphasizing key aspects of planning, execution.

1. Understanding the Landscape: Asia comprises multiple countries with diverse regulatory frameworks governing tank container repairs. Each country may have its own set of standards and requirements, necessitating a thorough understanding of local regulations. like in India most of depot are locating to Nhava Sheva, Kandla and Hazira. but now industry is spreading to other cities also like Channai, West Bangal, Coachin, Manglore, Visakhapayanam. there are so many depots in India some have good infastructure and some are still in developing stage. but all depot need to follow the same regulation stipulated by the ITCO and local authority.

TOP 7 Seaport in India:

• The biggest port in India, Mundra Port (INMUN), Gujarat
• Deendayal Port / Kandla Port (INIXY), Gujarat
• Paradip Port (INPRT), Odisha
• Jawaharlal Nehru Port/Nhava Sheva (INNSA), Maharashtra
• Haldia Port (INHAL), West Bengal
• Visakhapatnam Port (INVTZ), Andhra Pradesh
• Mumbai Port (INBOM), Maharashtra

same we have multiple depot in North and South Asia. Each country may have its own set of standards and requirements, necessitating a thorough understanding of local regulations.

Top Port In Asia.

• MYPKG – Port Klang (Malaysia)
• HKHKG – Port of Hong Kong (Hong Kong)
• CNTXG – Port of Tianjin (China)
• KRPUS – Port of Busan (South Korea)
• CNGZG – Port of Guangzhou (China)
• CNQDG – Port of Qingdao (China)
• CNSZX – Port of Shenzhen (China)
• CNNBG/CNZOS – Port of Ningbo-Zhoushan (China)
• SGSIN – Port of Singapore (Singapore)
• CNSHG – Port of Shanghai (China)

Asian depots have a skilled workforce to handle day-to-day activities. They are more practical and are always ready to support tank container operators in all situations, prioritizing relationships and a realistic approach over just making money. Whether it is in India, South Asia, or North Asia, depots in these regions are known for their supportiveness towards tank container operators. This is why many operators choose to move their tanks to this region for satisfactory and cost-effective repairs with quick turnaround times.

In terms of technology, this region is still in the process of development. Most depots still use manual cleaning procedures/systems, such as spray guns, instead of automated systems like Groninger. However, many depots are now investing in automated cleaning systems as they are safer, time-saving, and lead to quicker turnaround times for tanks. With this system, depots can program the PLC (Programmable Logic Controller) with different cleaning settings and simply select the corresponding number once the spinner is inserted, eliminating the need for manual programming each time. The pressure from the spinner, which depends on the pump being used, typically ranges from 100 to 150 bar. For the latex machine, also known as the circulation machine, the pressure varies from 200 to 250 bar. This pressure is crucial for efficiently and quickly cleaning the tank. However, many depots still use lower pressures, like 50 bar, which are not efficient for cleaning tanks, especially those with oil additives and hard cargo.

Optimizing Tank Container Maintenance Amidst Overload Challenges in Asia: All tank operators are relocating their tanks to the Asian market due to the growing chemical sector in China and India. The Asian market offers advantages such as numerous depots, low labor and material costs, especially for steel. This is why many tank operators are moving their tanks to Asia for affordable repairs. However, are the depots prepared to handle this increased workload? Most depots were not prepared for this overwhelming situation, resulting in lot of pending tanks for cleaning/repair/testing. This is negatively impacting the turnaround time for cleaning, repairs, and testing of the tanks, as well as the overall business. The tanks are not being prepared on time because all the operators are rushing to the depots to make their tanks available for them.

The Impact: Delays and Operational Disruptions: This surge in demand has resulted in delays in turnaround times, affecting operational efficiency for both tank operators and depots. The current situation calls for a collaborative approach to find sustainable solutions that ensure seamless operations and timely services for all.

The cost of overload: there is always additional cost for oveload of any organization and system.

