00/2015

Innovative Modelling Techniques

& Operational Improvements Henk Bester, Managing Director Rail

Christelle du Toit, Simulation Engineer

2

00/2015

Introduction

Agenda

• Background

• The Problem

• The Solution

–Data Analysis & Simulation

• Operational Improvements

• Rail Operation Philosophy

• The Before and After

• Important Points to Take Home

Operational improvements to increase capacity

Innovative modelling to test rail operation philosophy

3

00/2015

The End Result

4

00/2015

Volume

40%

Performance

Increase

5

00/2015

Road to End Result

Challenge the way people think

Rail but one element of bigger system

Sustainable actions

Do not compromise safety

Minor infrastructure changes

6

00/2015

Impact of thorough data analysis

Simulation as debottlenecking tool

Simulation to drive performance

initiatives

Benefits of

run-when-ready

Key Concepts

Specific Takeaways From This

Presentation

7

00/2015

Background

8

00/2015

MINE

MAINLINE

Shiploaders

Transhipment

Train

Loading

Train

Dumpers

TERMINAL

Stackers

Reclaimer

FEL

200 km

Dedicated

9

00/2015

The Problem

10

00/2015

Forecast export

volumes not being

achieved

Cash flow

constraints

11

00/2015

The Solution

12

00/2015

Data Capturing

Re-design

Identify

Gather

Improve

13

00/2015

Data Analysis

• Scatter

• Inconsistent operations

• Breakdowns

• Dumper congestion

• Dumper 1 can only service light wagons

• Long waiting times

• Low stockyard utilisation

• 50% simultaneous loading

14

00/2015

Simulation Study

Mine (G2) • Production profile

• Train loading

• Rail yard interface

Rail Line (RTC) • Operation

• Train config

• Infrastructure

• Rolling stock

• Maintenance

• Rail system

performance

Port & Marine (G2) • Rail yard

• Train offloading

• Stockpiling

• Reclaiming

• Shiploading

• Berth occupancy

15

00/2015

Simulation Study

Gather Info

Develop Validate Scenarios Results

De-bottlenecking

16

00/2015

Findings

Bottleneck

17

00/2015

Findings

Simultaneous

Use

18

00/2015

Findings

Additional

Conveyor

19

00/2015

Operational Improvement

Rail

Port

Effective

stockyard

utilisation

Predictable

performance

Isolate

disruptions

Operate

consistently

20

00/2015

Operational Improvement

Planned

maintenance

Reduce

turnaround time

Seasonal

constraints Plan ahead

Sustainable

targets

21

00/2015

Operational Improvement

Train splitting

Rolling stock maintenance

Pre departure activities

Long and short

trains

Minor structural

upgrades

Yard

process

Revise &

minimise

Choose

22

00/2015

Minor Infrastructure Improvement

Minor layout changes

Simultaneous entry

Loop extension

Re-design

of chutes

Priority from

data

23

00/2015

Rail Operation Philosophy

24

00/2015

SLOT SYSTEM

READY

RUN-WHEN-READY

• Fixed schedule

• Fixed departure

• Less coordination

• Wait for slot

• No schedule

• Depart when ready

• Active coordination

• No waiting

vs

Compare Philosophies

Train loading + main line crossings + train offloading + port interface

25

00/2015

The Simulation Challenge

Train Loading

Train Unloading

Terminal

Shiploading

Transhipment

Mainline

26

00/2015

“DON’T RUN AWAY

FROM CHALLENGES

RUN OVER THEM”

~Nike

27

00/2015

Innovative Modelling Screenshot of model train diagram

Screenshot of train animation

Train Crossings

Maintenance

28

00/2015

Configuring the Slot System

Train Diagram

Good Timing

Short Delay

Long Delay

29

00/2015

No Slot Offset

12:00

30

00/2015

No Slot Offset

12:15

31

00/2015

No Slot Offset

12:30

32

00/2015

No Slot Offset

12:45

33

00/2015

No Slot Offset

13:00

34

00/2015

No Slot Offset

13:15

35

00/2015

No Slot Offset

13:30

36

00/2015

Slot Offset

12:00

37

00/2015

Slot Offset

12:15

38

00/2015

Slot Offset

12:30

39

00/2015

Slot Offset

12:45

40

00/2015

Slot Offset

13:00

41

00/2015

Slot Offset

13:15

42

00/2015

Slot Offset

13:30

43

00/2015

Optimising the Slot Offset

44

00/2015

Run-When-Ready vs. Slot System

8%

45

00/2015

Run-When-Ready vs. Slot System

Increase in waiting

for slot time

Decrease in queuing

and crossing delays

46

00/2015

The Before and After

47

00/2015

$75

$85

$95

$105

$115

$125

$135

$145

$155

$165

$175

Gross Income

Average (Jan - Oct)

Average (Nov - Apr)

Iron ore price (62% benchmark)

Gross Income Increase

Project

Start

Average

Insufficient supply of

OGVs

28 day month

Average

Sales increased by $20.2M per month on

average from November

Note: Prices for

Iron Ore have fallen

and price of freight

have risen

48

00/2015

Before

Project

Start

Scatter

49

00/2015

After

Project

Start

Scatter

50

00/2015

Before

Project

Start Scatter

51

00/2015

After

Project

Start Scatter

52

00/2015

53

00/2015

Dump Rate Investigation

No correlation

Yard equipment destination

Grades being offloaded

Night or day shift

Number of routes

54

00/2015

Dump Rate Investigation

55

00/2015

Before

56

00/2015

After

Less

Scatter

GLR

+500t/h

57

00/2015

Impact of Scatter

58

00/2015

Impact of Scatter

59

00/2015

Impact of Scatter

60

00/2015

Impact of Scatter

+15%

61

00/2015

Important Points to Take

Home

62

00/2015

Proper data analysis is key

Strive for consistency

Identify bottlenecks using simulation

Set sustainable targets for operators

Do preventative maintenance

Focus on operational improvement first

63

00/2015

Run-when-ready can have significant benefits on a dedicated rail line

Each operation is unique. The rail operations philosophy should be determined

through analysis and testing

Dynamic simulation is a good tool to uncover inefficiencies and test operational

philosophies before implementation

64

00/2015

65

00/2015

For more

information,

please visit

www.hatch.ca