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Lemain TR - Repository TU Delft

1. A information call for e information H tender A2 1 i Ask questions to swers customer Internet gt customer remarks colleagues VI systems books A2 2 VI sales reference database J A VI Determine total total system strategy system requirements requirements D lt A2 3 Develop concept line diagrams concepts gt alternatives S l l gt y A2 4 i Choose system System Detail selected concept line di concept m _ line diagram I di iagram VI product data book A2 5 A2 6 MS Office visystems MS Office books Write technology iachiolog inti y gt description gt description A2 7 MS Office building gt drawing request 136 Appendices Level A2 1 Function Gather information Current situation proposal request form Collect info by mental problem model I communicating gt with sales man 7 select the system system proposal request form p 7 y A2 1 1 customer characteristics related info gt i terminal environment characteristics A2 1 terminal characteristics gt 1 6 Collect info on adi the Internet amp VI 2 atonal Into p gt orse Public Library A2 1 2 Internet l VI systems books y VI sales reference database Exchange additional VI knowledge of knowledge with Building gt Il drawing colleagues request A2 1 3 Collect info from Sub contracters info gt
2. When a model is created in the 2D model layout window a 3D visualisation is created automatically The shadow of a rotated Non accumulating conveyor atom is animated in a wrong way Not possible to define some named views in order to go through the model by using only the defined keys on the keyboard Wish option of named views you link a certain view to a unique key which you can use during building validating and presenting the model When atoms and or there icons overlap there is no possibility to send them to back or front Wish possibility to send atoms to front or back No standard drawing objects are implemented in ED e g line and shape atoms The visualisations of atoms including their contents disappear when the core the actual atom is of the screen This way zooming in order to observe parts of a model gets hard Wish In order to maintain overview on a big model some standard drawing possibilities are required Wish enlarge range in which the atoms are visualised also visualise if atom is of the screen In big models the visualisation of the channels is chaotic 1 6 4 Features 3D color resizing zooming and pixel vector Possibilities Wish The channels should be more flexible If the user can drag the channels in a certain shape the overview with the option show channels is much better Remarks Choosing the virtual real
3. 5 Procedural requirements Possible relevant factors Tender document content and layout Presentations or reports intermediary Actions in certain periods of time planning Open competition legislation Etc Requirm Description level mandatory according the characteristics guidance mentioned in the introduction Concept worksheet Man Den hianve Lae Us Eee Ss BHS concept documentation Document objective Support the complete documentation evaluation and justification of designed BHS concepts Content 1 Concept layout 2 Technology specification 3 Cost effectiveness 4 References EeE e PF ET EEE E E EEE E E EEE Gi 1 Concept layout 1 1 Material flow diagram add MFD from e g MS Visio by copy amp paste Comments Comments regarding the MFD Requirements and or constraints concerning this MFD concept Requirem Description Compliance VI Priority Assigned Organsiation Person constr level to ID code Requirement constraint Mandatory High initials Organisation name Person name description guidance medium low FT10 1 0 0 0 0 N A N A SR9 1 o 0 0 0 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A The same combination of input window remarks table and applying requirements table is provided for the line diagram and a layout drawing e g the 2D or 3D s
4. Possibilities Remarks Yes defined by a unit of time or by entering 4Dscript 1 5 4 Reset capabilities Possibility to stop the simulation during a run and restart Possibilities Remarks Yes the Run Control Window contains start stop pause reset and step facilities 1 5 5 Start in not empty state Possibility to start with a simulation model in which already objects or entities are included Possibilities Remarks Entering 4Dscript in the OnCreation event handler makes it possible 1 5 6 Speed control Possibility to change the speed of the simulation link to a real time clock stop and start save model during the run Possibilities Remarks The Run Control Window contains the follow options Reset run stop step Speed options unlimited real time approximately slide control custom sec min or hours real sec synchro real time catch up and slow down Slide control slide control to change the speed continuously between pause and unlimited 1 5 7 Executable models Availability of pack and go versions that can be shown at any location at any PC just with a part of the simulation or no simulation software at all 179 Appendices Possibilities Remarks Not available 1 6 Animation 1 6 1 Integrity Animation comes as an integral part of the package or is added Possibilities Remarks Integral animation ED is appropriate for buildi
5. Reasoned by analogy the expert strategy participative strategy and adaptive strategy as defined in Meel van 1993 apply here The expert strategy means that Vanderlande Industries designs the BHS all by itself That is efficient but the acceptation 61 Chapter 5 A new design methodology of the design will be hard because of the not invented here syndrome The opposite is the participative strategy all design choices are made by all stakeholders themselves and are based on consensus between the stakeholders The acceptation will improve but the design process will not be efficient Therefor the best is a mix between these strategies called the adaptive strategy Stakeholders including the customer can learn from Vanderlande Industries and vice versa For effective learning a close corporation between all stakeholders and Vanderlande Industries is needed in all phases of the design process Stakeholders outside Vanderlande Industries often have much knowledge of organisational business processes bottlenecks in current functioning and possible improvements Vanderlande Industries brings in knowledge about the design methodologies techniques and tools and can suggest possible overlooked alternatives So the process manager must control this alternation in the design process This means attention evaluation for both the completeness and correctness of the stakeholders and requirements analysis this includes the lobby feedb
6. 1 The employees of Vanderlande Industries who are involved in the sales phase of a BHS pay too little attention to the complex context of the decision process of the customer and therefor possibly not make the best of their chances to influence that decision The problem from a meso perspective 2 The employees of different departments and Customer Centres of Vanderlande Industries who are involved in the sales phase of a BHS do not work as a team regarding The elicitation interpretation and documentation of information regarding the total set of requirements on a BHS Structured evaluation of design choices made in the BHS design process The problems from a micro perspective 3 The Sales and Systems engineers of Vanderlande Industries do not adequately document their quantitative or qualitative foundation of the design choices that are made in the design process of a BHS 4 The Sales and Systems engineers of Vanderlande Industries seldom integrate quantitative results of dynamic behaviour and cost 4 4 Why is it a problem A second question to answer is Why are the stated problems as defined in the previous section a problem In order to locate the possible consequences of the problems at Vanderlande Industries more precise the three perspectives micro meso and macro are used again This shows that although a problem is described from a certain perspective the consequences of that probl
7. 8 Communication agreements 9 Meetings overview 10 Other communication overview 11 Strategy in stakeholders approach 12 General remarks 1 Initial problem description description of the problem with which the customer approaches VI Author ____ Jfinitials Problem description 2 Organisation chart customer Organisation chart including names communication lines 3 Stakeholders Not only those stakeholders that are intentionally selected and activated and thus more closely involved in the design process but also the indirect involved stakeholders who can play an important role such as blocking or promoting a solution Think of Airport authorities Airport employees levels management operations maintenance contracting finance etc Airport operators Main contractors Consultants Airlines Architects Project managers external Handling agent independent party with core business baggage handling e g OGDEN Competitors Agents working for VI or other stakeholders Partners mostly Controls Sub contractors Security stakeholder Shop owners Government different levels EU National District Local Passengers Media Commercial organisations with influence for instance large customer of airport Agents VI colleagues management Salesmen Area managers Sales engineers Systems engineers Simulation engineers CAD engineers Controls engineers Contracting Mechanical engineers R amp D eng
