Simulation of shunting processes at Novelis Deutschland GmbH

Overview

Location: Nachterstedt, Saxony-Anhalt, Germany
Project duration: 3 months
Focus: Simulation, rail logistics, shunting

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out the simulation of shunting processes for Novelis Deutschland GmbH. The aim was to realistically map shunting processes, dimension capacities and vehicle requirements and derive optimal sequences and travel times for a stable interface supply between logistics and production.

Project content

Simulation model of the shunting processes

Mapping of the shunting processes in a simulation model, taking into account the plant logistics and processes. Representation of routes, parking and transfer points.

Shunting logics under boundary conditions

Development of suitable shunting logics according to operational framework conditions. Ensuring robust processes despite restrictions and bottlenecks.

Optimal wagon sequences (inbound trains)

Determining optimal sequences for inbound trains. Reduction of transfer times and stabilization of the supply to the production areas.

Track system expansion requirements

Determination of the necessary expansion of the track systems in terms of number and length. Technical and economic assessment to safeguard investments.

Shunting vehicle numbers and utilization

Determination of the required number and utilization of shunting vehicles. Dimensioning for high-performance, cost-efficient operation.

Arrival and departure times

Determination of optimum arrival and departure times in the work cycle. Smoothing out peaks and ensuring plannable logistics windows.

Advantages of our solution

• Decision reliability: Realistic simulations and clear evaluations create a reliable basis for measures.
• Infrastructure clarity: Determined expansion requirements for track systems make investments comparable and plannable.
• Resource efficiency: Dimensioned number of vehicles and capacity utilization reduce operating costs and increase availability.
• Time stability: Optimized arrival and departure times smooth out peaks and ensure interface supply.
• Process quality: Optimal wagon sequences shorten turnaround times and stabilize the material flow to production.
   

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