• Delayed Services: Overloaded depots may struggle to handle the volume of tank containers efficiently, leading to delays in various services such as cleaning, repairs, and inspections. Tank operators may experience extended turnaround times for their containers.
• Increased Costs: Delays and inefficiencies in overloaded depots can result in increased operational costs for tank operators. Extended detention times, demurrage charges, and additional expenses for expedited services may contribute to higher overall costs.
• Resource Strain: Overloaded depots may face resource shortages, including a lack of skilled labor, equipment, and space. This strain can further contribute to delays and impact the quality of services provided.
• Limited Availability: Overloaded depots may have limited availability for new bookings or emergency services. Tank operators may find it challenging to secure prompt service slots, especially during peak periods.
• Quality Concerns: The rush to handle a large number of tank containers may compromise the quality of services provided. This could lead to inadequate cleaning, inspection oversights, or subpar repair work, posing potential risks during subsequent cargo transport.
• Customer Dissatisfaction: Longer turnaround times, increased costs, and potential service quality issues can result in customer dissatisfaction. Tank operators may face challenges in meeting customer expectations and maintaining positive relationships.
• Regulatory Compliance Risks: Overloaded depots may struggle to adhere to regulatory requirements, increasing the risk of non-compliance. This could have legal implications for tank operators if their containers are not processed in accordance with industry standards and regulations.

Proposed Solutions: Collaboration and Innovation: The dynamic work design to confronting overload.

To better understand the contrast between old and new technology, let’s take a look at an example of old and new GPS systems. The main difference lies in the advancement of technology and the inclusion of real-time data, which allows new GPS systems to display traffic jams and accidents. Here are a few important points to consider:

Real-Time Traffic Updates:

• Old GPS: Traditional GPS systems relied on pre-loaded maps and did not have the capability to provide real-time information about traffic conditions.New GPS:Modern GPS systems are often connected to the internet, allowing them to receive real-time updates about traffic situations, including accidents, road closures, and traffic jams.

New GPS systems have a significant advantage as they can offer real-time, dynamic, and interactive navigation experiences. This is made possible by their ability to connect to the internet, utilize user-generated data, and take advantage of advancements in mapping technologies. Similarly, depots can also benefit from modern technology by displaying visual representations of real-time data on tank movement, from the entry gate to the exit gate.

Distributed Load Balancing:To avoid overloading specific depots, you can try implementing load distribution strategies. By redirecting tanks to depots that still have available capacity, we can optimize resource utilization and minimize bottlenecks. To do this, it is important to have a visual management process in place. Create a list of all depots in the region and mark the ones that are already full in red, while marking the ones that can still accept tanks in green. Contact the depots marked in green to arrange for tank acceptance. Without a list of depots in your region, managing the situation becomes more challenging. This approach is known as visual management.

Capacity Expansion:Encourage depots to explore expansion opportunities or invest in scaling their capacity to meet the growing demand. This may involve improving infrastructure, adopting new technology, and enhancing operations. The government should also support investors who plan to open new depots by simplifying the process and providing loan facilities if necessary. This will motivate the younger generation to easily open new depots and distribute the workload. If a depot does not accept tanks in a country, it becomes an additional cost for the operator who needs to transport the tanks to another country, incurring repo and handling costs.

Yard Capacity Expansion: In South Asia, the government regulations now do not allow most depots to stack empty tanks more than three high. However, this reduces the depot’s capacity to store tanks. To maximize space, depots should be allowed to stack tanks at the maximum height. However, this depends on whether the depot’s equipment is capable of stacking tanks at five or six high. If depots are currently allowed to stack at three high but are permitted to stack at six high, it will double the capacity. Before making any decisions, the safety team should conduct a risk assessment for these changes. If the assessment is positive, then it is fine to implement the changes. This decision will definitely make more room in the yard.

Wash Bay Performance Expansion: The wash bay is essential for any cleaning depot because you cannot perform further service on a tank without cleaning it. It is a good idea to review the depot’s working process and make necessary changes to achieve the maximum number of cleans per day. If you cannot install more spinners or pumps, consider how you can increase the number of cleans in the wash bay with the available resources. If you are using a trolley to move tanks into the wash, it would be beneficial to fabricate more trolleys so that you can keep dirty tanks in advance outside of the wash bay. Once cleaning is done, remove the cleaned tank and immediately move the dirty tank into the wash bay. This will allow the spinner to keep moving each time. As a general rule, the spinner should be working at all times. If not all wash bay spinners are working simultaneously, it is a good idea to prepare another tank for cleaning while cleaning the tanks. This way, you can put the spinner in immediately once cleaning is done.