8. Call for tender gt or a gli VI experience terminal characteristics Make building and concept CAD concept layout drawing VI experience VI strategy expenditures Pricing Engineer A6 sc na pricing tool drawing gt remarks CAD Bi ASI vi experience CAD tools Desi trol remarks esign controls gt p i controls architecture architecture Controls Engineer A4 call for tender VI experience Determine simulation dynamic system report gt behaviour Simulation e remarks Engineer AS Simulation tools Appendices Current situation remarks Calculate capital gt gt system price VI experience Compose tender p document gt A7 Sales man Y characteristics building v drawing request Design system concept line diagram Systems Sales technology Engineer A2 description j j Internet amp MS Office VI product data book VI systems books VI sales reference database 135 Tender document MS Office Appendices Level A2 Function Design system concept Current situation proposal request form VI experience terminal characteristics customer characteristics pene environment characteristics Gather N system related
9. E Standard graph E lol x I Fie Edit Type Settings SES s aal elute alla Kael Joost p r year Bosio Buti Anm Lot Calculatori at 3000 20 000 sine 20600 2000 Figure 6 14 The input and output results after reset The graph that appears contains the cost the customer or Vanderlande Industries depending on the contract will have to face in the life cycle years of the BHS In the first year logically the cost are the highest In this year the customer has to invest in the system components installation training documentation initial spares etc The years after contain both fixed cost such as the consumables and personnel cost and variable cost the spare parts including overhaul The results in the graph can be documented easily by clicking the edit button in the graph window and then choosing between copying the data or the graph bitmap itself The results can be pasted in other applications such as MS Excel and therefor in the BHS concept justification tool introduced in section 6 2 If the engineer had chosen a cumulative graph in the first step of the input menu a graph as shown in figure 6 15 appears 88 Chapter 6 Supporting tools E standard graph 0 x File Edit Type Settings oe OS te i le AAAS Cumulative cost per year aj 1 2 200 E 5 2450 o 21004 5 i oo 20504 t 3 4 1 Le AT i 7 2000 Se ee ii l eal O1795
10. Interfaces with existing software Failure modes Start up after emergency stop Software up gradeability RFID Radio Frequency Identification Routing and balancing Peak shaving Ete Author Requirm Description Assigned Compliance VI priority Date Comments to level ID initials ID code Requirement description initials mandatory high dd mm yy further details and according the characteristics guidance medium yy possible changes mentioned in the introduction low Po SP71 __ SR7 2 SR7 3 4 8 Maintainability requirements Possible relevant factors Maximum TTR time to repair or MTTR mean time to repair No or few special tools required Reduced spare parts use Maintenance control systems Training operational capability International back up systems Ete Author Requirm Description Assigned Compliance VI priority Date Comments ID to level initials ID code Requirement description initials mandatory high dd mm yy further details and according the characteristics guidance medium yy possible changes mentioned in the introduction low Po SRO o T S LL ____ SR8 2 SR8 3 4 9 Safety requirements Possible relevant factors Emergency stops Danger detection Fencing Fire protection not only in a technical way but also in a human way e g fire escape routes operators Risk Analysis what can go wrong what
11. Systems Book Part2 Baggage handling Veghel internal document of Vanderlande Industries 2000 Blanchard B S System Engineering Management New York John Wiley amp Sons Inc 1991 Blanchard B S Verma D Peterson E L Maintainability a key to effective Serviceability and Maintenance Management New York John Wiley amp Sons Inc 1995 Bots P W G et al Inleiding Technische Bestuurskunde leerboek Delft Faculteit der Technische Bestuurskunde 1997 Bruijn de J A Heuvelhof ten E F Sturings instrumenten voor de overheid Over complexe netwerken en een tweede generatie sturingsinstrumenten Houten Educatieve Partners Nederland B V 1994 Bruijn de J A Heuvelhof ten E F Management in netwerken Second edition Utrecht Lemma 1999 Byrne P M Markham W J Improving quality and productivity in the logistics process Oak Brook the Council of Logistics Management 1991 Enserink B et al TB2 1 Analyse van complexe omgevingen Diktaat leerboek Delft Subfaculteit der Technische Bestuurskunde 1999 Hazelrigg G A Systems engineering an approach for information based design Upper Saddle River Prentice Hall Inc 1996 Hooks I F Farry A Customer Centered Products creating succesul products through smart requirements management New York Amacom 2001 Ludema M W Roos H B Systeemlogistiek college materiaal 1999 2000
12. Table of contents 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 41 SIX Table of contents Chapter 1 Introduction 1 Introduction When people take a flight for instance for holidays they deliver their baggage at a check in desk at the airport From there on the Baggage Handling Systems BHS of two or more airports take care of the baggage to make sure it ends up at the right destination One of the activities of Vanderlande Industries on behalf of who this project is performed is to design manufacture and install such Baggage Handling Systems on airports The desire of Vanderlande Industries to enlarge her market share by improving the current BHS design process formed the lead in this thesis This chapter introduces the company Vanderlande Industries section 1 1 and the main characteristics of a Baggage Handling System section 1 2 To guide the reader through the report section 1 3 contains the report structure including reference instructions to increase the readability 1 1 Vanderlande Industries B V Vanderlande Industries B V is an international company that provides among other things automated material handling systems The company s head office is based in Veghel The Netherlands It incorporates design engineering test and production facilities In addition to the head office subsidiaries so call
13. The structured documentation of a BHS concept the design choices is guided by a template containing the following 1 Concept layout import of the material flow diagram the line diagram a drawing and or another 2D 3D system representation 2 Technology specification includes the same functionality areas as the functionality and technology requirements in the requirements template 3 Cost effectiveness includes throughput in system times resource utilisation redundancy maintainability reliability availability flexibility controllability safety ergonomics and life cycle cost compare Blanchard 1991 4 References includes document name description and location 5 4 4 BHS concept design choices justification The justification of a choice made in the design process exists of a description of the choice including the foundation the reason The description of the choices is included in the template for BHS concepts as described in the previous sub section The foundation can be formed by referring to the requirements on those parts of the systems that are affected by the concerning choice Tracing the requirements a main issue of Requirements Management is the technique used to provide relationships between requirements design and implementation of a system in order to manage the effect of change and ensure the success of the delivered system These relationships are the justification of the designed system by linking the s
14. Transfer gt Read Figure 3 3 An example of a process flow diagram VI internal drawing technique Material Flow Diagram MFD The step from a PFD to a MFD is a small one The MFD is similar to the PFD but now the expected and calculated peak baggage flows between the processes are added The peak flows are the highest expected baggage flows number of bags per time unit that can occur due to fluctuations in the offered bag volumes Note that the MFD represents the peak flows that may occur at different times not simultaneously so the flows can not be added or subtracted without knowledge about their relation in time Line diagrams Based on the PFD MFD and choices of used technology the Sales engineer draws the system layout in a line diagram Figure 3 4 shows a part of a BHS visualised by a line diagram Together with a textual description the line diagram forms the backbone of a BHS concept In a line diagram each line represents a transport line The figure shows the screening and coding configuration from check in and transfer baggage The number of required transport lines and equipment are based on the expected peak flows and the capacity of the used technology In this line diagram for instance three manual coding stations are integrated to handle the total expected flow of no read baggage a N Chapter 3 Current baggage handling system design process Transfer Check In Check In Island 1 Island 2 e
