container terminal automation experiences & lessons learnt€¦ · automation: experiences...
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State of the Art October 2015 Bob Histon AAPA Facilities Engineering Conference Regional Director San Diego TBA North America
Container terminal automation Experiences & lessons learnt
© TBA 2015 / Bob Histon
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Contents
Automation: Experiences & Lessons learnt / (c) TBA 2
1. Types of automation – Process Automation – Automated Decision-making – Robotization
2. The business case for automation
3. The latest automated terminals reviewed – APMT MV2 – RWG – LBCT
4. Optimizing container terminal automation: – Selection of horizontal transportation system
– Lift AGV vs. AGV vs. Automated Shuttle Carrier – Selection of yard stacking system
– ARMG vs. CRMG vs. ARTG
5. Experiences & lessons learnt
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Automation today
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Automation globally
Automation: Experiences & Lessons learnt / (c) TBA
Abu Dhabi Algeciras Antwerp Barcelona Brisbane Dubai Hamburg (2) Kaohsiung Lazaro London (2) LA / LB (2) Nagoya New York Pusan (4) Rotterdam (4) Sydney Tokyo Norfolk Semarang Surabaya
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Types of automation
5 Automation: Experiences & Lessons learnt / (c) TBA
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Return on investment “Auto technology”
Automation: Experiences & Lessons learnt / (c) TBA
Data for 1M TEU terminal
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Process Automation & Automated decision making
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Process Automation: Gate operations
1. Truck appointment, including container number
3. OCR read + known appointments >99.9% quality
4. X-ray / radiation scan 5. Pedestal for driver ID + ticket
2. LPR + OCR
6. Routing advise
Automation: Experiences & Lessons learnt / (c) TBA 8
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Process automation
TOS
Location of Prime Mover
Location of RTG
Location of container
Container weight
Location of road truck
Automation: Experiences & Lessons learnt / (c) TBA 9
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Automated decision making
Automated vehicle dispatching (using Prime Route)
Automation: Experiences & Lessons learnt / (c) TBA
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Automated decision making
Automation: Experiences & Lessons learnt / (c) TBA 11
Automated stow planning of vessels, based on optimizing the #rehandles, and well as
the flow to the QC
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Automated decision making
Automation: Experiences & Lessons learnt / (c) TBA 12
Automated container decking (position assignment) based on algorithms & parameters
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Building a business case for automated terminals
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Building blocks for automation business case
Automation: Experiences & Lessons learnt / (c) TBA 14
FINANCIALS
OPERATIONS
ENVIRONMENT
SAFETY
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Financial business case
Automation: Experiences & Lessons learnt / (c) TBA 15
Reduced labour deployment
Less unproductive time
Less training costs Less wear & tear
Between -40 and -60% ops labour
Between -10 and -20% time for shift changes
and breaks
Between -10 and -25% less M&R costs due to damages and abuse
Between -20 and -50% lower training costs
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Example: CAPEX increase versus OPEX reduction High labour cost level (75 USD / h)
Automation: Experiences & Lessons learnt / (c) TBA 16
Reference manning level: 0.60 - 0.70 man hour /
container
Reference manning level: 0.20 - 0.30 man hour /
container
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Example: OPEX High labour cost level (75 USD / h)
Automation: Experiences & Lessons learnt / (c) TBA 17
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Example: CAPEX increase versus OPEX reduction Medium labour cost level (40 USD / h)
Automation: Experiences & Lessons learnt / (c) TBA 18
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Operational business case
Automation: Experiences & Lessons learnt / (c) TBA 19
Continuity Control Consistency
Predictability Information availability
Tracking & tracing No loss of containers Saving: TBD
10 – 20% increase in vessel operating time
5 - 10% increase in productivity
Increase service level to customer: TBD
Less slack time in berth schedules more
capacity (10% or more)
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Environmental business case
Automation: Experiences & Lessons learnt / (c) TBA 20
Less noise (smooth operation)
Less noise (no diesel engines)
Less lighting Electrical equipment (no emissions)
Performance dependent behaviour
5 - 15% less energy consumption
100% cut in local emissions
-25% reduction in sound levels
-25% - 75% reduction lux levels
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System consumption comparison
Automation: Experiences & Lessons learnt / (c) TBA
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Safety business case
Automation: Experiences & Lessons learnt / (c) TBA 22
