Production and distribution research center

Issued as Annual report, Project no. E-24-62

Progress in Material Handling Research: 2016

Table of contents

Progress in Material Handling Research: 2012

Table of Content

Sea Container Terminals

Due to a rapid growth in world trade and a huge increase in containerized goods, sea container terminals play a vital role in globe-spanning supply chains. Container terminals should be able to handle large ships, with large call sizes within the shortest time possible, and at competitive rates. In response, terminal operators, shipping liners, and port authorities are investing in new technologies to improve container handling infrastructure and operational efficiency. Container terminals face challenging research problems which have received much attention from the academic community. The focus of this paper is to highlight the recent developments in the container terminals, which can be categorized into three areas: (1) innovative container terminal technologies, (2) new OR directions and models for existing research areas, and (3) emerging areas in container terminal research. By choosing this focus, we complement existing reviews on container terminal operations

Nature Inspired Metaheuristics for Optimizing Problems at a Container Terminal

Nowadays, maritime transport is the backbone of the international trade of goods. Therefore, seaports play a very important role in global transport. The use of containers is significantly represented in the maritime transport. Considering the increased number of container shipments in the global transport, seaport container terminals have to be adapted to a new situation and provide the best possible service of container transfer by reducing the transfer cost and the container transit time. Therefore, there is a need for optimization of the whole container transport process within the terminal. The logistic problems of the container terminals have become very complex and logistics experts cannot manually adjust the operations of terminal processes that will optimize the usage of resources. Hence, to achieve further improvements of terminal logistics, there is a need to introduce scientific methods such as metaheuristics that will enable better and optimized use of the terminal resources in an automated way. There is a large number of research papers that have successfully proposed the solutions of optimizing the container logistic problems with well-known metaheuristics inspired by the nature. However, there is a continuous emergence of new nature inspired metaheuristics today, like artificial bee colony algorithm, firefly algorithm and bat algorithm, that outperform the well-known metaheuristics considering the most popular optimization problems like travel salesman problem. Considering these results of comparing algorithms, we assume that better results of optimization of container terminal logistic problems can be achieved by introducing these new nature inspired metaheuristics. In this paper we have described and classified the main subsystems of the container terminal and its logistic problems that need to be optimized. We have also presented a review of new nature inspired metaheuristics (bee, firefly and bat algorithm) that could be used in the optimization of these problems within the terminal

Robotized Warehouse Systems: Developments and Research Opportunities

Robotized handling systems are increasingly applied in distribution centers. They require little space, provide flexibility in managing varying demand requirements, and are able to work 24/7. This makes them particularly fit for e-commerce operations. This paper reviews new categories of robotized handling systems, such as the shuttle-based storage and retrieval systems, shuttle-based compact storage systems, and robotic mobile fulfillment systems. For each system, we categorize the literature in three groups: system analysis, design optimization, and operations planning and control. Our focus is to identify the research issue and OR modeling methodology adopted to analyze the problem. We find that many new robotic systems and applications have hardly been studied in academic literature, despite their increasing use in practice. Due to unique system features (such as autonomous control, networked and dynamic operation), new models and methods are needed to address the design and operational control challenges for such systems, in particular, for the integration of subsystems. Integrated robotized warehouse systems will form the next category of warehouses. All vital warehouse design, planning and control logic such as methods to design layout, storage and order picking system selection, storage slotting, order batching, picker routing, and picker to order assignment will have to be revisited for new robotized warehouses

Optimization of yard operations in container terminals from an energy efficiency approach