• Seperate space for internal inspection after cleaning: It is recommended to use a separate space for internal tank checks after cleaning. If you only use the wash bay for inspections, it will cause delays in cleaning other tanks. Inspecting one tank takes an average of 15-20 minutes. So, if you inspect tanks in the wash bay, it will affect the wash bay’s performance. Easy cleaning can be done within 15-20 minutes. If you clean 20 tanks easily each day, it means you waste an average of 300 minutes inspecting tanks in the wash bay. If you inspect tanks in a separate space, it will increase the productivity of the wash bay and help reduce the load of dirty tanks.
• Cleaning Operator: It is advisable to consider hiring and training additional cleaning operators, especially if you plan to increase the capacity of the wash bay. Having more personnel in the wash bay will be necessary to handle tasks such as tank preparation, cleaning, and inspection. If you are unable to hire trained individuals, it would be beneficial to hire and train newcomers. Additionally, you can transfer employees from other departments according to your internal policy. Remember, cleaning operators play a crucial role in the tank container depot.

Cleaning pending list: It is crucial to share the daily cleaning pending data with the cleaning operators. This helps them understand the workload and the type of products that need cleaning. It is advisable to create a list of both easy and difficult cleaning tasks to ensure smooth movement of tanks in the wash bay. If all the hard cargo tanks are placed in the wash bay, it will block the bay and result in fewer clean tanks by the end of the day. For optimal performance, it is recommended to have two hard cargo tanks and two easy cargo tanks in each wash bay if there are four available.

Workshop performnace expansion: Workshop performance is also dependent on the number of people and equipment used to repair and test the tanks. If you are using a trailer to repair the tanks in the wash bay, it is advisable to keep the tanks outside of the workshop in advance. This way, you can immediately put the tank in the workshop once the repair is done, reducing the time it takes to pick the tank from the stack, place it on the trailer, and bring it to the workshop. This allows you to repair a maximum number of tanks. If a tank only requires minor repairs, you can keep it on the ground and repair it without using the tank rotator, as it takes more time to handle the tank in and out. Therefore, it is recommended to keep all minor damage tanks outside of the workshop (in a designated area) and repair all major damage tanks with the tank rotator. The advantages of using a tank rotator are listed below.

Tank Rotator: A tank container rotator in a workshop is a specialized equipment designed to rotate or turn tank containers during maintenance and repair operations. The use of a tank container rotator offers several benefits and applications in the workshop setting.The rotator allows technicians and maintenance personnel to access different parts of the tank container easily. By rotating the container, they can reach specific areas, such as the top, sides, or bottom, for inspection and repairs. During welding or fabrication work, the tank container rotator enables technicians to position the container optimally. This facilitates the welding process, ensuring proper joint integrity and minimizing the need for manual repositioning. For coating applications, such as painting or protective coatings, the rotator ensures a consistent and uniform application across all surfaces of the tank. This is crucial for corrosion prevention and maintaining the container’s structural integrity. Rotating the tank container allows for thorough testing and quality assurance checks. Technicians can inspect welds, check for leaks, and perform non-destructive testing methods more effectively as they rotate the container to different angles. When work at heights is required, such as on the top of the tank, the rotator provides a safer alternative. Instead of working from elevated platforms or ladders, technicians can rotate the tank to a convenient working height, reducing the risk of accidents. The use of a rotator streamlines the workflow in the workshop. Technicians can complete tasks more efficiently without the need for manually repositioning the container multiple times. This contributes to overall productivity and time savings.

Robogrind brings more precision, safety to tank pit grinding and polishing: RoboGrind is our latest addition designed to revolutionize the way we approach the critical tasks of grinding pitting and polishing stains on tank container surfaces. This state-of-the-art robotic system brings unparalleled precision and efficiency to our maintenance operations.