15. 12 12 13 17 18 20 23 26 28 29 29 30 31 33 36 39 41 41 41 41 41 41 41 41 41 viii 6 3 Simulation tool 6 4 Cost calculator 6 5 Maintenance of supporting tools 6 6 Summary 7 Evaluation of methodology and tools 7 1 Evaluation method 7 2 Evaluation of the design methodology 7 3 Evaluation of design choices justification tool 7 4 Evaluation of the simulation tool 7 5 Evaluation of the cost calculator 7 6 Summary 8 Suggested implementation plan 8 1 Designing versus developing the organisation 8 2 Pilot project 8 3 Actual implementation 9 Conclusions and recommendations 9 1 Conclusions 9 2 Recommendations References Appendices Appendix A Vanderlande Industries the company Appendix B Interaction between a BHS and its environment Appendix C Involved employees of Vanderlande Industries Appendix D1 IDEF 0 model of the current design functions Appendix D2 IDEF 0 model of the new design functions Appendix E The design choices justification tool layout Appendix F Cost Breakdown Structure Appendix G Components of a BHS and their functionality Appendix H Object model of a BHS Appendix I Enterprise Dynamics and the BAX Suite evaluation Appendix J Attributes of the cost calculator Appendix K Calculation steps of the cost calculator Appendix L Internal table of the cost calculator Appendix M Adjustments of the BAX Suite objects Appendix N Cost estimation guidelines
16. behind the initial problems These questions are What is the problem section 4 3 and Why is it a problem section 4 4 Section 4 5 describes the solution direction and framework for the solution The findings of this problem analysis are summarised in section 4 6 4 1 Initial problem verification The first initial problem as stated by the Systems Group reads as follows At Vanderlande Industries lives the notion that the Baggage Handling Systems offered in the tender documents can be tuned in a better way to the requirements and wishes of the customer and the system s environment Vanderlande Industries has a good reputation regarding the quality of delivered BHS Now Vanderlande Industries wants to enlarge her market share in the field of baggage handling but with competitors getting closer Vanderlande Industries is compelled to reconsider the current way of designing and offering BHS to potential customers In consultation with Vanderlande Industries the potential customers of the BHS are not involved in the verification of the first initial problem A fulfilling market research would take too much time in relation to the thesis project time and the change to arrange an interview with the decision makers about BHS purchase in the customer s organisation would be small Therefor the information about market demands is mainly obtained by interviewing employees of Vanderlande Industries and reading internal documentati
17. between VI departments Teamwork regarding evaluation and information processing Team formation Team based evaluation Primary tasks at workplace level Integral justification including documentation of design choices BHS design choices justification amp documentation BHS dynamic behaviour analysis BHS cost analysis controlling Pe lt Stakeholders Way of analysis template modelling Requirements analysis template Support Responsibilities division amp documentation BHS concept justification Table 5 5 The new design methodology for the BHS sales phase lt TR BHS concept description template lt designchoices gt lt Simulation model gt Cost breakdown structure Chapter 5 A new design methodology 74 Chapter 6 Supporting tools 6 Supporting tools In the previous chapter the new design methodology is described Within this methodology new activities and models intermediary products are to be introduced in the BHS sales phase at Vanderlande Industries In order to support the employees of Vanderlande Industries in performing these activities automated tools are developed or existing tools of the shelf are evaluated for use in the sales phase In the first section 6 1 the general requirements on the supporting tools will be described In section 6 2 the developed design choices justification tool will be il
18. between requirements and system concepts in text graphical way Visualising the differences No It is not possible to compare two requirement templates and between two versions of visualise the differences only Newer versions of requirements requirement sets within the same template are recognised by an ID code that is derived from the old requirement Generating of reports No No definable reports can be printed the tool layout only Performing a validation by No Besides some defaults the ID codes of relevant requirements or checking whether all constraints have to be linked to the concept by the engineer requirements are himself The only way to check the correctness of these links is by consistently related to the colleague validation during the team evaluations concept Proving the BHS concept is Yes When all requirements and constraints are added in the compliant with the gathered requirement template and the related ID s appear at least once in requirements from the the concept template validated by colleagues the specific part of customer and his the concept can be determined where the requirement is met environment Table 7 1 Evaluation results of test of justification tool against the requirements 7 3 2 Expert validation The reactions on the tool were positive It helps the concerned Vanderlande Industries employees to realise the importance of the process side of the sales phase Although the methodology is based o
19. departments or organisations who are involved in the total project The results of a stakeholder analysis support the engineers in handling the following aspects of the complex network situation in the sales phase e Multiformity The customer exists in all cases of more than one person and in some cases of more then one organisation Understanding of what is going on in the customer s environment and predicting the reactions of the different stakeholders on the proposed system characteristics helps Vanderlande Industries to deal with the threat of multiformity This threat is the possibility that stakeholder s to whom the system is fit do not have enough power to make purchase decisions Bruijn de Heuvelhof ten 1994 Besides it helps exploiting the opportunity of multiformity being the possibility to get awarded with the contract even with just a small effort because the right stakeholders were satisfied touch the right chord e Uncertainties In an early stage of the sales phase the stakeholders themselves often cannot make their requirements and performance indicators clear A stakeholder analysis can then support the concerned Vanderlande Industries employees in weighing the different factors impact and therefor their importance priority to the stakeholders e Interdependencies All the stakeholders who are involved or can be involved in the system decision making process are in some way related to each other Being aware of
20. developed Table 6 1 shows the relation between the developed methodology and the introduced tools Macro Meso Micro Cooperation of Coordination of processes Primary tasks at organisations between VI departments workplace level Getting grip on the Teamwork regarding Integral justification Way of ca J x 7 hinki decision process of the evaluation and information including documentation of thinking customer processing design choices Lobby BHS design choices justification Way of Stakeholders analysis Team formation amp documentation i Requirements analysis Team based evaluation BHS dynamic behaviour analysis working SRO Feedback elicitation BHS cost analysis lt lt Process manager H lt Commitment gt Way of Drop out prevention _____ controlling a Suppor lt Responsibilities division amp documentation Stakeholders s lt BHS concept Way of analysis template BHS concept description template lt __ design choices lt Simulation model gt justification Cost breakdown analysis template Pe gt structure modelling Requirements Design choices justification tool gt Supporting A tools lt Simulation tool gt lt Cost calculator gt Table 6 1 The new design methodology including supporting tools The design choices justification tool is a MS Exc
21. experience and preferences icro sai DS Therefor it is possible that certain design directions are not considered which can lead to sub optimal BHS concepts Table 4 2 Consequences of problem 2 34 Chapter 4 Problem analysis What is the problem 3 The Sales and Systems engineers of Vanderlande Industries do not adequately document their quantitative or qualitative foundation of the design choices that are made in the design process of a BHS Considered Why is it a problem Perspective A lack of documented design choices foundation can undermine the professional appearance to external parties e g if a Sales man presents a BHS concept to a Macro customer without knowing why certain choices are made by a Systems engineer Besides there are no checks possible whether Vanderlande Industries adapts to the dynamic environment Lack of a documented foundation means no possibility of structured team based and efficient evaluation of design choices It also discourages cooperation because the origin of design choices are unclear to employees of other Meso departments and increases the chance for double work same considerations regarding the design choices are made by different employees Finally the lack of foundation of choices makes taking over someone else his work quite difficult The Sales and Systems engineers do not have the opportunity to reuse earlier Mi work because the ba
