The Role of Virtual Terminals in Optimising Terminal Processes. Holger Schuett ISL Applications GmbH

Transcription

1 The Role of Virtual Terminals in Optimising Terminal Processes Holger Schuett ISL Applications GmbH

2 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

3 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

4 ISL Applications GmbH Founded 2010 as ISL s commercial subsidiary Holger Schütt Horst-Dieter Kassl CEO, Prof. Dr.- Ing. CTO, Dipl.-Ing.. (R&D) Institute of Shipping Economics and Logistics founded 1954 private foundation suited in Bremen & Bremerhaven some 70 employees research based consultancy institute in maritime logistics

5 Terminal planning and optimisation Seasonality preplan. planning start-up operation

6 ViTO Virtual Terminal Optimisation Tool

7 Simulation tools: Terminal Planning and Optimisation

8 Optimisation and Simulation References (selected) APM Terminals ASEAN Terminals, Philippines Bejaia Mediterranean Terminal, Algeria Centerm Terminal, Vancouver, Canada Contship, La Spezia, Italy CSX, Jacksonville, USA DP World Terminal Antwerp, Europe DP World, Australia EUROGATE, Bremerhaven, Germany EUROGATE, Hamburg, Germany HHLA, Hamburg, Germany HPA Hamburg Port Authority, Germany HIT, Hong Kong JadeWeserPort, Germany Kalmar Industries, Finland CMSA, Manzanillo, Mexico MCT, Gioia Tauro, Italy MTL, Hong Kong Nhava Sheva Terminal, India Noell Crane Systems, Germany NTB, Bremerhaven, Germany P&O Headquarter, London, Europe Port of Odessa, Ukraine Port of Tacoma, USA PORTEK International Ltd., Singapore Ports America, North America Red Sea Gateway Terminal, Jeddah, UAE Sandwell Eng. Inc., Vancouver, Canada SCT, Southampton, U.K. SPIA, Columbia TecPlata ICTSI, Buenos Aires, Argentina TotalSoftBank, Korea TPT, Durban, South Africa TRP, Buenos Aires, Argentina VTE, Genoa, Italy Warsteiner Brewery, Germany

9 ISL Applications product strategy Marketing Software Products training, customising first model getting started supporting the start-up of new projects (e.g. Eurogate group and Sandwell) complete studies or black box models (including analyzing, optimizing, )

10 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

11 Terminal planning and optimisation Seasonality preplan. planning start-up operation

12 Capacity planning

13 Capacity planning What will be the result if an other vessel mix will arrive? What s the impact of vessel s accuracy? Terminal capacity : 2,85 MTEU pa What will be the result if QC s productivity decreases from 30 to 27 mv/h?...

14 Simulation cycle Simulation means the copy of a dynamic process in form of a model to get knowledge which can be applied to the real system.

15 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

16 Layout definition

17 Layout definition

18 Various layouts, which one is the best? Tandem lift cranes, truck/chassis and RTG

19 Various layouts, which one is the best? Dual hoist cranes, shuttle carrier, RMG

20 Various layouts, which one is the best? Straddle carrier 1o3

21 Animation

22 Case study Comparison of operation systems selected equipment use evaluation production centres costs... But what are the ecological impacts of the terminal? SC 1 over 3 RTG/TC RMG/AGV auto No. of STSCs No. of SCs 45 X X No. of TCs/AGVs X No.of RTGs/RMGs X STSC operation hours SC operation hours 5016 X X TC/AGV operation hours X RTG/RMG operation hours X aver. service time external trucks 20 min 8 min 4 min average service time DS1000 aver. moves/hr (total) aver. moves/hr per STSC average service time DS800 aver. moves/hr (total) aver. moves/hr per STSC average service time F120 aver. moves/hr (total) aver. moves/hr per STSC average service time F250 aver. moves/hr (total) aver. moves/hr per STSC total berth operation time The decision from an economical view is supported based on operational costs and investment costs per move [ ]

23 Use the results of simulation for economic aspects as well as for ecologic aspects productivity costs environment

24 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

25 TOS development challanges Central control instead of decentral intelligence Prevention of Collisions Direct handshake requires synchronisation Find the optimal sequence of working orders (OR methods) Terminal Operating Systems are getting more and more complex Within the first step the development of the IT for the fully automated Terminal in Altenwerder had cost 26 M (Interview with IT Director Michael Busch, Logistik Heute, 7-8/2004)

26 The main mission of CHESSCON VIRTUAL TERMINAL what you can do with CHESSCON Emulation: use your Terminal Operation System (TOS) use your software interfaces but use a Virtual Container Terminal TOS Real switch Virtual

