An Integrated Lean-Informed Simulation Framework for Evaluating Break-Bulk Vessel Service Times

Break-bulk cargo operations are characterized by high variability and complex resource synchronization, yet they have received limited research attention compared to containerized logistics. This paper proposes an integrated lean-informed simulation framework for evaluating vessel service time (VST) in multipurpose terminals handling break-bulk cargo. The framework sequences three analytical stages: Value Stream Mapping paired with Ohno’s waste taxonomy to diagnose non-value-adding activities, a discrete-event simulation model built in Simio to quantify their impact on VST, and Sobol sensitivity analysis to decompose the remaining variability across operational factors. Demonstrated at DP World Lirquén, a multipurpose terminal in Chile, the lean diagnostic identified 101 min of waste per cycle across waiting, motion, and overproduction categories. Scenario evaluation showed that eliminating shift-transition delays and standardizing load composition reduced VST by 14.3% and 10.6%, respectively, without capital investment. The sensitivity decomposition revealed that warehouse machinery composition, particularly the interaction between equipment types, dominates VST variability, while truck fleet size operates as an independent factor. These findings demonstrate that coordination-related policy interventions outperform incremental resource additions. More specifically, machinery allocation must be optimized jointly rather than by equipment type in isolation.