A comprehensive qualitative and quantitative assessment of harvesting and other sugarcane supply chain disruptions within the Eston Mill supply area.
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Date
2014
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Abstract
The Eston Mill, which was established in 1994, is the newest in the KwaZulu-Natal sugar
belt. Like for most other mills, it can be argued that there are inefficiencies in the supply
chain due to systemic issues, which reduce optimum performance. The literature study
involved a review of the factors which cause inconsistencies in sugarcane supply chains
and the strategies implemented for improvement. This research study involved five main
aims. First, a novice qualitative diagnostic analysis of the Eston sugarcane system, to
identify a range of systemic issues and one pertinent problem, involving pay-weekends and
subsequent labour absenteeism, was isolated for further investigation. This was conducted
through explorative interviews and network analysis approaches. Secondly, based on the
information from the diagnostic analysis, a model that predicts and quantifies the factors
which influence daily crush rate disruptions at Eston, was developed, validated and
verified. Thirdly, the extent of the pay-weekend problem area was systematically estimated
in terms of frequency, variability and predictability. Fourthly, the cost of cutter
absenteeism was conservatively quantified, based on two factors, namely, sugar recovery
and mill operational costs. Lastly, a case study was carried out, which involved the
feasibility of a mechanical harvesting system, to mitigate the impacts of labour
absenteeism. The model involved the calibration of parameters for mill maintenance and
operational stops, rainfall events and days in the week when slow crush rates occurred. The
model captures approximately 64% of the variation observed in daily crush rates.
Subsequent to the development of the model, additional cane supply disruptions, caused by
cutter absenteeism, were also investigated. It was statistically verified that a significantly
detectable degree of labour absenteeism occurs immediately after pay-weekends. There has
been a general increased trend in cutter absenteeism from about 2007 until 2010. An
economic analysis estimated the costs associated with cutter absenteeism to be
approximately R1.3 million per season, for the Eston region. The alternative harvesting
system case-study solution, was found to be risky. However, acquiring second-hand
equipment, which was available on the market, is estimated to make the solution more
feasible. Based on a literature search, this research is considered to be the most
comprehensive analyses of sugarcane supply consistency at mill-scale worldwide. The
model developed can be utilized to critically evaluate different sugarcane milling areas and
could potentially make significant contributions to commercial sugarcane operations. The effectiveness of the model is dependent on usage in other milling areas, as well as other
industries. In addition, the specific labour absenteeism coefficients for each season can
possibly be investigated using other industries as well.
Description
Ph. D. University of KwaZulu-Natal, Pietermaritzburg 2014.
Keywords
Sugarcane--Harvesting--South Africa--KwaZulu-Natal., Sugarcane industry--South Africa--KwaZulu-Natal., Sugarcane industry--Risk management--South Africa--KwaZulu-Natal., Sugarcane--Milling--South Africa--KwaZulu-Natal., Absenteeism (Labor)--South Africa--KwaZulu-Natal., Theses--Agricultural engineering.