27 Container Terminal Bremerhaven - CTB

28 CTB model

29 CTB emulation

30 TOS Start-Up: Time is Money Without emulation technology: going live demand analysis system design TOS development configuration on-site test Using emulation technology: demand analysis system design TOS development configuration build model virtual terminal test

31 JadeWeserPort, 28th November 2011 (no on-site-test available)

32 TecPlata, Argentina, (no on-site-test available)

33 TOS Start-Up: Time is Money Without emulation technology: going live demand analysis system design TOS development configuration on-site test going live Using emulation technology: demand analysis system design TOS development configuration on-site test build model virtual terminal test virtual terminal test Saved time = earned money

34 TOS Start-Up: Time is Money Without emulation technology: demand analysis system design TOS development configuration on-site test Using emulation technology: demand system analysis design TOS development configuration emulation toolboxes (Virtual Terminals) are available and time and costs are reduced dramatically on-site test build model virtual terminal test virtual terminal test

35 Greenfield terminal (N4)

36 CHESSCON Layout Importer

37 Greenfield terminal model (automatically imported)

38 Greenfield terminal 3D model

39 Greenfield terminal 3D model

40 Greenfield terminal 3D model

41 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

42 CHESSCON Virtual Terminal Emulation architecture online offline Device Communication Network Quay Emulator Equipment Emulator Gate Emulator 3D realtime animation Yard Emulator and more.. online offline 42

43 CHESSCON Virtual Terminal Message exchange between clients = XML Straddle Emulator Client 2 Client Device Communication Network See also: CHESSCON Virtual Terminal Interface Specification Emulation Manager Logger Realtime 3D Animation

44 Upgrading TOS NAVIS online NAVIS SPARCS N4 3.7 NAVIS N4 Device Communication Network offline Quay Emulator Equipment Emulator Gate Emulator 3D realtime animation Yard Emulator and more.. online offline

45 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

46 CICT (controlled by Sparcs 3.7)

47 CICT (controlled by Sparcs 3.7)

48 CHESSCON Layout Importer

49 CICT (controlled by Sparcs 3.7)

50 CICT (controlled by Sparcs 3.7)

51 Motivation for existing terminals Quay Crane Productivity: technical (100%) Achievable (80-90%) stowage plan Hatch cover m. Real P. (50-80%) Potential for optimisation increase no. of transport devices synchronise devices (TOS) decoupled handshake increase device utilisation (TOS) short distance algorithms (TOS) effective pre planning (yard and eqiupment) (TOS)

52 Example Vessel service with 4 cranes mv/h

53 Agenda ISL Applications GmbH Terminal Planning based on Simulation Planning phase 1 Capacity Planning phase 2 Layout and Equipment Holistic approach Terminal Start-Up secured by Virtual Terminals Greenfield: Start-Up phase Test the TOS Existing terminals: TOS upgrade Test the TOS Terminal Operation optimised by Virtual Terminals Operational phase Optimise Terminal processes and TOS parameters Operational phase Train your staff

54 Terminal productivity TOS Equipment Terminal productivity Process automation Terminal staff The first ALV of KMI

55 Vessel simulator train your control staff (as shipping lines do)

56 Become a grandmaster in terminal control train your control staff (as shipping lines do)

57 A smart example of simulation procedure

58 A smart example of simulation procedure 500 bx in, 500 bx out 3 cranes 80 bx in, 80 out 1 crane 3 TTU/STS 14 RTG 160 bx in 160 bx out 2 MTY handler

59 A smart example of simulation procedure

60 A smart example of simulation procedure low crane productivity

61 A smart example of simulation procedure Training exercise You are the shift planner: - achieve at least 25 mv/h on the first vessel as an average of all three cranes - To include the economical view to your planning task, the team with the lowest cost per container will win the competition (and the first price). high costs per move

62 A smart example of simulation procedure Training exercise You are the shift planner: - achieve at least 25 mv/h on the first vessel as an average of all three cranes - To include the economical view to your planning task, the team with the lowest cost per container will win the competition (and the first price). Results during training sessions Buenos Aires, August 2012 : 25.2 mv/h, 51,6 MU/bx Bremerhaven, November 2012 : 25.8 mv/h, 52,1 MU/bx

63 Conclusion Simulation/Emulation technology will support Expansion of existing terminals Start up of new terminal / TOS changes Testing functionality of the TOS Stress-tests for the TOS (before the terminal is available) Stress-tests for new equipment (without integration problems) Optimisation of terminals productivity (fine-tuning) Virtual Terminals are ready to be used by the terminal operator Are supporting the whole lifecycle of the terminal are available yet We open the black box with Virtual Terminals

64 ViTO Virtual Terminal Optimisation Tool