Key Advantages of RoboGrind:

1. Precision Engineering: RoboGrind’s advanced sensors and programming ensure precise targeting of pitting areas and accurate polishing of stains, minimizing the risk of over-grinding and preserving the integrity of the tank’s structure.
2. Time Efficiency: By automating the grinding and polishing processes, RoboGrind significantly reduces the time required for these critical tasks. This translates to faster turnaround times, allowing us to deliver your tanks promptly and with the highest quality.
3. Consistent Quality: RoboGrind maintains a consistent level of quality across all maintenance tasks. The robotic system follows predefined parameters, ensuring uniform results and reducing the likelihood of human error.
4. Enhanced Safety: With RoboGrind taking over intricate tasks, our maintenance team can focus on overseeing and managing the process, enhancing overall safety measures and reducing the risk of accidents.
5. Data Insights:The system provides valuable data insights into the condition of tank surfaces, allowing us to make informed decisions regarding the extent of repairs needed and contributing to proactive maintenance planning.

Workshop Technician: The workshop personnel plays a crucial role in repairing and testing tanks. After the tanks are repaired and tested, they become available and are moved to the yard for resting until their next journey. As the pending list for tank repairs and testing increases, it is important to consider hiring more trained technicians to expedite the work. If hiring externally is not possible, transferring personnel from other departments and providing them with training can be a viable option.

Digital Solutions for Transparency: Is it possible to view the current storage status of a depot in real-time? This would include information on the depot’s capacity and the number of available slots, allowing us to make informed decisions. Unfortunately, the depot currently only sends stock notifications, and if the depot is full, the operator is denied acceptance of tanks without prior notice. This sudden situation leaves the operator with little time to find an alternative depot. It would be beneficial if the depot could share real-time data on storage, cleaning, repair, and testing with all operators through a centralized system. This would promote transparency among operators and assist in making productive decisions.

This dashboard belongs to Lucrasoft software. You can easily share it with the tank operator to view the current tank cleaning/repair/testing data and make necessary decisions.

There is another software named DepotMan developed by Nadia Technology Hyderabad. It is a fully capable software that connects the depot dashboard with the tank operator to display the real-time workflow of tanks.

Efficient Execution: a. Streamlined Processes:

Efficient execution in tank container management involves the implementation of streamlined processes to eliminate bottlenecks and the adoption of lean principles to reduce unnecessary steps. Here are some key strategies to achieve this:

There are many steps to follow in the tank’s workflow as it moves from multiple points.

Conduct a thorough analysis of the entire tank container management process. Map out each step from the point of loading to unloading, including documentation, inspections, and maintenance.

Tank order is received for loading. The tank is picked up and taken to the loading plant for loading. After loading, the tank is taken to the port for customs and other documentation processes and is offloaded at the port. As per the booking, the tank is loaded onto the vessel. The vessel arrives at the destination country where it is offloaded and waits for collection from the consignee. The consignee collects the tank and unloads the cargo. The empty tank is then returned to the depot to rest and prepare for the next load. This marks the end of the cycle as the offloading is completed and the tank is delivered to the depot. There are multiple stages involved in this process, increasing the chances of delays, damages, incorrect documentation, wrong labeling, improper sealing, cleaning, repairs, transportation accidents, and incidents.

In order to ensure efficient execution, we must examine each cycle thoroughly and assess its performance. Are there any delays in a particular cycle? Is there a delay in documentation? Is there a delay in transportation? Is there a delay at the loading site? Is there a delay at the depot?

Identify whether the issues are related to inefficient workflows, lack of resources, or communication breakdowns.

Create and enforce well-defined and standardized operating procedures for every phase of the tank container lifecycle. These procedures will establish a consistent and effective approach. Develop comprehensive SOPs for each stage, starting from collecting empty tanks from the depot to returning dirty tanks back to the depot. It is beneficial to involve the team in preparing the SOPs since they handle these tasks on a daily basis. Once the SOPs are finalized, conduct a training program for all employees. In case of any errors, incidents, or accidents, provide a refresher training to the team to enhance their skills and awareness.

