Henk Bester & Christelle du Toit - Hatch - Case study – Realising capacity increase through combining innovative modelling techniques and practical operational improvements without

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Innovative Modelling Techniques

& Operational Improvements Henk Bester, Managing Director Rail

Christelle du Toit, Simulation Engineer

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Introduction

Agenda

• Background

• The Problem

• The Solution

–Data Analysis & Simulation

• Operational Improvements

• Rail Operation Philosophy

• The Before and After

• Important Points to Take Home

Operational improvements to increase capacity

Innovative modelling to test rail operation philosophy

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The End Result

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Volume

40%

Performance

Increase

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Road to End Result

Challenge the way people think

Rail but one element of bigger system

Sustainable actions

Do not compromise safety

Minor infrastructure changes

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Impact of thorough data analysis

Simulation as debottlenecking tool

Simulation to drive performance

initiatives

Benefits of

run-when-ready

Key Concepts

Specific Takeaways From This

Presentation

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Background

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MINE

MAINLINE

Shiploaders

Transhipment

Train

Loading

Train

Dumpers

TERMINAL

Stackers

Reclaimer

FEL

200 km

Dedicated

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The Problem

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Forecast export

volumes not being

achieved

Cash flow

constraints

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The Solution

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Data Capturing

Re-design

Identify

Gather

Improve

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Data Analysis

• Scatter

• Inconsistent operations

• Breakdowns

• Dumper congestion

• Dumper 1 can only service light wagons

• Long waiting times

• Low stockyard utilisation

• 50% simultaneous loading

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Simulation Study

Mine (G2) • Production profile

• Train loading

• Rail yard interface

Rail Line (RTC) • Operation

• Train config

• Infrastructure

• Rolling stock

• Maintenance

• Rail system

performance

Port & Marine (G2) • Rail yard

• Train offloading

• Stockpiling

• Reclaiming

• Shiploading

• Berth occupancy

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Simulation Study

Gather Info

Develop Validate Scenarios Results

De-bottlenecking

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Findings

Bottleneck

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Findings

Simultaneous

Use

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Findings

Additional

Conveyor

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Operational Improvement

Rail

Port

Effective

stockyard

utilisation

Predictable

performance

Isolate

disruptions

Operate

consistently

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Operational Improvement

Planned

maintenance

Reduce

turnaround time

Seasonal

constraints Plan ahead

Sustainable

targets

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Operational Improvement

Train splitting

Rolling stock maintenance

Pre departure activities

Long and short

trains

Minor structural

upgrades

Yard

process

Revise &

minimise

Choose

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Minor Infrastructure Improvement

Minor layout changes

Simultaneous entry

Loop extension

Re-design

of chutes

Priority from

data

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Rail Operation Philosophy

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SLOT SYSTEM

READY

RUN-WHEN-READY

• Fixed schedule

• Fixed departure

• Less coordination

• Wait for slot

• No schedule

• Depart when ready

• Active coordination

• No waiting

vs

Compare Philosophies

Train loading + main line crossings + train offloading + port interface

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The Simulation Challenge

Train Loading

Train Unloading

Terminal

Shiploading

Transhipment

Mainline

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“DON’T RUN AWAY

FROM CHALLENGES

RUN OVER THEM”

~Nike

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Innovative Modelling Screenshot of model train diagram

Screenshot of train animation

Train Crossings

Maintenance

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Configuring the Slot System

Train Diagram

Good Timing

Short Delay

Long Delay

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No Slot Offset

12:00

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No Slot Offset

12:15

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No Slot Offset

12:30

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No Slot Offset

12:45

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No Slot Offset

13:00

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No Slot Offset

13:15

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No Slot Offset

13:30

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Slot Offset

12:00

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Slot Offset

12:15

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Slot Offset

12:30

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Slot Offset

12:45

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Slot Offset

13:00

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Slot Offset

13:15

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Slot Offset

13:30

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Optimising the Slot Offset

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Run-When-Ready vs. Slot System

8%

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Run-When-Ready vs. Slot System

Increase in waiting

for slot time

Decrease in queuing

and crossing delays

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The Before and After

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$75

$85

$95

$105

$115

$125

$135

$145

$155

$165

$175

Gross Income

Average (Jan - Oct)

Average (Nov - Apr)

Iron ore price (62% benchmark)

Gross Income Increase

Project

Start

Average

Insufficient supply of

OGVs

28 day month

Average

Sales increased by $20.2M per month on

average from November

Note: Prices for

Iron Ore have fallen

and price of freight

have risen

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Before

Project

Start

Scatter

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After

Project

Start

Scatter

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Before

Project

Start Scatter

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After

Project

Start Scatter

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Dump Rate Investigation

No correlation

Yard equipment destination

Grades being offloaded

Night or day shift

Number of routes

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Dump Rate Investigation

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Before

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After

Less

Scatter

GLR

+500t/h

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Impact of Scatter

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Impact of Scatter

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Impact of Scatter

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Impact of Scatter

+15%

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Important Points to Take

Home

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Proper data analysis is key

Strive for consistency

Identify bottlenecks using simulation

Set sustainable targets for operators

Do preventative maintenance

Focus on operational improvement first

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Run-when-ready can have significant benefits on a dedicated rail line

Each operation is unique. The rail operations philosophy should be determined

through analysis and testing

Dynamic simulation is a good tool to uncover inefficiencies and test operational

philosophies before implementation

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For more

information,

please visit

www.hatch.ca