maintenance of automated terminals - kalmar global · 2017-09-19 · manual straddle carrier...

Maintenance of automated terminals

9/19/2017 Kalmar Automation Technology Days / Arto Keskinen 1

Arto Keskinen, VP Intelligent Service Solutions, Kalmar

Who am I ?


Arto Keskinen

5 years in Kalmar. Currently VP,

Intelligent Service Solutions

8 years in marine industry working

in sales and product management

for diesel engine manufacturer

5 years in software business,

in product management,

consultation and sales


In automated terminals an equipment

breakdown can shut down part

of the terminal for 15-30 minutes.


One 30 min downtime in 8 hour shift means:

6% reduction in STS moves

12% longer truck turn around.

Topics


What is special

in automated

terminal?

Start up phase.

Using and

analysing data for

decision making.

What is special in

automated terminal ?

Effective exception handling

Operations, maintenance and IT

teams working as one team

Planning is essential

A change in skills sets

Software maintenance and support

Automation infrastructure

maintenance

What needs to be taken into consideration?

New role in the operator’s room: the system operator

Acts as a gatekeeper

Monitors the equipment and overall performance

Decides which machines require repair

Manages the exception handling

Ensures the equipment is in good condition

Things to remember

Planning of availability and needs from operations point

of view

Coordination between operations, IT and maintenance


Exception handling in automated terminal

Sensitive automated equipment

requires a targeted, routine preventive

maintenance program to ensure

proper operation and provide

maximum in-service lifespan

Systematic maintenance procedures

Calibration and regular inspections are

requirements, not options

Decisions are based on the data

gathered from the machines

Manual Straddle

CarrierAutomated Straddle

Carrier

Human errors

Unscheduledmaintenance

Scheduledmaintenance


Maintenance planning - from unscheduled to scheduled

Example Manual vs Automated Straddle Carrier Maintenance hours*

Testing of new releases in emulation

environment

Identify competences in own

organisation/ partner with supplier

Ensure level 1 capabilities on site

for quick fixes and work arounds

Supplier providing level 2 and 3

support 24/7


Software maintenance and support program secures operational efficiency

LEVEL 1 Problem

definition

LEVEL 2 Problem

analysis &

determination

LEVEL 3 Problem

resolution

Infrastructure maintenance to ensure safety


Fences Gates Light

curtains Sensors

The most demanding phase

of your automation deployment

is your start-up phase.

Be ready for go-live


Stage of

service life

Failure rate

characteristics

Root cause

Fail

ure

ra

te

Time

Start up/commisioning Normal operations End of life

Decreasing failure rates Quasi-constant failure rates Increasing failure rates

Early problems Random failures Wear out

Overall failure rate

Shorten time

to reach full throughput

potential (30 moves/hr)

from 12 to 10 months.

Higher customer

revenue per month

starting from the second

month of operation.

1,4 M$ potential

revenue improvement

2 M$ improvement

in cash flow

Potential savings in

maintenance costs and

initial investments.

Almost €2M cash

flow improvement

for the terminal.

Maintenance cost

savings of €9M (appx.

16%) over a 10-year

service contract.

Calculation parameters

30 STS moves per hour

First year throughput target 250 000 TEU’s

150 $ per move


Case study:

Ramping up operations in 10 months instead of 12 and it’s impact on financials

What Start-up means?


You need to establish your:

Maintenance processes

Competencies for

managing automation

Inventory strategy

Health and safety plans

Environmental plans

IT administration support.

How much data does your business produce

everyday and what do you do with it?

Data is available, but are we able to act?


Remote

diagnostic

tools

Advanced

analytics

Human

analysis

Human analysis is still needed

While algorithm developers continue to

make progress in enabling computers to

address tasks of greater complexity, there

are still many types of analysis people can

be more effectively done by people

Domain knowledge is the key!


Human analysis

Kalmar Onwatch

Brings the knowledge

and skills to the

customer remotely

Modern tools make it

possible to do this

efficiently


Remote diagnostics tools

Select basic KPI’s to

be followed up in the

beginning and group

them for different roles

i.e. maintenance, IT

and operations

Once organisation is

capable to go more in

details then add more

analytics

Domain knowledge

is crucial to be able

to make right analysis


Using data in decision making

Summary


Maintenance in automated terminal

is key for efficient operation

Maintenance in automated terminal

is a cooperation between operations,

engineering and IT

Start up phase is critical for

successful ramp up of operations

Use of data for decision making and

continuous improvement

maintenance of automated terminals - kalmar global · 2017-09-19 · manual straddle carrier...

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