Implementing digital solutions for documentation, tracking, and communication can greatly minimize the need for manual work and decrease errors. By utilizing GPS installation on tank containers, we can easily determine the current location of the tank. With real-time GPS tracking, we can promptly notify the relevant parties if there are any delays in the tank’s journey, whether it be from the depot, transporter, loading site, or even the port.

It is crucial to have effective communication across departments for a fast tank turnaround. We must guarantee a seamless flow of communication between the maintenance team, operations, and commercial departments, as they are responsible for managing the tank’s journey from depot pickup to depot drop-off.

Embrace a culture of continuous improvement. Encourage teams to regularly review processes and suggest improvements. Implement the Kaizen philosophy to make incremental enhancements over time.

Define key performance indicators (KPIs) to measure the efficiency of tank container processes. Regularly track and analyze these metrics to identify areas for improvement.

Collaborate closely with suppliers, service providers, and partners to align processes and eliminate redundancies. Ensure seamless integration of activities between different stakeholders.

Collaboration with Stakeholders: a. Communication Protocols:

Effective communication helps streamline processes, minimize delays, and keep all stakeholders informed. Here are steps to establish clear communication protocols for a quick turnaround:

Identify all relevant stakeholders involved in the tank container turnaround process. This may include shippers, depots, regulatory bodies, logistics partners, and internal team members.

Make sure to share the SOP with these stakeholders in order to decrease the turnaround time. Especially with the depot, when making the agreement, make sure to provide clear instructions on what we want from them and the timeline. It is beneficial to share a specific timeline for cleaning, repairing, and testing. This will assist the depot in working proactively and ensuring the tanks are available quickly.

Determine the primary communication channels for different stakeholders. This could include email, phone calls, messaging apps, or a dedicated communication platform.

It is common to use email as an approved way of communication. However, we may not always check our email and there is a possibility of missing urgent emails, especially those related to incidents or accidents. Therefore, it is advisable to approve alternative communication channels such as WhatsApp, Zoom, or Teams for a quick response. Making a quick call is always better than sending multiple emails. To ensure effective communication, create detailed contact lists for each stakeholder category. Make sure the contact information is current and includes the relevant personnel who are responsible for making decisions.

various type of communication channels:-

It is beneficial to create a worldwide contact list for depots, shippers, and agents and make it available to all staff members. Whenever anyone requires information about a depot or shipper, it is advantageous to gather the details from this list. This practice facilitates quick communication with the relevant individuals and saves time that would otherwise be spent searching for information elsewhere.

Use tracking systems or software that allow stakeholders to monitor the progress of tank container repairs in real-time. This can enhance transparency and reduce the need for manual updates.

Create a unique tank container management software that includes live tracking capabilities. This software will serve as a centralized platform for overseeing repair and cleaning tasks. Both depots and operators can utilize the same software to record every tank activity from entry to exit. By eliminating the need for email, this software allows for seamless updates on gate in, cleaning, estimates, picture approvals, and gate out information. Operators can access this information in real-time.

If the tank container needs to be transported between locations, consider using GPS tracking technology. This allows you to monitor the container’s location in real-time during transit.

Incorporate sensor technology within the tank container to monitor various parameters, such as temperature, pressure, or cleanliness, clear picture of location ETA at depot. Sensors can automatically transmit data in real-time to a central system.

Some operators are already using GPS to install on tank containers in order to determine the exact location of the tank and the temperature of the product. The GPS provides real-time data to the operator and keeps a record in case it is needed as evidence.

Is there a sensor that can detect real-time cleaning, repair, temperature, or location?

Currently, operators are solely relying on GPS to determine the location and temperature of the tank. However, there is no sensor available to provide information about cleaning/repair status.

That’s why we can utilize mobile apps that offer live updates to operators. This enables them to keep track of incoming tank containers and organize their tasks accordingly.

Field personnel are provided with tablet apps that enable them to update the status of gate in/cleaning/repair/testing in real time. The tablet app should also include the tank operator for integration. These updates are immediately shown in the central system.