This Thesis addresses common operational issues related to maritime container terminals. In the last decades, containerization of maritime transportation has grown very rapidly, forcing terminal operators to cope with unprecedented volumes of containers in a continuous manner. As a consequence, terminal efficiency is always a critical factor. In the near future, operators are also expected to face increasing operational costs deriving firstly from the energy crisis and secondly from new regulations enforcing ports to become more environmentally friendly. As a consequence, operational inefficiencies deriving from periods of congestion require innovative solutions and optimization techniques to improve the efficiency and productivity in the terminal yard. This Thesis addresses such problems by introducing an electric energy consumption model that characterizes energy expenditure of yard cranes. For each gantry, trolley and hoist movement of the cranes, the model takes into account the different resistances that must be overcome during the acceleration, constant speed and deceleration phases of each movement. The energy consumption model is coupled to two different discrete event simulation models of one parallel and one perpendicular container terminals, with the goal to analyze the handling operations and optimize energy efficiency and productivity. One additional innovative aspect of the works is that they include the effect of the volume of container traffic in the analysis with the aim to assess differences in the performance of the algorithms under a range of realistic scenarios, which is usually neglected in similar studies. Finally, in addition to stacking and retrieval operations, the works also introduce housekeeping operation, which are common in the real world but often disregarded in the literature. Such operations are relevant as they may be critical in terms of achieving good productivity, but on the other hand they amount for a significant portion of the overall energy consumption. In particular, the works of the Thesis deal have four particular objectives: (1) providing such flexible and customizable numerical models of discrete event type to simulate and analyze parallel and perpendicular terminals, (2) proposing a new stacking algorithm to reduce energy expenditure and improve automatic stacking crane productivity in perpendicular terminals; (3) optimizing the dimensions of a perpendicular layout; and (4) analyzing the distribution of containers in the yard layout as a function of the moment at which space for export containers is reserved while looking at the operational costs. In the first place, results show the models are capable of characterizing in detail the energy consumption associated to crane movements in both parallel and perpendicular terminals. With respect to perpendicular terminals, the proposed stacking algorithm is capable of improving the energy efficiency up to around 20% while achieving greater productivity at the same time. In addition, results show that the dimensions of a perpendicular terminal block can be optimized so as to improve the productivity; with respect to energy consumption, although a smaller block induces lesser electrical consumption, the random nature of housekeeping operations produce a significant degree of distortion in the results, revealing that such operations constitute a promising flied for future research. Finally, considering parallel terminals, a greater degree of clustering is observed as the reservation is made earlier. When considering the associated operational costs associated to yard cranes and yard trucks, greater clustering results in more efficient use of the energy, and therefore reservation may be desirable when possible to enhance terminal productivity.Esta Tesis aborda temas operativos comunes relacionados con terminales marítimas de contenedores. En las últimas décadas, la contenerización del transporte marítimo ha crecido exponencialmente, obligando a los operadores a hacer frente a volúmenes de contenedores sin precedentes de manera continuada. Como consecuencia, la eficiencia de las operaciones es siempre un factor crítico. En un futuro próximo, los operadores también deberán afrontar crecientes costes operativos derivados de la crisis energética, y también de nuevas regulaciones que obligan a los puertos a volverse más respetuosos con el medio ambiente. Por estos motivos, las ineficiencias operativas derivadas de períodos de congestión requieren soluciones innovadoras y técnicas de optimización para mejorar la eficiencia y productividad en los patios de contenedores. Esta tesis aborda estos problemas introduciendo un modelo de consumo de energía eléctrica que caracteriza el gasto de las grúas de patio. Para cada movimiento de "gantry", "hoist" y "spreader", el modelo tiene en cuenta las diferentes resistencias que deben superarse durante las fases de aceleración, velocidad constante y deceleración del movimiento. El modelo de consumo de energía se ha acoplado a dos modelos de simulación de eventos discretos de terminales de contenedores, una paralela y otra perpendicular, con el objetivo de analizar las operaciones de manipulación y optimizar la eficiencia energética y la productividad. Otro aspecto innovador de este trabajo es que analiza el efecto del volumen de tráfico de contenedores con el objetivo de evaluar el comportamiento de los algoritmos bajo un rango de escenarios realistas, lo que generalmente no se tiene en cuenta en estudios similares. Por último, además de las operaciones de apilamiento y salida de contenedores, la tesis también considera las operaciones de reordenamiento del patio, muy comunes en el mundo real, pero que a menudo no se tienen en cuenta en la literatura. Tales operaciones pueden ser críticas para lograr una buena productividad, pero por otra parte representan una parte importante del consumo total de energía. En particular, los trabajos desarrollados en esta Tesis tienen cuatro objetivos concretos: (1) proporcionar modelos numéricos flexibles y configurables de tipo eventos discretos para simular y analizar terminales paralelas y perpendiculares, (2) proponer un nuevo algoritmo de apilamiento para reducir el gasto de energía y mejorar la productividad de la grúa automático en terminales perpendiculares; (3) optimizar las dimensiones de un bloque de una terminal perpendicular; y (4) analizar la distribución de los contenedores en la disposición del patio en función del momento en que se reserva el espacio para los contenedores de exportación. Los resultados muestran que, en primer lugar, los modelos son capaces de caracterizar en detalle el consumo de energía asociado a los movimientos de las grúas en ambos tipos de terminales. Con respecto a las terminales perpendiculares, el algoritmo de apilado propuesto es capaz de mejorar la eficiencia energética hasta aproximadamente un 20%, al tiempo que se consigue una mayor productividad. Además, los resultados muestran que las dimensiones de un bloque perpendicular pueden optimizarse para mejorar la productividad; con respecto al consumo de energía, aunque un bloque más pequeño induce un menor consumo eléctrico, la naturaleza aleatoria de las operaciones de reordenación inducen un grado significativo de distorsión en los resultados, indicando que tales operaciones pueden ser objeto de futura investigación. Por último, respecto a las terminales paralelas, a medida que se adelanta la reserva de espacio los contenedores presentan un mayor grado de agrupación, lo que redunda en un uso más eficeficiente de la energía debido a los menores costos operacionales asociados a grúas y camiones de patio, por lo que la reserva puede ser aconsejable cuando sea posible para mejorar la productividad del termina

