© 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

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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

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min

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Proc

ess

Civil Structures

Terminal Equipment

Operating Layout

Operations Aut

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sCivil Structures

Terminal Equipment

Operating Layout

Operations

Layout and Operations Validation

Aut

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inal

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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

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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

f.kasiske@hpc-hamburg.de

Marine Terminal Productivity in the new Era of Automation