22. graphical oriented simulation package including BHS objects 3 The cost calculator developed based on the simulation tool containing different elements of life cycle costs with the emphasis on the investment costs Evaluation sessions with employees of different departments and Customer Centres showed appreciation and support for the suggested methodology and tools It is broadly recognised that introduction will help reaching the objective which implies improvement of the professional appearance the design process efficiency and the competitiveness of Vanderlande Industries The new methodology and tools are not tested in a real situation because of the limited time available for this thesis Therefor Vanderlande Industries is advised to use them in pilot projects first followed by an evaluation before implementation in the entire organisation As a result of this thesis recommendations are made towards Vanderlande Industries concerning further research or activities The following recommendations focus on efficiency improvements e Tailoring of the methodology and tools for usage by other disciplines such as Warehousing amp Distribution and Express Services Industry e Keeping up to date regarding the linking of AutoCad and Enterprise Dynamics software e Research on possible efficiency improvements regarding reuse of work in phases after the sales phase e Involvement in the development of the ED BAXSIM library Two recommendations a
23. mentioned in the introduction low SR4 1 SR4 2 SR4 3 4 5 Flexibility requirements Possible relevant factors Modular concept or different alternatives Extendibility future extensions possible Phaseability installations in phases possible without operational interruption System functionality Down gradeability system used only partly in quiet hours Ete Author a Description Assigned Compliance VI priority Date Comments to level initials ID aa Requirement description initials mandatory high dii further details and according the characteristics guidance medium possible changes mentioned in the introduction low PoE SRE LUI LuUEOul o _ E SR5 2 SR5 3 4 6 Conveyability requirements Possible relevant factors Straight lines few curves allowed Minimum points of transfer Minimal slopes Tubbing of raw baggage Handling smoothness Ete ID to level initials ID code Requirement description initials mandatory high dd mm yy further details and according the characteristics guidance it possible changes mentioned in the introduction SR6 1 Po sree _ ____L__L__ rr__ spes PT 156 Appendices 4 7 Controllability requirements Possible relevant factors Tracking and tracing Status information operational continuous information Management reporting statistics what data at what moment in what form
24. note that this is applicable for the Sales and Systems engineers in general and might not apply to each engineer individually The awareness of the inadequately attention for the customer oriented way of working sets in as appears from the CARE project but the link between the corporal thinking and the individual actions are still missing The moment the engineers are aware of the incompetence they can put effort in learning how to work customer environment focused and then will end up in phase 3 After a while CARE Customer Awareness Reinforcement A project started at VI leaded by external consultants to improve the employee s awareness of the importance of customer satisfaction 45 Chapter 5 A new design methodology working customer focused becomes the standard way of working and the awareness slowly disappears The engineers do not know better than to concentrate on the customer s environment and phase 4 is reached But because of the dynamics of the world outside Vanderlande Industries new incompetence can be discovered and if recognised by Vanderlande Industries the whole process starts all over again Integration of a stakeholder analysis and requirement definition in the design process of the Vanderlande Industries engineers could support the transitions from phase 1 to phase 2 and from phase 2 to phase 3 5 1 2 Way of thinking a meso perspective The lack of teamwork regarding evaluation of BHS concepts and
25. parts of the model can be selected in order to hide the involved channels But this activity takes much time Wish possibility to change the way the channels are lay down in the model layout make it flexible connectors in order to create a conveniently arranged overview Wish possibility to develop models in different layers Incontrol ED Containers can be very useful to create sub models layers Incontrol ED Atoms can also be connected by selecting the atom and channel to connect to from a list By default the dimensions of the atoms as displayed are used in the logic This connection can be switched of in the pop up menu of every atom Use physical dimension 1 4 2 Input of data Provide the simulation model with data Important issues include reading from file variables that need to be set interactive input with menus automatically read from database checking input values Possibilities Remarks After and during building a model the reset function makes it possible to check the consistence of the model before running it 176 Appendices When wrong syntax is entered in an atom this is reported in the error monitor right after the apply or ok button of the 4Dscript window is activated or on clicking the F10 button Some input parameters of the atoms are checked automatically If the entered value or string is not correct the possible range is
26. size and speed e Label fields By using the atom editor these characteristics can be accessed and changed When an atom is created it is always a daughter of another atom This other atom can be an existing atom from a library but can also be a base class atom A base class atom is an empty atom that has no functionality and only has default settings like no attributes no behaviour an empty table and its colour is black All atoms are built using the ED programming language called 4Dscript I 3 Vendor 1 3 1 Pedigree Pedigree discusses issues on the historical information about the software and the vendor It includes age of the software references upgrades other products and spread of the product 172 Appendices Characteristics Remarks Enterprise Dynamics focuses on large and medium sized companies and authorities Main markets are industry manufacturing material handling warehousing and infrastructure airports ports rail References several case studies are placed on their website www EnterpriseDynamics com ED can be used for capacity determinations designing internal transport Incontrol ED The cost systems designing warehouse size strategy and transport storage levels benefit analysis can be done analysis bottleneck analysis and performance analysis Cost benefit using cost atoms attributes analysis is not supported by ED event handlers and 4DScript Updates of th
27. support the engineers in the cost analysis activity the breakdown structure as shown in figure 5 5 is used to allocate different cost aspects of a BHS It is meant to be a convenient framework upon which further details can be introduced Life Cycle Cost Total installed Total operating cost cost Project installed Maintenance osi O amp M set up cost Operation cost cost Capital expenditure Training Management Maintenance team Documentation Operating team Spare parts usage Installation equipment Handling team Initial spares Energy Figure 5 5 Life Cycle Cost breakdown structure These elements are based on the elements as mentioned in the Cost Breakdown Structure of Blanchard see figure appendix F Since this breakdown structure is too detailed to implement at Vanderlande Industries to introduce the Life Cycle Cost design thought the start has to be simple and conveniently arranged elements are omitted or joined The following demarcation for the cost calculator came into being while consulting engineers of different departments Proposal Verification amp Pricing Maintenance Service International Simulation and Systems Development As mentioned above for now only the costs from the owner s point of view are included This means that the development and production costs are not considered separ
28. 1 and 6 2 Besides the tool is judged by several employees of Vanderlande Industries for a list with names is referred to appendix C This expert validation is described in sub section 7 3 2 The final sub section recapitulates the findings 7 3 1 Test against the requirements In the following table the requirements are shown including the level of compliantness and the characteristics it is based on Requirement Com Tool characteristic pliant Form a guideline in the Yes The stakeholder worksheet of the tool offers a template for the exploration of the stakeholder analysis including hints regarding possible factors of stakeholders environment influence Applicable for all BHS Yes It is not required that each field of the templates is filled so also systems less complex environments can be documented The templates can be extended if required Stimulate engineers to Yes For each part of the designed concept the relevant requirements document their design must be filled in which offers evaluation and justification foundation possibilities in meetings with colleagues Enable efficient and Yes The gathered information is shared with colleagues and stored in effective knowledge capture related groups Use graphical Partly The tool includes edit fields that must be filled with diagrams and representations for layouts All edit fields in the templates are coloured white _ 97 Chapter 7 Evaluat
