Pekka Ranta, Moffatt & Nichol, Senior Project Manager, Automation CONNECT. COLLABORATE. INNOVATE. Managing the Challenge Implementation of Terminal Automation Moffatt & Nichol Founded in 1945 in Southern California to serve the U.S. Navy & the evolving port & maritime industries 600+ employees w/29 offices (North America, Europe, Latin America, Middle East, Pacific Rim) A recognized leader in marine terminal planning, analysis, design & goods movement economics Agenda Defining the challenge Setting targets & establishing the team Integrated design Putting the pieces together Project charter Initialization of the challenge Managing the program Closing the project, start of operation Defining the challenge Why is it called a challenge? Implementing automation has been impacted by: Schedule delays Cost overruns These impact: Port authorities Terminal operators Equipment suppliers Investors What is the challenge? Demand today Bigger vessels Larger call sizes Capacity, density Cost of operation Productivity Schedule for implementation Finding right tools meeting the challenges Business plan Infrastructure study Equipment Applications/IT Integration Implementation The challenge is how to respond changing conditions Ways of meeting demand Types of new implementation of terminal development Small scale New sub-system integration with existing operation Smaller process improvements to gain productivity Greenfield New build out Redevelopment of old facility Brown field Extension to the current operation Changing mode of operation Enhancement current operation Drivers to take the challenge Drivers Evolution of technology Operational requirements Performance Capacity Efficiency Governmental requirements Business requirements New requirements of services Extensions Competition Setting targets & establishing the team Project phases Getting started Looking into options “What to do?” Feasibility study Mode of operation Footprint of the terminal Environmental impact Business study Business goals Future scenarios Political landscape Where do we want to go? Why do we want to go there? Feasibility study Based on business requirements Analyses of productivity, capacity, market development Intended way of operation is tested by simulation Different solutions can be experienced Does not limit experimenting various options Answers to the questions Is this functional and economically feasible? Will analyzed solutions provide required operational parameters Determining goals Scoping options New investment Investment estimate Implementation schedule Return on Investment “Do nothing” scenarios Can you survive Will competition run over you Are there any threads for current situation Goals are dreams with deadlines Creating organization Decision making team (core team) Principal(s) to lead towards setting goals Supported with group of experts 4-5 members to start with, expanding organization later in time Getting stakeholders involved Owners/investor Port authority/governmental agencies Future clients Integrated design Importance of design Integrated design Design is based on processes Each main process is described and it drives the design Breaking the organizational silos, where process is the driver for the design Designing main processes Operational processes Maintenance processes Breakdown to manageable entities – “building blocks” Defining functionality of each block Identifying interfaces on each block Who to communicate What data is communicated STS options Single trolley Hand off and coning between crane legs Hatches at the back reach STS options Single trolley Coning at the elevated platform Hand off at back reach Hatches between legs STS options 20 Tandem hoist Dual trolley Automated portal trolley Coning at the elevated platform Hand off at back reach Hatches between legs Driver assisted features Horizontal transport Detailed gathering and distributing tasks to/from storage Move any box, from any location to any location at any time Must be rubber-tired AGV/L-AGV (diesel/ battery operated) AShC/AStraddle (hybrid diesel) 21 Container yard End-loaded stacking/retrieval cranes Side-loaded stacking/retrieval with landside transfer cranes 22 Intermodal yard Wide span cranes cantilever cranes Demand by amount of rail tracks Straight track or curved Rotating trolley/spreader Engineered to purpose Manned/ remote operated Land side transfer Does landside transfer need to be part of the yard, as it is now? Can that be separated to be own entity where, horizontal transport will support it as in water side Has own operations planning process Needs new type of equipment for truck handling? Applications - automated equipment Application – water side Applications at container yard Applications at intermodal yard Application at gate Putting the pieces together Preparing the Integration 1/2 It’s all about communication and coordination Unified definitions and terminology brings clarity and reduced confusion “I know you think you understand what you thought I said but I'm not sure you realize that what you heard is not what I meant.” ‐ Alan Greenspan Preparing the integration 2/2 Each building block needs “definition of done” Integration of different building blocks is following the design Where connecting two different blocks requires an interface definition What is needed When it is needed How interface functionality is verified Managing the interfaces When each building block & interface has been identified, each interface needs an owner who will: Coordinate interface requirements between parties Maintain documentation between parties Distribute information The number of interfaces & building blocks determines your resource needs. Integration plan 1/2 Create integration strategy where: Approach is decided (Top Down, Bottom Up, Mix of both) Module level test scope is defined Interface test scope between modules are defined Integrated module test scope Flow test scope where all main processed are defined Volume test scope Integration plan 2/2 Create Testing scope where: Test targets are identified All functions are covered by test cases Basic functions Exceptions Failovers Test pass/fail criteria are clear Documentation of test cases and results are centralized Test execution monitoring is transparent Project charter Project charter Good comprehensive charter will support the project through the lifetime Clear Targets Performance WHAT? Capacity HOW MUCH? Budget WHEN? Schedule Work Breakdown Structure HOW? Setting project organization PROJECT PRINCIPAL PROGRAM MANAGER ADMNISTRATION