Predictable equipment behaviour
Programmed safety features
Systems rather than humans in control No people on the ground
Extra measures in hazardous areas
99% reduction of errors 70 - 80% reduction of # people exposed
Double safety systems Reduction of risks
99% reduction of errors
Double safety systems Reduction of risks
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Summary of building blocks for automation case
Automation: Experiences & Lessons learnt / (c) TBA 23
Reduced labour deployment
Less unproductive time
Less training costs Less wear & tear
Continuity
Control Consistency
Predictability Information availability
Tracking & tracing
Less noise (smooth operation)
Less noise (no diesel engines)
No lighting Electrical equipment (no emissions)
Performance dependent behaviour
Predictable equipment behaviour
Programmed safety features
Systems rather than humans in control
No people on the ground
Extra measures in hazardous areas
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The latest terminals reviewed
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State-of-the-art in terminal automation: HPH Euromax(2008)
Automation: Experiences & Lessons learnt / (c) TBA 25
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State-of-the-art in terminal automation: APMT Rotterdam (2014)
Automation: Experiences & Lessons learnt / (c) TBA 26
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State-of-the-art in terminal automation: APMT Rotterdam (2014)
Automation: Experiences & Lessons learnt / (c) TBA
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State-of-the-art in terminal automation: RWG (2015)
Automation: Experiences & Lessons learnt / (c) TBA 28
Rail terminal
Barge stack and barge quay Cantilever modules Block of 10 modules
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RWG terminal Rotterdam Maasvlakte 2
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RWG terminal Rotterdam Maasvlakte 2
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Patrick Port Botany Terminal: Automated Straddles (2015)
Automation: Experiences & Lessons learnt / (c) TBA 31
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Basic Terminal Data Terminal Layout - Final Phase
Planned yearly capacity: 3.3Mio TEU Waterside Productivity: 500boxes/hour Quay wall length: 1,300m Modal split: Approx. 35% rail Final Phase: 14 STS 37 ASC Modules 72 B-AGV LCBT will service the shipping lines
– OOCL (mother company) and – Grand Alliance partners and – Third party vessels
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Long Beach Container Terminal (Port of Long Beach) (Planned 2016)
Automation: Experiences & Lessons learnt / (c) TBA
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AGV System for LBCT
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Fully Automated Zero Emission Container Handling at Long Beach Container Terminal
based on Terex Gottwald Automated Guided Vehicles
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Battery Exchange Station – Exchange Positions
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Battery Exchange Position 1
Battery Exchange Position 2
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Rack Feeder- Battery Handling Robot
Battery Exchange Station – Rack Feeder
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Chargers in Rack Gangway
Power Distribution behind Rack
Battery Exchange Station – Charger and Power Distribution
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Yangshan phase 4 (Planned: 2017)
Automation: Experiences & Lessons learnt / (c) TBA 38
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Experiences & lessons learnt
Automation: Experiences & Lessons learnt / (c) TBA 40
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The right concept for the circumstances: how to?
Automation: Experiences & Lessons learnt / (c) TBA 41
There is no single best automated terminal solution for any location The optimal solution is the one that:
– Satisfies throughput objectives (quay, yard, gate) – Satisfies handling performance objectives – Provides the most cost-efficient mode based on cost /
move – Provides acceptable characteristics in terms of
environment and safety
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Concluding remarks
Automation: Experiences & Lessons learnt / (c) TBA
Automated terminals are (very) successful from cost-efficiency point of view Automation is the future, but is also all around us already Humans determine the success of automation If you fail to plan, better plan to fail use tools like simulation & emulation to ensure the quality of the design Integrated planning is key for an automation project When planned properly, automated terminals can deliver the highest performance levels, and highest cost-efficiency
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Contact Details
Automation: Experiences & Lessons learnt / (c) TBA
TBA b.v. Company registration number NL27197330 Karrepad 2A 2623 AP Delft The Netherlands Internet www.tba.nl
Company board: Ir. Martijn Coeveld – CEO / Managing Director Dr. ir. Yvo Saanen – COO / Managing Director Office +31 (0) 15 3805775 Fax +31 (0) 15 3805763 [email protected]
Thank you
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