29. 2 1 In the first kickoff meeting of 63 Chapter 5 A new design methodology that team the responsibilities for all activities as planned in the design effort have to be allocated and documented including the planning Lobby Lobby takes place at several levels Besides the Agent the Salesman and the Areamanager also other team members or members of the higher management can lobby The process manager must take care of the adjustment and the frequency of the lobby activities The exchange of relevant information gained during lobby should happen via the process manager he she must judge whether information can be documented or not Stakeholders analysis The Salesman must start the stakeholders analysis the moment he she or a Agent discovers a potential market The analysis results are reported to the Area manager The results at the moment of the team formation enable the other team members to study the situation preparation on the kick off meeting During the total project the Salesman is the main responsible for the stakeholders analysis Changes or additions discovered by others should be documented via the Salesman The process manager must enable frequent team based evaluation of the stakeholders results Both the composition and the evaluations are guided by a template checklist Requirements analysis The requirements on a BHS start at an abstract level and get more and more detailed during the sales phase The
30. 2 Research description business process were made and communicated in order to elicit feedback maintain and create support for the solutions and support the evaluation activities The models exist of an activity actor diagram and an IDEF 0 model both accompanied by textual description Develop supporting tool In order to support the new business process activities automated tools were introduced First the requirements for the new tools were defined by talking to the future users and reading literature concerning automated support Then tools were developed or just evaluated in case of existing tools More details on the tools can be found in chapter 6 Evaluate solution Because of the limited time during the thesis project the proposed solutions were not evaluated in a real situation Instead the prescriptive models of the new to be situation were evaluated with Vanderlande Industries employees see appendix C for the list of involved employees The supporting tools were evaluated by confrontation with Vanderlande Industries employees and application in test cases More details on the evaluation can be found in chapter 7 Write implementation plan To initiate the change from the current as is situation to the proposed to be situation a brief implementation plan is included in this report It advises Vanderlande Industries on how to realise the change to the new desired situation chapter 8 15 Chapter 2
31. 3 1 The Sales engineer or Systems engineer makes several schematic diagrams of BHS concepts see section 3 2 In the meanwhile the CAD engineer starts drawing the area of the terminal where the system has to be installed During the creation of several options of BHS concepts the Sales engineer analyses and discusses the options and choices made with other colleagues such as the Controls engineer If remarks made convince the Sales engineer that the concepts have to be modified he does so Then one concept is chosen from the options and further detailed Very important in this process is the feedback from the CAD engineer whether a concept configured in a schematic way physically fits in the terminal area Besides the schematic diagrams the Sales engineer also describes the planned technology briefly The CAD engineers draw the chosen BHS concept in the terminal building in order to convince the customer that the BHS will fit The Simulation engineer builds a simulation model to confirm the performance of a BHS concept First of all this confirmation preserves Vanderlande Industries from offering a BHS which can not meet the performance requirements Besides it convinces the customer that the presented concept will meet the performance requirements If more complex controls are necessary the Controls engineer is involved in the simulation model building too Now more than one engineer of Vanderlande Industries is working on the details of the
32. 4 During team meetings the relevance of each element must be clarified to determine the time that can be spend on the calculations 5 2 4 The new overall BHS design process in the sales phase All activities of the previous sub sections are brought together in the new design process based on the iterative process steps of Systems Engineering requirements definition functional analysis synthesis optimisation design test and evaluation Blanchard 1991 12 Figure 5 3 presents the activity actor diagram of the new situation This diagram mainly clarifies the changes from the macro and meso perspective The micro perspective is considered in the IDEF 0 models included in appendix D2 and described in sub section 5 2 5 The boxes of the activity actor diagram contain the activities that should be performed In this diagram the columns represent the expertise of a certain discipline not necessarily an engineer of that discipline e g calculation of a system price can be done on different levels of detail not necessarily by a calculation engineer Stakeholders and requirements analysis The first step taken by Vanderlande Industries analysing and documenting the stakeholders and the initial requirements starts long before the customer writes the call for tender It can take years before the customer actually tenders after a long time of speaking to different parties and letting the world know that a new BHS will be required During th
33. ID 12C B 21 BAX_LCC 1D 122 1 A027 Lead Times D 2 A001 Atom Attributes D 3 A002 Baggage D 1 4 A003 Baggage Generator E 5 A004 Baggage Generator FS 8 4005 Baggage Source I H 7 VI Carousel ID 131 8 VI Checkin Isle ID 13 3 A008 Curved Non Accumulating Conveyor 10 VI Manual Coding Station IC 11 VI Belt Conveyor D 1 12 A011 Switch D 1 13 A013 Line Sorter D 14 VI SideMerge D 1 15 A015 Originating Point D 16 VI Automatic Coding Station Il 17 VI Screening Level amp 2 IC 18 A018 Sorter Curve D 19 VI TraySorter Chute D 20 VI TraySorter Induction D 21 A021 Sorter Scan D 22 VI EBS ID 152 23 A023 Transfer Unloading Quay E 24 VI Tray Sorter 1 15 E 25 A025 Tub Station D 26 VI VertiSorter ID 161 27 VI Start Stop Conveyor D 28 A029 Curved Accumulating Conveyor 29 A012 Lateral Sink D 30 A030 Buffering Belt Conveyor 31 A031 Sink ID 18 32 Naming atom ID 1 33 VI VertiMerge ID 1E 34 VI Screening Level3 DI x OE 7 749 16 515 atom A031 Sink7 at 14 000 19 000 size 5 000 2 000 Figure 6 5 2D model layout library tree and run control window within the ED window When the 2D model layout is created the simulation package automatically generates a 3D model layout This supports the engineer in presenting the model to other people and validating the configuration and logic Figure 6 6 shows the 3D representation of the simulation model of figure 6 5 82 Chapter 6 Supporting tools E Model 3d View lol x Figure 6 6
34. Industries Therefor communication with these stakeholders is very important and Vanderlande Industries must prevent that one or more stakeholders stop communicating This can be achieved by convincing the stakeholders that their opinion really matters and influences the BHS design Realising that their remarks are heard and they really have possibilities to influence the BHS design prevents these stakeholders to shut the door for employees of Vanderlande Industries From a meso perspective the process manager must prevent that certain team members drop out of the team never show up at meetings and avoiding communication with other members This can be realised by delegating not only the primary design tasks but also managerial tasks regarding the team functioning such as preparation of meetings planning and evaluation tasks 5 3 5 Responsibility division and documentation In order to clarify the responsibilities of the activities in the design effort and to create the possibility to verify the results the responsibilities have to be divided documented and delegated to the different team members Besides for the activities already included in the current design process the responsibilities for the activities as stated in the way of working have to be allocated during the team meetings Team formation The team must be formed by the Salesman final responsibility of the Area manager involving the colleagues as mentioned in sub section 5