4. Real Time Data update(Mobile Appication) : In the previous method, the inspector would carry the inspection checklist and camera to inspect the tank once it entered the gate. They would then send the pictures to the desktop and make a copy of the gate in checklist to hand over to the driver. If an average of 30 tanks enter daily, this would result in approximately 20 pictures per tank if no damage was found. Therefore, if 30 tanks enter daily, it would require sending 600 pictures to the desktop and then to the customer. This process consumes a significant amount of time for depot personnel. The same applies to estimates. If you are generating an average of 30 estimates per day for external purposes only, you are essentially repeating the same process. This involves sending pictures to the desktop and preparing the estimate, which leads to a considerable waste of time for data entry and document uploading.

Modern Depot Digital M&R Process:

Once a tank arrives at the gate depot, the security personnel will input the tank’s information into the tablet and take external pictures. At the same time, the tank operator will also be notified that the tank has entered the gate and can view the gate-in pictures. During the gate-in process, the operator will be able to determine if the tank has any major damage and raise a claim accordingly.

If there is major damage, the operator can request a port EIR from the driver for claim purposes. After this, the tank will be moved to the inspection area where an inspector, equipped with another tablet, will have already received the information about the tank’s entry from the security guard. However, the security guard only performed basic checks, so the inspector will conduct more thorough and technical inspections, update the information, and take pictures. Once the inspection is complete, the inspector will obtain a digital signature from the driver and sign it themselves, thereby releasing the trailer. The tank’s EIR and external pictures will also be reflected in the customer’s portal.

From here, the tank will be taken to the cleaning station for on-the-go cleaning. The cleaning station team will also have a tablet and upon the tank’s entry into the wash bay, they will input the tank number and access all the details about the previous cargo, cleaning procedure, and safety precautions. Based on this information, the wash bay team will select the appropriate program from the Groninger PLC and commence the cleaning process( in case depot is using automated system).

Simultaneously, this information will be updated in the customer’s data, indicating that the tank is currently being washed. Once the washing is completed, a surveyor will conduct an internal inspection and close the cleaning process in the system. At this time, the customer will also be notified that the cleaning has been finished. The real-time information regarding gate-in and cleaning will enable the operator to take necessary actions promptly.

If the tank has a package deal, it will be transported to the workshop for a leak test and gasket replacement. Similarly, the workshop team will also use a tablet to update the system. Once the tank is received, the leak test and gasket replacement will be carried out. After the leak test, gasket replacement, and technical inspection are completed, the tank will be moved to the yard and the estimator will send an estimate to the customer. The tablet is directly connected to the desktop, where the estimator can view the details filled out by the surveyor. Based on the damage and pictures, the estimator will prepare the estimate and share it with the customer. Once the approval is obtained, the estimator will share it with the workshop team and the reach stacker operator through the tablet function. The workshop team will then inform the RS guy to bring the tank to the workshop for repair.

Upon receiving the tank, the workshop team proceeds to input the tank number into the system and access the estimate to review the approved repairs and indicate the tank’s status as “under repair.” Once the repair is completed, the workshop team conducts a quality check, captures post-repair pictures, and finalizes the repair process. Consequently, the tank is marked as “available” (AV) in the system. Simultaneously, the operator is notified of the repair completion and can access the post-repair pictures, eliminating the need for multiple reminders to the depot for picture sharing.

In the traditional approach, the depot used to capture images on a mobile or camera and then transfer them to a desktop in order to send them to operators. However, with the advanced system, this process is eliminated as images can be sent directly from a tablet in real-time.

Set up automated alerts and notifications to inform relevant stakeholders when a specific stage of the repair or cleaning process is completed. This reduces the need for manual communication

Develop a user-friendly dashboard that provides a snapshot of the real-time status of all ongoing repair and cleaning activities. Stakeholders can quickly assess progress without delving into detailed reports.

Conclusion: Optimizing turnaround times for tank container repairs in Asia demands a holistic and collaborative approach. By combining strategic planning, efficient execution, and meaningful collaboration with stakeholders, the industry can not only reduce downtime but also enhance overall operational resilience. As the region continues to play a pivotal role in global trade, these optimization strategies will contribute to the sustainability and growth of the tank container sector in Asia.