Key Success Factors to deliver your terminal automation project on time

TOC Europe, 26 June 2013

Joost Achterkamp

Managing Director

Solid Port Solutions

The approach is based on the successful delivery of the

EUROMAX Container Terminal in Rotterdam With 16 STS, 58 ASC and 96 AGV until now the biggest one time delivery of a fully automated terminal

and the KHALIFA Port Container Terminal in Abu Dhabi The first semi-automated terminal in the Middle-East with 6 STS, 30 ASC and 20 SC’s

The Approach

Key Success factors

1. Business Process Modeling2. Procurement Strategy3. Validation by Simulation4. End-user involvement5. Integrated Testing & Commissioning6. Measuring Performance and Reliability7. Good teamwork & the right people!

Business Process: A specific ordering of work tasks and activities across time and place, with a beginning, an end, and clearly defined inputs and outputs. Business processes are the structure by which the organization physically does what is necessary to produce value for its customers.

Business Process Modeling: BPM is the analytical representation to describe and communicate the current or intended future state of a business process in a structured manner so that it shows how the work gets done and by whom.

BPMNADPC and ADT used NIMBUS CONTROL as a BPM Notation tool for describing all the business processes on the different levels in flow-chart like diagrams that can easily be understood by operations and IT.

1. Business Process Modeling

1. Business Process Modeling

Benefits

• Input for TOS specifications and supporting systems

• Tool to develop test scenarios, test cases and acceptance criteria

• Centralize control of human resources, systems and processes

• Create visibility into end-to-end business processes

• Agility to rapidly re-engineer processes

• Improve process efficiency with productivity improvement

• Effective management and cost control

• Can been used as a Training Tool

• Job Task descriptions can be extracted from the BPM

1. Business Process Modeling

2. Procurement Strategy

Team huddle Project/Procurement

• Contract type selection

• Strategic planning of the Scope of Work

• Single point of coordination on site

• Dedicated Procurement team

• Segregation of technical and commercial bid openings

• Concentrate on the project risks

Quay Crane

ASC

Straddle C

AGV

Other vehicles

TOS

High

LowHigh

Price

Risk

ASC/TOSinterface

2. Procurement Strategy

2. Procurement Strategy

Options Plus Minus

Individual Contracts(STS, SC, ASC and TOS separately)

Greater competition, better price ADPC control over all suppliers Not all suppliers are influenced when one doesn’t perform

Responsibility. ASC/TOS with Employer

Employer as Integrator More management time/cost Delivery mismatch possible No integrated planning

ASC/TOS combined STS, SC individual

Good OEM competition Single point responsibility for ASC/TOS Proven ASC/TOS Solution Best OEM bids to be selected

Implementation could delay No overall integrated planning

One Turn Key contract for all Equipment Incl. ASC/TOS

Single point responsibility Proven ASC/TOS Solution Less Employer Supervision Overall Integrated Planning

Reduced Competition Back-to-Back contract takes time Unable to select best OEM bids Increased overall price

Future?

3. Design validation by Simulation

Minimum number of studies:

Berth capacity

Can your quay wall handle the predicted number of vessels?

Handling capacity

Does the system deliver you the designed performance under a 24 hr peak load?

Storage capacity

Can your yard still perform under the predicted peak storage?

Sensitivity Analysis for various scenarios:• vessel types, arrival patterns and call sizes• quay lay-out under the crane• equipment numbers• various dwell times and seasonal patterns

3. Design validation by Simulation

• Every simulation study highly depends on the quality of the input parameters

• Validation of the input parameters by Operations is essential and even small changes can have a big impact on the result

• It is advised to look at ranges of productivity rather than at exact figures. The actual operational influences will fluctuate and are not easy to calculate by simulation

• It is also advised to check the input parameters during the execution of the project, updated information can be a reason to adjust the design assumptions

• Check the simulation results with a full terminal emulation study to validate the performance of the TOS under peak load

• The involvement of the operational and technical dept of the end-user is key for a successful delivery in order to be able to:

- Validate the simulation assumptions

- Give input to and sign off of the BPM

- Approve the functional design

- Define the Acceptance Criteria for both equipment and TOS

- Deliver the IT-infrastructure/hardware

- Assist the Testing & Commissioning team

- Phased hand-over over of areas

- Organize Go-Live tests

•

4. End-user Involvement 4. End-user involvement

13

During the project execution it is preferred option that the Testing & Commissioning process should be a joint effort for the Operator, the OEM and the TOS supplier in a

Collaborative Testing Strategy (CTS)

This integrated approach has following advantages:

- Shorter lead time of overall testing (no repeat!)

- Better use of the testing resources

- Direct involvement of the end-user

- Predefined Test scenarios & test cases based on BPM

- Clear acceptance criteria per Contract Milestone

- Defects administrated in one system (Quality Center)

- Clear governance structure to resolve conflicts with a

Triage Committee and Collaborative Testing Board

5. Integrated Testing & Commissioning

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5. Integrated Testing & Commissioning

C

AssemblyandYard

Preparation

ASC-1/ LS

ASC-2 / WS

Commission

Commission

Live

EquipmentandTOS

Testing

BlockDeliveryReport

Performance Testing

1152 moves24 hours

Startup

Startup

Example 1 Stack lane with 2 ASC (Landside and Waterside)

Testing Cycle per ASC block

PrepWork

Endurance(8 hours)

Endurance(8 hours)

BlockTest

AccuracyTesting

FunctionalTesting

FunctionalTesting

ROSTesting

CTS team

5. Integrated Testing & Commissioning

5. Integrated Testing & Commissioning

17

TOS performance test by means of emulation (TBA Controls)

Example Khalifa Port, peak performance scenario full terminal:

WS : 390 mvs/hrQC : 39 mvs/hrLS: 300 mvs/hrYard density: max. 85%

10 QC52 ASC30 SC2 Deep sea vessels1 Feeder vessel

The emulation test resulted in 41.8 QC mvs/hr under realistic operational conditions

6. Performance and Reliability Measurement

Continuous cooperation between OEM, Electrical supplier and operator is needed to reach the contractual MMBF figures

1194 744 742 553 1229

Week avg

6. Performance and Reliability Measurement

Study ModifyImproveDeliverConstructDesign

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Simulation

Government

PPP/BPM

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Procurement

Finance

PPP/BPM

Proj. Control

Simulation

7. Good teamwork & the right people!

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Procurement

Finance

PPP/BPM

Proj. Control

Simulation

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Procurement

Finance

PPP/BPM

Proj. Control

Simulation

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Procurement

Finance

PPP/BPM

Proj. Control

Simulation

Disciplines

Operations

Civil

H&S

Environment

Equipment

Security

Systems

IT-Infra

Procurement

Finance

PPP/BPM

Proj. Control

Simulation

Interface management

7. Good teamwork & the right people!

The approach of Solid Port Solutions:

Step 1: Analyze your project

Step 2: Advise on the project organization

Step 3: Check the availability of experienced staff within your own company

Step 4: Review the project scope and focus on the main deliverables

Step 5: Form a team of own staff and Solid Port Solutions experts

Step 6: Take responsibility of the delivery of the agreed scope

Step 7: Team up with consultants, contractors and suppliers

GOOD TEAMWORK with all parties involved.

Detailed control of the INTERFACES.

-

T

7. Good teamwork & the right people!

THE PRACTICAL AND PROFESSIONAL APPROACH

www.solidportsolutions.com