MANAGEMENT OF SUPPLY CHAIN RISKS ASSOCIATED WITH DISASTERS IN PETROCHEMICAL COMPLEXES Akira NAKAJIMA*, Kenji WATANABE** Graduate Student, Nagoya Institute of Technology* Professor, Nagoya Institute of Technology** ABSTRACT: In the Great East Japan Earthquake, several weaknesses of the supply chains were found. Although many companies had not suffered the direct damages of the earthquake, it fell into the disruptions of productions in response to the influences from the companies that played key roles in its supply chain. In this research, we assumed that it was required to build a business continuity management framework among the companies which constitute a supply chain in order to prepare for future disasters. Then, case analysis was executed on the petrochemical complex which suffered serious damages by Tsunami, liquefaction, a tank fire by the Great East Japan Earthquake. In the process of the analysis extraction of the problems at the time of the disaster in petrochemical complexes of Japan, visualization of a supply chain, and dynamic grasp were performed. At last, we proposed the goal of development the design of the measure considered to reduce the damages of supply chain for petrochemical complexes at the time of a disaster. KEYWORDS: Supply Chain Risk Management (SCRM), disaster prevention, Great East Japan Earthquake 1. INTRODUCTION 2. DISASTER CASE ANALYSIS IN THE In the Great East Japan Earthquake, we found the weaknesses of some The Maruzen Petrochemical Complex suffered petrochemical complexes in Japan. In this area, a lot serious damages in the Great East Japan Earthquake of companies produce basic materials that uses from and experienced a serious tank fire. This complex is automobile parts to daily needs, and the area is located in Chiba prefecture and a lot of chemical positioned Japanese products factories gathering around of this area. manufacturing. It is necessary to continue to supply Figure 1 shows the flow of supply chain in this and maintain the supply chain when emergency complex. And some X-marks are showed the arises. In this research, case analysis was executed facilities that stopped its production in the Great East on the petrochemical complexes which suffered Japan Earthquake. This shows the companies and serious damages in the Great East Japan Earthquake. products which accept materials were also affected And, we propose some measures to reduce the because suppliers suffered serious damages in as the a core HDPE EO offgas UBE-MARUZEN poryethylene acethylene DENKA supply LDPE Acetate bm Styrene monomer chains industry Ethylene glycol eabe VCM KEIYO monomer naphtha AGC ethylene EDC MARUZEN KUREHA APC Pc-ethylene JNC HDPE propylene JAPAN PP JNC CHIBA Butadiene B-B fraction polypropylene CG ester DOP octanol UBE Industries butanol butadiene UMG ABS DENKA S-butyl alcohol T-butyl alcohol ABSresin ABSresin MEK GOI Chemical KH Neo Chem C₅fraction benzene toluene xykene Fig.1 Supply Hi-dicyclopentadiene Petroleum resin HITACHI chemical JSR chain petrochemical complex way, we found a lot of supply chain disruptions. And, complex at the supply chain was stopped the whole of this complex. time of disaster. In another case, the Kashima Complex suffered isooctane diisobutylene tributylene Cracked petroleum petrochemical Butadiene rubber butylene MARUZEN consideration of tank fire in The Cosmo-Oil. In this Vinylidene chloride resin KEIYO ethylene ethylene damage for the polystyrene TOYO-st ABSresin Styrene-butadiene COSMO-OIL for for GREAT EAST JAPAN EARTHQUAKE POF isononanoate nonanol serious damages by Tsunami and also stopped their methyltetrahydrophthalic acid anhydride dicyclopentadiene JSR-kashima disruption in IR Maruzen supply chain. 3. MEASURES TO REDUCE THE DAMAGE 4. THE YOKKAICHI COMPLEX TO THE PETROCHEMICAL COMPLEXES The Yokkaichi Complex is suspected to suffer 3.1 Cooperation between companies in the serious damages by the Nankai Trough Earthquake petrochemical complexes which has the high potential to happen near Fig.2 shows the case of back-up solution in the Great Yokkaichi. So, in this study, we attempted to survey East Japan Earthquake in the Maruzen Complex. The about supply chain in the Yokkaichi Petrochemical Ube-Maruzen Polyethylene Co.,Ltd. and the UBE Complex. In this complex, supply chain consists of a Industries Co.,Ltd. were located same site and lot of chemical companies (Fig.4) like as the suffered damage from stopped supply. But it was Maruzen and the Kashima complex. In addition to different in the time of restart. The Ube-Maruzen the problem about supply chain disruption, this Polyethylene had an alternate supplier (Keiyo complex has problem of geographical aspect. This Ethylene,Ltd.). So, it was possible to procure factory area is located next to a residential area. So, ethylene and continue their operation. We speculate this complex have the risk of fire spread to it is available to reduce supply chain disruptions by residential area, mass evacuation include community means of alternate supply that accommodate people, and so on. MARUZEN Chemical materials each other companies in the complex. MITSUBISHI Chemical KH Neo Chem VCM ethylene oxide ethylene glycol ethylene oxide A ethanol acetaldehyde TAIYO Vinyl Alternative supplier KEIYO Ethylene COSMO-OIL ethylene A subsidiary of Maruzen No damage by the earthquake TOSOH ethylene SM UBE-MARUZEN Polyethylene MARUZEN Chemical butylaldehyde isobutylaldehyde cumene octanol PS J-Plus octylic acid KH Neo Chem propylene Required only a safety check B-B fraction DIC polyethylene 3/19~ Restart Operation (FULL) 3/11 stop 4/4~ restart PVC polyethylene (LDPE・ ・LLDPE) EVAC polyethylene (HDPE) ethylene naphtha acetone DOP Butyl-acetate GE Isobutyl-acetate butanol Iso-butanol MIBK DAA CHIBA Butadiene butadiene 4/5~ restart UBE Industries JAPAN PP butadiene rubber 3/19~ restart operation (small-scale) (because of supply problems) Synthetic gum B-B fraction 4/16~ Restart Operation (FULL) In the same site (UBE industries) No damage for facilities polypropylene butadiene JSR C₄₄ fraction raffinate Cracked petroleum Petroleum resin toluene xylene Techno Polymer TOSOH ABSresin CR TBA benzene Fig.2 Case of back up solution 3.2 Wide-area cooperation between complexes Fig.4 Supply chain map in Yokkaichi 5. CONCLUSION throughout Japan It is important to cooperate in the petrochemical complex, but it will be necessary to cooperate with complexes between separated areas at the time of widespread disaster happened. As petrochemical complexes are located around Japan (Fig.3). So, they may reduce the damage of supply chain disruption if they can achieve implementing the wide-area mutual cooperation and also lead to strengthened Japanese In this research, we attempted to visualize about the situation of supply chain disruption by analyzing petrochemical complexes which suffered damages in the Great East Japan Earthquake. So, we found the problems for concentration risk. In response, we propose some measures to make the chain more robust at the time of disaster. And, we attempted to find problems in Yokkaichi petrochemical complex. It will be necessary to consider about supply risk not petrochemical industry. only at a company but also at whole complexes. REFERENCES ･Japan Petrochemical Industry Association K a was a ki The epic enter of the Great East Japan Earthquak e Os ak a M izushim a S huna n Ka s him a Chiba Yok k aic hi Oita Fig.3 the 8 major petrochemical complexes in Japan URL: http://www.jpca.or.jp/ (Website References) ･Disaster prevention plan at petrochemical complex in Chiba Prefecture ,2010 (Journal Articles)
© Copyright 2024 ExpyDoc