35. JGr JGr 501 Screening machine Levell amp 2 20 MB 502 Screening Machine Level3 10 MB 601 Automated Coding Station 20 JGr 602 Manual Coding Station 10 JGr 197 Appendices 701 TraySorter Helixorter 20 25 30 35 JGr JGr JGr JGr 702 TraySorter Induct 30 JGr 703 TraySorter Chute 35 JGr 801 VertiMerge 10 JGr 802 Sidemerge 20 JGr 901 EBS Conveyors 10 15 Maaike Maaike Gremmen Gremmen Table J 1 Internal table of the LCC calculator February 2002 Clarification of the internal table content The first column contains the LCC code that refers to the specific BHS component as mentioned in the second column These codes are also added as an attribute to the simulation atoms of the BAX Suite see appendix M The columns named CAPEXI to CAPEXA are different unit prices that are necessary to calculate the total purchase price The calculation method depends on the concerning BHS component Each component has an attribute that contains a unique LCC code Based on this code the LCC calculator finds the right row to be used for the calculation in the internal table If besides the LCC code another attribute of the BHS component is used these attributes are also mentioned below Conveyor belt A conveyor belt costs 10 see table euro meter or 15 euro meter if the speed exceeds the 80 m min please note that these prices already include
36. Justification of the design choices prevents engineers to add extra features to the BHS without real needs Integral design The philosophy of Concurrent Engineering also applies to the to be situation at Vanderlande Industries The Concurrent Engineering approach is focussed on making the designers aware right from the start of all aspects involved in the life cycle of the system such as quality cost planning and user requirements Ludema Roos 1998 The quality of a system consists not only of the quality of the components and the configuration of the system itself but of both that system and its associated processes in designing building using and maintaining it over its useful system life Justification quantification by simulation experiments As explained in section 1 2 a bag in a BHS follows a certain sequence of processes depending on all kind of characteristics of both the bag it self and the status and number of BHS components All these relations influence each other which results in a complex dynamic behaviour of the BHS that determines the performance of the BHS Simulation experiments offer the engineers quantified characteristics of proposed BHS performance The definition of simulation given by Shannon Sol e a 1999 The process of designing a model of a real system and conducting experiments with this model for the purpose either of understanding the behaviour of the system or of evaluation various str
37. Pilot projects The methodology and tools are not evaluated in reality yet Therefor before implementing the methodology and tools in the entire organisation Vanderlande Industries is advised to evaluate them in real situations in pilot projects 9 2 Recommendations As concluded above Vanderlande Industries is advised to implement the introduced methodology and supporting tools in pilot projects In this report different aspects of improvement of the BHS sales phase are explored Based on these findings several recommendations are made for further improvements concerning the future processes at Vanderlande Industries Recommendations regarding efficiency improvements are included in sub section 9 2 1 In sub section 9 2 2 two recommendations are discussed concerning further research on the cost aspects of a BHS 9 2 1 Efficiency improvements To start with in general standardisation of procedures methods and tools and the reuse of work improve the efficiency of processes in organisations Introducing standardisation in procedures and methods at different departments improves the manageability of the organisation Standardisation in the supporting tools improves the return on investment training and purchases and the adjustment of intermediary products Applying this to the situation at Vanderlande Industries results in the following recommendations Tailoring methodology and tools to usage by other disciplines Many aspects of the metho
38. Research description 16 Chapter 3 Current baggage handling system design process 3 Current baggage handling system design process Within Vanderlande Industries there are three phases that are distinguished during a total BHS project life namely the sales build and service phase figure 3 1 This thesis focuses on the sales phase Most of Vanderlande Industries orders are handled as a turnkey project The sales phase is carried out before the project is actually sold A BHS is sold on the basis of a designed system concept a price and a planning A system concept exists not only of a functionality definition but also includes the layout the technology used for each part of the system and often the results of a simulation study When the system is sold the build phase starts with elaborating the system concept design and manufacturing the equipment After installation and extensive testing of the system to take care of possible start up problems the customer can use it for operation In the service phase a service team will take care of preventive maintenance and will be stand by to solve occurring problems BUILD SERVICE Activities Activities Installation Service Testing Training Research scope Figure 3 1 Project phases at Vanderlande Industries with the main activities If a new project is relatively small and simple the Customer Centres take care of all three phases except for the manufacturing
39. Rotterdam Erasmus Universiteit Rotterdam 1998 Mayer R J Delivering results evolving BPR from art to engineering Texas Texas A amp M University College Station 2001 Chapter 1 to be published in a forthcoming book on Business Process Reengineering by Kluwer Meel J W van The dynamics of business engineering Reflections on two case studies within the Amsterdam Municipal Police Force Delft proefschrift 1993 Meel J W van A hard core for soft problems A business engineering case study within the Amsterdam Municipal Police Force In A Verbraeck et al Proceedings of the fourth international working conference on dynamic modeling and information systems Delft Delft University Press 1994 239 270 Nikoukaran J et al A hierarchical framework for evaluating simulation software In Verbraeck A et al TB9309 Simulation masterclass reader Delft Faculteit Techniek Bestuur en Management opleiding Technische Bestuurskunde 2000 121 References Putten van R Life Cycle Costs and Availability for Materials Handling Systems Master thesis University of Twente 1999 Sol H G et al 7B232 Discrete Modellen deel 2 Delft Subfaculteit Technische Bestuurskunde 1999 Sol H G 7B311 Introductie Reader In H G Sol TB311 Introductie reader 2000 Delft Faculteit Techniek Bestuur en Management opleiding Technische Bestuurskunde 2000a Sol H G De vier
40. Systems engineers e A good adjustment of the design choices to the total set of requirements and wishes or a good adjustment of the total set of requirements and wishes to the design choices Based on these implications the following underlying problems are defined e Too little attention for the decision process of the customer e Too little teamwork regarding information processing and evaluation e No structured and complete documentation of the design choices including justification e Seldom integration of quantified results of a dynamic behaviour analysis and cost analysis in an early stage of the design process The main consequences of these problems are e Vanderlande Industries does not maximise her possibilities to influence the decision process of the customer which can lead to missing orders e They can damage the professional appearance of Vanderlande Industries e They can lead to an inefficient design process e The engineers do not found their designed BHS concepts on a thorough insight which can lead to sub optimal solutions The problems cover a wide spread of problem areas so in order to structure the compound solution a new design methodology is developed The framework of the methodology includes a way of thinking working controlling and modelling and the methodology can be supported by automated tools The new methodology is described in the following chapter 39 Chapter 4 Problem analysis 40 Chapter 5
41. a suggested implementation plan is described to implement the new methodology in the Vanderlande Industries organisation Finally conclusions are drawn in chapter 9 including recommendations for further research At the beginning of the report a glossary is included to clarify used terminology and abbreviations In the text is referred to literature and electronic data on the Internet These references are enclosed in square brackets Right after chapter 9 a references overview is included Finally there are appendices included with alphabetical index They can be helpful in clarifying parts of the report and are referred to in the text 10 Chapter 2 Research description 2 Research description This chapter deals with the reason why Vanderlande Industries needed the research as described in this master thesis and with the research approach The first section 2 1 describes the initial problem as stated by Vanderlande Industries at the beginning of the project Section 2 2 contains the research objective based on the initial problems Then the research scope is demarcated to get research proportions that can be handled in the research time available section 2 3 and finally the research approach is presented in section 2 4 2 1 Initial problem description When a new airport is built or an existing airport decides to replace or extend their Baggage Handling System usually a call for a tender is sent to potential suppliers cont
