© HPC Hamburg Port Consulting GmbH
Productivity and Performance in Automated TerminalsSession: Marine Terminal Productivity in the new Era of Automation
Dr.-Ing. Felix Kasiske, HPC Hamburg Port Consulting GmbH
TPM Conference Long Beach – March 03, 2013 to March 06, 2013
2
Agenda
Marine Terminal Productivity in the new Era of Automation
Era of Automation
Marine Terminal Productivity
© HPC Hamburg Port Consulting GmbH
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Automation changes Terminal Ops Paradigms
Marine Terminal Productivity in the new Era of Automation
© HPC Hamburg Port Consulting GmbH
Civil Structures
Terminal Equipment
Operations
Operating Layout
Con
vent
iona
l Ter
min
al P
lann
ing
Proc
ess
Civil Structures
Terminal Equipment
Operating Layout
Operations Aut
omat
ed T
erm
inal
Pla
nnin
g Pr
oces
sCivil Structures
Terminal Equipment
Operating Layout
Operations
Layout and Operations Validation
Aut
omat
ed T
erm
inal
Pla
nnin
g Pr
oces
s
Source ABB
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Automation changes Terminal Ops Paradigms
Marine Terminal Productivity in the new Era of Automation
© HPC Hamburg Port Consulting GmbH
Civil Structures
Terminal Equipment
Operations
Operating Layout
Con
vent
iona
l Ter
min
al P
lann
ing
Proc
ess
Civil Structures
Terminal Equipment
Operating Layout
Operations Aut
omat
ed T
erm
inal
Pla
nnin
g Pr
oces
sCivil Structures
Terminal Equipment
Operating Layout
Operations
Layout and Operations Validation
Aut
omat
ed T
erm
inal
Pla
nnin
g Pr
oces
s
From freely adaptable
To fixed configurations
From manual handling and decision making
To robotics and automated decisions
Automated Terminals are long term running Machines with inherent Processes!
Source HHLASource HHLA
Source HHLASource HHLA Source HHLA
Source HHLA
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Source HHLA
© HPC Hamburg Port Consulting GmbH
System Decisions
Marine Terminal Productivity in the new Era of Automation
All System Component Capacities must be balanced
All System Decisions determine a long term, difficult-to-change Investment
Source Gottwald
Source HHLA
single vs. twin 20?single vs. double 40? single trolley vs.
double trolley?
back reach handling vs. portal served?
semi-automated main trolley?
remote controlled
or automated truck handover?
connection to rail
terminal also
automated?Source Cargotec
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Scope of Automation and Trade-Offs
Marine Terminal Productivity in the new Era of Automation
© HPC Hamburg Port Consulting GmbH
Benefits
Cost Ability Investment cost Training cost M&R cost Cost of operations breakdown Opportunity cost for reduced flexibility
TOS capabilities Ability to integrate Complexity management Usability Safety and regulatory frameworks
Productivity and operating cost gains Quality improvement Process stabilisation and reliability Electrification and emission reduction Safety improvement Image gains
System Decisions Trade-Offs determine long term Capacity, Performance and Cost
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What is Terminal Productivity?
Marine Terminal Productivity in the new Era of Automation
© HPC Hamburg Port Consulting GmbH
Source HHLA
8© HPC Hamburg Port Consulting GmbH
Performance Demand Impacts on Terminal Design
Scenario 10/35:
10 quay cranes
Target gross productivity 35 mvs/h (totalling to 350 mvs/h peak)
waterside handling requirement: 26 ASC‘s
26 max 8-wide stacks
Scenario 9/30:
9 quay cranes
Target gross productivity 30 mvs/h (totalling to 270 mvs/h peak)
waterside handling requirement: 19 (20) ASC’s
20 max 10-wide stacks
Required Peak Performance determines Terminal Design
Marine Terminal Productivity in the new Era of Automation
9© HPC Hamburg Port Consulting GmbH
Performance Demand Impacts on Terminal Cost
Additional CapEx of 22,000 US$ + 34,000 US$ Operating Cost per utilized Berth Day
Marine Terminal Productivity in the new Era of Automation
Assumptions: Realistic footprint 35% berth utilization
CapEx:
Operating cost: increase at 4.35 mill US$ p.a.Capacity: decline by 0.02 mill TEU p.a.
Capital Cost unit cost (mill US$) No.
CapEx (mill US$) No.
CapEx (mill US$)
Difference (mill US$)
Difference (%)
Quay Cranes 11 9 99 10 110 11 111%Automated Stacking Cranes 3,2 40 128 52 166,4 38,4 130%Shuttle Carriers 0,65 37 24,05 41 26,65 2,6 111%Reach Stackers 0,5 2 1 2 1 0 100%Sets of RMG Rails 0,4 40 16 52 20,8 4,8 130%Reefer Racks 0,45 2 0,9 2 0,9 0 100%Transformer Substations 0,1 10 1 10 1 0 100%
269,95 326,75 56,8 121%
Scenario 9/30 Scenario 10/35
10© HPC Hamburg Port Consulting GmbH
CONTACT ADDRESS
HPC HAMBURG PORT CONSULTING GMBH
HPC Hamburg Port Consulting GmbH
Dr.-Ing. Felix Kasiske
CTA Container-Terminal Altenwerder
Am Ballinkai 1
D-21129 Hamburg
Germany
Phone: +49 40 74008 132
Fax: +49 40 74008 133
Marine Terminal Productivity in the new Era of Automation