Hierarchical modeling and analysis of container terminal operations

After the breakdown of trade barriers among countries, the volume of international trade has grown significantly in the last decade. This explosive growth in international trade has increased the importance of marine transportation which constitutes the major part of the global logistics network. The utilization of containers and container ships in marine transportation has also increased after the eighties due to various advantages such as packaging, flexibility, and reliability. Parallel to the container throughput, the capacities of ships and sizes of fleets as well as the number of terminals have been increased considerably. Substantial pressure of competition on ship operators and terminal managers has forced them to consider the issues regarding operational efficiency more deeply. Thus, the operational efficiency at port container terminals has become the major concern of terminal managers to satisfy the rapid transshipment of goods. In this thesis, we focus on a set of decision problems regarding container terminal operations. Since these problems are interrelated hierarchically, we attempt to model and analyze them consecutively. First, we consider the storage space allocation problem over a rolling horizon as an aggregate planning model. Since the model has the minimum cost flow network structure there exist polynomial time solution procedures via linear programming models. Although ship turnaround time is the principal performance criteria for whole container terminal operations, the total distances traveled by containers in the terminal throughout the planning horizon is determined as the surrogate objective function for the allocation model. The output of the storage space allocation problem is used as the input for the next step of our methodology, namely the location matching model. With the location matching model, the routes of vehicles for each time period have been identified while minimizing the total distance traveled by the vehicles, which reveals the ship turnaround times. The routes that are found subject to the output of storage space allocation models are better than those of random allocation in terms of total distances traveled. Next, the vehicle scheduling problem is discussed for different levels of complexity. The solution procedures proposed for similar problems in the machine scheduling literature are provided. Finally, we discuss the problem of simultaneous vehicle dispatching with precedence constraints. We have modeled the problem as a nonlinear mixed integer programming model and proposed an iterative solution procedure to obtain reasonable solutions in considerable times. Moreover, we have presented the worst-case performance analysis for this heuristic