42. a defined system configuration through the top down iterative process of requirements definition functional analysis synthesis optimisation design test and evaluation Blanchard 1991 12 This approach is relevant because it forms the main lead in the current design process at Vanderlande Industries Business Engineering BE defined as a design perspective on the organisation of the business processes themselves as well as on the supporting role of ICT in these processes Meel van 1993 Other terms than BE referring to designing business processes are Business Process Re design Business Process Re engineering and Business Systems Engineering Verbraeck 2000 5 In the now a days BHS design processes supporting ICT can not be omitted SocioTechnical Design defined as a design perspective on the integral design of social and technical structures with the emphasis on organisational change Meel van 94 Because the problems also include aspects of teamwork this field of knowledge should be taken in consideration when finding solutions Requirements Management defined as tracking requirements status and change activity and tracing requirements to the various phases and products of the development effort Young 2001 316 The relevance of the requirements is stressed by the implications of the desired situation section 4 2 therefor this field of knowledge must be integrated in the solution s Management of change changin
43. a separate function 1 7 7 Display features Dynamic display of variables attributes and functions during the run and during debugging Possibilities Remarks The monitor atom can be linked to any atom in the model and is able to Wish A stand alone display properties like average content current content average stay time variable atom that can be status and output The user can also define other properties in 4Dscript placed in the model atom and Some atoms display in the 2D window their main performance indicator displays its current value e g the output of a source the occupancy of a server and the contentofa with options in displaying queue the value over time etc Incontrol ED In E D 4 0 a watches window is available that shows values of expressions in run time The clock item which can be chosen from the main pull down menu has different ways of displaying the time analogue digital and the date The refresh period can be adjusted high normal and low frequency 184 Appendices 1 8 Output 1 8 1 Reports Standard reports about queue lengths waiting times etc Possibilities Remarks The standard report includes the current and average content the throughput and the average stay time of all atoms Besides that the start and stop time are reported together with the run length in seconds The average occupancies of servers are displayed in th
44. and simulation parts see appendix A for additional details on Vanderlande Industries When a project becomes more complex the engineering parts of the sales phase are supported by the Systems Group in Veghel As mentioned in section 2 4 the work centred analysis framework is used to map the current situation in the sales phase The elements of this framework being the stakeholders the business process the products the information and the technology are discussed in the following sections starting in 3 1 with the stakeholders being a combination of the customer Vanderlande Industries employees and other participants 17 Chapter 3 Current baggage handling system design process 3 1 Stakeholders involved in the current BHS design process In this thesis the customer is not only the stakeholder person group or organisation in the sales phase that wants to buy a BHS but also the stakeholders who are involved in the purchase on wish of the buyer For instance often the airport management calls in a consultancy firm in order to compose the requirements for the desired system or to evaluate the offered system solutions This way the consultants have a great influence on the final decision of the buyer which supplier to choose So the term customer can include e Airport employees on several levels such as management operations and maintenance e Consultants it has become usual that a consultancy firm is hired by the
45. are to be found The engineer should also determine if necessary in consultation of a Simulation engineer whether simulation is the appropriate methodology for the objectives as stated Besides the objectives a planning has to be made and communicated to the design team about which alternatives are to be simulated how the results are evaluated and how long the study will take 3 Model conceptualisation The initial line diagrams already designed by the engineer are used to evaluate different concepts with colleagues in the first place These diagrams are the conceptualisation of the concept s to be simulated 4 Information collection In most situations this step is performed iterative because while talking about the objectives building the model and analysing the results the complexity of the model will changes and therefor the required data will changes Information about the BHS equipment related input such as the speed or capacity can be found in the Vanderlande Industries Product Data Book If available the drawing of the terminal building must be integrated in the simulation study to determine layout _ 54 Chapter 5 10 11 12 A new design methodology possibilities Information about required baggage flows different scenarios and redundancy must be collected and documented in a structured way see section 5 4 and verified with customer and colleagues Model specification The engineer now has to translate th
46. as the location and number of check in desks and the location of the make up area and the main performance requirements are defined Process Flow Diagram PFD Based on the information gathered the Sales engineer starts defining the configuration of the BHS In order to make a line diagram first two smaller steps are made namely making a PFD Process Flow Diagram and a MFD Material Flow Diagram The PFD see figure 3 3 shows what happens with the baggage It deals with questions such as does the baggage need to be screened is there a storage in what sequence are the several baggage handling processes connected etc In the PFD shown below the baggage brought in the system at the check in desks is first read If the label on the bag cannot be read the bag goes to manual coding Then based on the security level for the different countries the bag can go to the Hold Baggage Screening level 1 amp 2 and based on the results to Hold Baggage Screening level 3 amp 4 If it concerns early baggage it will be stored in the Early Baggage Storage for a while before sorting it out to the destinations The transfer baggage can follow the same flow but can also skip the processes and go directly to the destinations 20 Chapter 3 Current baggage handling system design process HBS 1 amp 2 Manual HBS EBS E zI ER Check In Read x gt Destinations E x
47. be defined in 4Dscript 1 4 6 Other items Possibilities Remarks The availability of all atoms can be influenced by the Availability Control atom in combination with the Mtbf Mttr Availability atom These atoms include deterministic as well as stochastic down periods and intervals It is also possible to turn the availability of one or more atoms of by clicking the Switch Availability atom by mouse The time Schedule Availability atom allows the user to create a down period table I 5 Execution 1 5 1 Multiple runs Possibility to execute a simulation replication several times without user interface Possibilities Remarks When the atom Experiment is placed in the model atom it is possible to define the number of runs observations including the run length and warm up period Possibility to set repetitive on in order to get the exact same stream of random numbers after reset and run again The run length can be defined in various units of time or in 4Dscript 178 Appendices 1 5 2 Automatic batchrun Feature to execute several simulation runs with different sets of parameters for several replications without user interface Possibilities Remarks Not possible Incontrol ED There is an atom available that supports this functionality See Myplant 1 5 3 Warm up period Feature to start gather data after the simulation has been started
48. by the moment they appear in the process The IDEF 0 model of the current situation in appendix D1 as introduced in the previous section also contains these products in relation to their process activity Proposal request form PRF The first step of the Salesman when approached by a potential customer is gathering the most fundamental requirements global functionality description Based on these requirements the Salesman the management of Vanderlande Industries and Engineers decide whether to tender or not If Vanderlande Industries decides to tender the Salesman writes a PRF to officially identify the project inside Vanderlande Industries and to put the engineers to work Note that the customer often approaches several suppliers before they have written down their requirements and therefor the engineers of Vanderlande Industries often start working on a project before the official requirements are received Call for tender The call for tender is a document made by the customer or e g by a consultancy firm hired by the customer The compositions of a call for tender differ enormously In some projects there were only a couple of pages describing the main requirements of the system related to the performances In other cases there were piles of requirements and constraints completed with the required layout and performances of the future system and the contractual conditions In most occurring projects parts of the system layout such