DOCUMENT CONTROL/SCHEDULE/ FINANCIAL MODELING OPERATIONS Project Manager TOS/application Project Manager IT SYSTEMS Project Manager HANDLING EQUIPMENT Project Manager TEAM OPS TEAM TOS TOS application Gate application OCR’s application RFID applications Integration testing TEAM IT SYSTEMS IT HW Network WLAN RFID OCR CCTV EQUIPMENT TEAM M&R TEAM CONSTRUCTION TEAM STS ASC ATH RMG Other Equipment M&R Planning M&R Staff mgmt. Commissioning support Training Civil schedule & Engineering Site Planning Site Safety Buildings OPS SOP Flow Testing Volume Testing Training MAINTENANCE Project Manager INFRASTRUCTURE Project Manager Responsibility areas 1/2 OPS Review of operational SOP with applications Develop SOP’s for each operational flow Testing support (volume testing) Training planning and coordination TOS/Applications Manage SW vendors Manage own development Manage SW interfaces Integration test IT Systems Manage IT HW Servers Workstations Tablets Network devices Mobile devices Mange fiber network design and implementation Equipment Manage Equipment vendor contracts Equipment testing and commissioning Technical reviews Support integration testing Facilitate training Responsibility areas 2/2 Maintenance & Repair SOP Provide resources for commissioning support Spare part purchase/ management Training planning and coordination Facility maintenance planning Power network Buildings Infrastructure Coordinate Civil construction Schedule Vendor requirements Power network Buildings Site Management Area utilization Site Safety Initialization of challenge Procurement strategy How do you source your needs? Turn-key Pick per purchasable components (collecting the ingredients) Combined own implementation & purchased Equipment delivery method Fully tested – focus on factory testing In components – built on site, commissioned & tested on-site Scoping the purchase “What you write is what you get” For each sourced component importance of Contract Technical specifications Delivery limits Service and support agreement Budget Liquidated Damages Selecting KPIs KPIs measure Performance Reliability Each sub-process should have own KPIs KPI data Is collected by the “system” without additional human input Is analyzed, result provides a value which can be compared to previous analyses to identify changes over time analyses should be executable automatically by database search or log file scripts in regular intervals Forming the contractor map Each building block needs contractors to Design/build civil main contractor Equipment supplier Cranes Assembly Commissioning Safety system ECS with interface to TOS IT network contractor Design Foundation Pavement Rails Fencing Gates Power Fibers Switches Servers WLAN Landside trucker interface Hardware, touch screens actuators Application Interface to TOS/Gate system RF ID system Path to Completion Design Programming Manufacturing Construction Lab testing ‐ Emulation Factory testing Integration testing Site testing Volume testing Process Flow testing Managing the program Program management 1/4 Main project is constructed from various sub-projects, this is called Program Program Management team is constructed from Program Manager Project Manager Project Principal (s) Program Management overlooks each sub-projects Critical interfaces Schedule Budget Program management 2/4 Program Management team makes decisions where A single project can suffer over other project(s) Program gains on the decisions Decisions can impact to Project budget and schedule Project Resources Program management 3/4 Monitoring progress is done by weekly meeting where each project is reporting Status Critical issues Decisions Monthly reporting to principal and executive team Project management 4/4 Manages delivery of one particular sub-process, where Can have multiple contractors Monitoring progress in weekly bases Reports on Program Management meetings Communicates needs of interfaces Coordinates test resources Coordinates training resources Integration Management Implements integration plan Verifies that interfaces are complying to design Manages version control Schedules test resources Documents Defects Interface changes Test cases with expected results Monitors test progress Project close out, start of operations Transition when operations start President PROJECT PRINCIPAL Operations organization PROGRAM MANAGER General services HR/FINANCIAL/LABOR/ OPERATIONS OPS Manager IT SYSTEMS IT Manager TEAM OPS TEAM IT SYSTEMS IT HW Network WLAN RFID OCR CCTV Application Support SLA management New release testing OPS SOP Testing Training Improvement MAINTENANCE M&R Manager M&R TEAM M&R Planning M&R Staff mgmt. Training Service contracts Project organization DOCUMENT CONTROL/SCHEDULE/ FINANCIAL MODELING TOS/application Project Manager HANDLING EQUIPMENT Project Manager INFRASTRUCTURE Project Manager TEAM TOS Application punch list EQUIPMENT TEAM INTEGRATION TEAM Contract support Warranty Punch list Civil schedule Engineering Punch list Operations Operation Customer Service Planning Operations planning Resources Execution Monitoring KPI’s Cost control Continuous process development Monitoring main KPI’s Identifying development items Engages other organizations to new improvement Use of Emulation as a tool for trials Continuous improvement program IT Reactive IT Support operations by monitoring communication network and applications of each sub-system Will assist on troubleshooting an detail analyses Preventive IT Will execute test program of new application version prior to launch to operations environment Manage remote access for operations, maintenance and vendors Execute and follow up Service agreements with IT vendors Version control Interface management for new deployment IT Support by functional areas Maintenance Reactive maintenance Monitors equipment condition operations and is prepared to resolve disturbances instantly Report incidents and changing conditions to preventive maintenance Preventive maintenance Plans and executes maintenance program for equipment & infrastructure Process improvements to improve performance and reduce costs Execute and follow up Service agreements with IT vendors Management of spare part inventory Re-cap SUMMARY Base your Design on Business Plan and Processes Structure your approach for manageable building blocks Go-Live can’t be accomplished unless critical mass of deliverables is in place Importance of Reliable Suppliers which can meet the technical requirements and schedule Questions
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