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
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
Key Success factors
1.
2.
3.
4.
5.
6.
7.
Business Process Modeling
Procurement Strategy
Validation by Simulation
End-user involvement
Integrated Testing & Commissioning
Measuring Performance and Reliability
Good teamwork & the right people!
1. Business Process Modeling
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.
BPMN
ADPC 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
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
2. Procurement Strategy
High
ASC
Quay Crane
ASC/TOS
interface
AGV
Price
Straddle C
TOS
Other vehicles
Low
High
Risk
2. Procurement Strategy
Options
Future?
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




Implementation could delay
No overall integrated planning


Good OEM competition
Single point responsibility for
ASC/TOS
Proven ASC/TOS Solution
Best OEM bids to be selected




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
One Turn Key contract
for all Equipment Incl.
ASC/TOS
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
4. End-user
involvement
4. End-user
Involvement
• 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
•
5. Integrated Testing & Commissioning
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
13
Triage Committee and Collaborative Testing Board
5. Integrated Testing & Commissioning
14
5. Integrated Testing & Commissioning
Testing Cycle per ASC block
ASC-1/ LS
Prep
Work
Startup
Commission
Assembly
and
Yard
Preparation
ASC-2 / WS
ROS
Testing
Startup
Commission
Block
Test
Functional
Testing
Functional
Testing
Endurance
(8 hours)
Performance
Testing
Accuracy
Testing
C
Live
Endurance
(8 hours)
1152 moves
24 hours
Equipment
and
TOS
Testing
CTS
team
Example 1 Stack lane with 2 ASC (Landside and Waterside)
Block
Delivery
Report
5. Integrated Testing & Commissioning
6. Performance and Reliability Measurement
TOS performance test by means of emulation (TBA Controls)
Example Khalifa Port, peak performance scenario full terminal:
WS :
QC :
LS:
Yard density:
390 mvs/hr
39 mvs/hr
300 mvs/hr
max. 85%
10 QC
52 ASC
30 SC
2 Deep sea vessels
1 Feeder vessel
17
The emulation test resulted in 41.8 QC mvs/hr under realistic operational
conditions
6. Performance and Reliability Measurement
1194
744
742
553
1229
Week
avg
Continuous cooperation between OEM, Electrical supplier and operator is
needed to reach the contractual MMBF figures
7. Good teamwork & the right people!
Study
Design
Construct
Deliver
Improve
Modify
Disciplines
Disciplines
Disciplines
Disciplines
Disciplines
Disciplines
Operations
Operations
Operations
Operations
Operations
Operations
Civil
Civil
Civil
Civil
Civil
Civil
H&S
H&S
H&S
H&S
H&S
H&S
Environment
Environment
Environment
Environment
Environment
Environment
Equipment
Equipment
Equipment
Equipment
Equipment
Equipment
Security
Security
Security
Security
Security
Security
Systems
Systems
Systems
Systems
Systems
Systems
IT-Infra
IT-Infra
IT-Infra
IT-Infra
IT-Infra
IT-Infra
Simulation
Procurement
Procurement
Procurement
Procurement
Procurement
Government
Finance
Finance
Finance
Finance
Finance
PPP/BPM
PPP/BPM
PPP/BPM
PPP/BPM
PPP/BPM
PPP/BPM
Proj. Control
Proj. Control
Proj. Control
Proj. Control
Proj. Control
Simulation
Simulation
Simulation
Simulation
Simulation
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.
7. Good teamwork & the right people!
T
THE PRACTICAL AND PROFESSIONAL APPROACH
www.solidportsolutions.com