Simulations have mainly been carried out in the greenfield during the design and operation stages. However, due to recent demand, verifying full automation by applying autonomous vehicles in non-fully automated and semi-automated terminals is necessary. Additionally, it requires converting to automation by remodeling using manual equipment and verifying stable operation during terminal integration and expansion. The terminal must be flexible in responding to volume increases by introducing automated equipment, which is why the verification of new equipment introduction is being done in operating terminals.

As the various requirements grow, the demand for operation simulation is increasing. An automated Equipment Control System (ECS) must be selected in the automated terminal, along with the equipment. The simulation's complexity rises to meet the synergy with the appropriate equipment control system and operation system.

The diagram below shows the Equipment-Controller-Operation System in Korea’s 1st fully automated terminal. 

Continuous simulation is an important tool used during both the design and operation stages. However, traditional simulations have limitations as they can only be used once, which makes it difficult to reflect the persistent changes that happen during actual operations. There are now more options for terminal operations, which can make it increasingly complex to choose the best one.

For instance, when it comes to automatic transfer equipment like AGV, there are various options available such as Lift AGV, IGV with changed Transponder reclamation method, and AMR with autonomous driving function. The total gross productivity and TGS of the yard crane depends on whether the Cantilever uses equipment on both sides or one side only.

With more options to choose from, the interaction and dependency also increase, making it even more important to find the optimal decision through simulation. By estimating the impact of each option, the simulation can help establish an effective strategy. It is necessary to evaluate and improve the stability and efficiency of the process, considering the increased interaction and dependency. Simulation can be applied at any stage, from the design phase to after the go-live stage.

The Simulation, which can be applied before the design stage, even after the go-live stage, is needed.

- Terminal layout, Equipment types, Simulation, which is configurable equipment quantity

- Possible to apply the actual operating volume and operation patterns

- Need future predictions about the current operation condition

- The Simulation includes an equipment emulator

- Likely to use a gate Import/Export volume pattern

- Possible to process at least 200 times speed simulation (1month operation base, the simulation result for 720 hours non-stop operation simulation needs to be extracted within 4 hours max)

- Draw the results that could confirm bottlenecks

- Includes standard API for the equipment emulator – Compliance of TIC(Terminal Industry Committee) 4.0 equipment layer (level 1) data standardization

The result below is for applying a hybrid layout to terminals in the construction stage, adjusting the transshipment ratio, and the scenario created in which the type of equipment used and the number of equipment are changed.

-      Apply yard layout “Vertical Layout / End Loading” and “Horizontal Layout / Side Loading”

-      Modify transshipment ratio (T/S ratio)

-      Change the equipment type and quantity

Please find below a breakdown of the analysis results from 15 different operation scenarios regarding average gang productivity, peak time productivity decline ratio, and operation time increase ratio compared to total gross operating time. The impact of peak time productivity decline is more critical for terminal operations than the off-peak period productivity decline of yard capacity and equipment.

• Gang Productivity = Total Container Moves (VAN) / Gross Gang Operation Time (Total gross working time from all of applied STS)

• GI (Gang Intensity) = Gross Gang Operation time / Gross working time (The operation time of STS which has the longest working time)

The average GI is 2.43 in scenario “1c” Derive Peak time Productivity of the vessel experiencing bottlenecks based on GI value

• High GI Productivity (Peak time Productivity) = Gang Productivity of the vessel which has more than GI value 3.0

When Peak time productivity decreases by more than 10%

Ÿ   100% end loading only operation (Scenario 3a) experienced the most decline in Peak time productivity (15.65%)

Ÿ   When quantity of assigned mover is less (Scenario 1a – AGV x 36, Scenario 2a – LAGV x 32)

Ÿ   When transshipment ratio is below 50% (Scenario 4c – T/S 40%, Scenario 4d – T/S 30%)

Scenario-wise AGV Productivity and Waiting time

Productivity comparison by AGV quantity

Integrated operation simulation is a type of simulation that is useful throughout the whole process of a project, from its initial design stage to its post-go-live operation stage. This simulation allows you to test various scenarios, with free configuration options for terminal layout, equipment type, and quantity. By processing the simulation and applying the operation strategy provided as an outcome from the previous simulation, you can contribute to continuous operation improvement.

CyberLogitec offers a simulation solution that supports all stages of terminal yard design, equipment selection, and operation optimization. OPUS Solutions can help improve productivity and system integration through simulation before the terminal's opening and continuous simulation tailored to the changing operating environment.