The Role of Virtual Terminals in Optimising Terminal Processes Holger Schuett ISL Applications GmbH
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
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
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
Terminal planning and optimisation Seasonality preplan. planning start-up operation
ViTO Virtual Terminal Optimisation Tool
Simulation tools: Terminal Planning and Optimisation
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
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, )
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
Terminal planning and optimisation Seasonality preplan. planning start-up operation
Capacity planning
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?...
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.
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
Layout definition
Layout definition
Various layouts, which one is the best? Tandem lift cranes, truck/chassis and RTG
Various layouts, which one is the best? Dual hoist cranes, shuttle carrier, RMG
Various layouts, which one is the best? Straddle carrier 1o3
Animation
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 12 12 12 No. of SCs 45 X X No. of TCs/AGVs X 53 56 No.of RTGs/RMGs X 25 17 STSC operation hours 1130 1074 1057 SC operation hours 5016 X X TC/AGV operation hours X 5683 5300 RTG/RMG operation hours X 3141 2737 aver. service time external trucks 20 min 8 min 4 min average service time 13.6 12 11.7 DS1000 aver. moves/hr (total) 147.0 167.0 171.0 aver. moves/hr per STSC 29.5 32.3 33.4 average service time 12.5 10.5 10.1 DS800 aver. moves/hr (total) 128.0 152.0 158.0 aver. moves/hr per STSC 29.3 31.5 32.9 average service time 4.5 4.3 4.1 F120 aver. moves/hr (total) 53.0 56.0 59.0 aver. moves/hr per STSC 21.3 21.6 22.83 average service time 8.8 8.0 7.8 F250 aver. moves/hr (total) 57.0 62.33 64.0 aver. moves/hr per STSC 20.4 21.5 22.6 total berth operation time 218.0 195.0 189.0 The decision from an economical view is supported based on operational costs and investment costs per move [ ] 143.36 157.44 132.76 22
Use the results of simulation for economic aspects as well as for ecologic aspects productivity costs environment
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
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)
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
Container Terminal Bremerhaven - CTB
CTB model
CTB emulation
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
JadeWeserPort, 28th November 2011 (no on-site-test available)
TecPlata, Argentina, 4.7.2012 (no on-site-test available)
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
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
Greenfield terminal (N4)
CHESSCON Layout Importer
Greenfield terminal model (automatically imported)
Greenfield terminal 3D model
Greenfield terminal 3D model
Greenfield terminal 3D model
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
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
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
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
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
CICT (controlled by Sparcs 3.7)
CICT (controlled by Sparcs 3.7)
CHESSCON Layout Importer
CICT (controlled by Sparcs 3.7)
CICT (controlled by Sparcs 3.7)
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)
Example Vessel service with 4 cranes mv/h 30 28 26 24 22 20
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
Terminal productivity TOS Equipment Terminal productivity Process automation Terminal staff The first ALV of KMI
Vessel simulator train your control staff (as shipping lines do)
Become a grandmaster in terminal control train your control staff (as shipping lines do)
A smart example of simulation procedure
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
A smart example of simulation procedure
A smart example of simulation procedure low crane productivity
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
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
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
ViTO Virtual Terminal Optimisation Tool