Logistics simulation
The discrete event simulation technique allows for the modeling, analysis and optimization of logistics systems. The evaluation of complex processes, for which the use of simple calculation methods is not sufficient, requires a more specific approach.
The analysis of the transportation of materials or goods in a port, for example, makes it possible to identify possible bottlenecks in the system even before operations begin. The interaction between the various pieces of equipment is not trivial, and involves the statistical distributions of equipment availability, atmospheric and maritime conditions (swell), as well as other operational conditions.
The use of software such as Plant Simulation enables project optimization, with greater planning efficiency, layout optimization and equipment selection. It is also possible to adjust the operation to maximize production and reduce maintenance costs.
The tool can be used to evaluate the entire production process, from complete industrial complexes to a single stage or station in the system, with as much detail as necessary or depending on the availability of data.
CASES
Analysis of a coal port
Analysis of a coal export port, involving everything from the receipt of the material by the railroad logistics, through transportation and stacking in the storage yards and then retrieval of the material, transportation to the port and loading onto ships.
Various aspects were taken into account in this simulation, including the time needed to handle the material using wheel loaders, the logistics of train arrivals, which was modeled using a Gaussian statistical distribution, the different capacities of the ships made available by the shipowner, and other details of the process.
Using the model, it was possible to establish and quantify the occupancy rate of the equipment in each phase of the port's operation, from run-up until the system reaches full shipping capacity.
Based on the results of the simulation, problems were detected in maintaining the port's stocks, which prompted the following changes to the plant:
Ship queuing has been optimized to reduce demurrage (more expensive ships have preference in the queue);
- Adjusting the arrival of trains according to the ship schedule;
- 16% increase in the size of the train;
- The sequence of large ships drastically reduces stocks, so the queue of ships has been adjusted by the shipowner so as not to result in problems at the port. Capesize ship requires full yard (1 ship = 76% stock);
Once the changes to the plant had been implemented, a new simulation was carried out, proving the effectiveness of the changes and the suitability of the port in relation to the handling capacity envisaged in the project. In this case, no additional investment was needed in the plant, just adjustments to the process.
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