49. can exist of several parties The Vanderlande Industries employees directly involved in the sales phase are divided in the Sales Men the Sales or Systems engineers the Controls engineers the CAD engineers the Simulation engineers and the Calculation engineers The boxes contain the different primary activities being the activities that are directly related to the BHS concept design process The managerial activities of the management of Vanderlande Industries are not included 23 Chapter 3 Current baggage handling system design process Calculation Engineer Controls Simulation Engineer Engineer Engineer CURRENT Customer Sales Man Sales System SITUATION Engineer Lu fp Du Gather customer po er suppiets requirements Write PRF Write Call for Tender Gather customer requirements and additional info Gather customer requirements Ask questions Develop concept alternatives Exploring controls architecture Sales phase Analyse physical l Analyse physical limitations I limitations Choose concept Make final line diagram and documentation of chosen concept Make concept Capital Expenditures calculation Design controls Draw system concept in Building simulation architecture terminal layout model of concept Fine tuning concept amp write final documentation Compose tender l document l Present offered concept to customer y Choose supplier Figure 3 5 Activity actor diagram of the cur
50. can offer insight in the dynamic behaviour of complex systems Arsham 2001 Regarding the costs of a system analysis of not only the purchase costs but also other system related cost aspects such as costs for required operations and maintenance resources offers information based on which design decisions can be made Ludema Roos 1998 Regarding the organisational aspects of a design effort involvement of all disciplines in an early stage can create commitment and a team feeling Bruijn de Heuvelhof ten 1999 which can offer efficiency and quality improvements To support and guide the team communication in a creative design process information and communication technology can be useful To make the different levels and dimensions of a various improvement effort with attention for the organisation processes and supporting technology explicit a design framework can be used Sol 2000a Part of this structure can be a design methodology defined as a coherent set of activities guidelines and techniques that can structure guide and improve a complex design process Meel van 1993 Suggested solution a new methodology and supporting tools In combination with suggestions of employees application of these notions to the situation at Vanderlande Industries resulted in the development of a new design methodology Based on evaluation results the expectation is that adaptation of this methodology in combination with the three supp
51. choices gt justification Way of modelling Requirements analysis template Design choices justification tool gt lt lt Simulation tool lt Cost calculator gt Supporting tools Table 9 1 The new design methodology including the supporting tools The developed design choices justification tool is a MS Excel document containing templates for the stakeholders network analysis the requirements analysis and the documentation of a BHS concept including justification of the design choices The existing simulation tool software of Enterprise Dynamics including the BAXSIM library is a graphical oriented simulation package including BHS objects The third tool the developed cost calculator is based on the simulation tool and contains different elements of life cycle costs with the emphasis on the investment costs Benefits new methodology Evaluation sessions with employees of different departments and Customer Centres showed appreciation and support for the suggested methodology and tools It is broadly recognised that introduction will help reaching the stated objective which implies improvement of the professional appearance the design process efficiency and the competitiveness of Vanderlande Industries Therefor Vanderlande Industries is advised to implement the design methodology and supporting tools as introduced in this report 117 Chapter 9 Conclusions and recommendations
52. common configuration of the main BHS processes Following the originating flow the first process after check in is the merger of all bags from the different check in desks Depending on the airport safety philosophy the departing baggage is then screened HBS hold baggage screening in order to prevent explosives entering the aircraft Hold baggage is the baggage that will be stacked in the cargo hold of the aircraft The next process is sorting the bags in order to make a distinction between early baggage and other baggage Early baggage consists of bags that enter the BHS a long time e g more than 2 hours before the departure of the concerning aircraft To handle this early baggage an Early Baggage Storage EBS is added to the BHS This storage makes it possible to pick baggage out of the main baggage flows and store it for a certain time depending on the time remaining till the STD Scheduled Time of Departure of the aircraft That way the early baggage will not block the transportation lanes of the BHS and less flight make up positions are necessary The bags that don not have to go to or exit the EBS follow their way on the main flow to the build area where they are sorted again into different containers depending on flight numbers classes and destinations the outbound flows Res Chapter 1 Introduction originating flow _ eee _destinating terminating flow M HBS Legend S EBS Transpo
53. concept which in most cases results in several changes and adjustments fine tuning of the concept Finally the Salesman gathers all the system descriptions and study results in a tender document and if allowed by the customer illustrates the offered system during a presentation The sales phase ends at the moment the customer announces the supplier they awarded with the order 3 3 2 Current BHS design process of the Sales and Systems engineer This report focuses on the concepting activities of the Sales and Systems engineer Therefor IDEF 0 models are made in order to divide the activities in sub activities and 25 Chapter 3 Current baggage handling system design process zoom in for more detail Appendix D1 contains these IDEF 0 models They can support the understanding of the textual description of the design activities in this subsection When designing a BHS a Sales and Systems engineer starts with gathering information The first information is obtained from the Sales Man During a conversation the engineer forms a mental model of the system to be designed With this mental model in mind further information is gathered In some cases e g the engineer uses the Internet when seeking for additional information e g the current terminal buildings configuration or the airport authorities ownership balance or uses the Vanderlande Industries Public Library local network to find information about the Vanderlande Industries products a
54. course of a pilot project showed extreme abnormality it could be wise to consider the start up of another pilot project Note that it is possible and even advisable to split the presented solutions of this master research when starting pilot projects The simulation tool and therefor also the cost calculation tool should be used in a pilot project at a Customer Centre situated in the Veghel office because of the presence of simulation engineers These engineers can if necessary support the user a Sales engineer of Benelux or International or a Systems engineer of the Systems Group and answer questions related to the software package Besides the Pricing engineers are situated at Veghel what makes communication about the calculator contents easier Training of the concerned Sales or Systems engineer can be done by reading the Enterprise Dynamics Users Manual and making example models if necessary supported by a simulation engineer To understand and correctly use the calculation tool sections 5 4 6 4 7 5 and appendices J K and N of this report should be read The BHS that must be designed in this pilot project should reach a certain level of complexity the number of passengers per year should exceed a million to point out the benefits of the tools and related activities The other parts of the new methodology including the design choices justification tool should be tested in a pilot project in a Customer Centre outside the Veghel off
55. did we do about it Etc Author Requirm Description Assigned Compliance VI priority Date Comments to level ID initials ID code Requirement description initials mandatory high dd mm yy further details and according the characteristics guidance medium yy possible changes mentioned in the introduction low Po SP91 __ SR9 2 SR9 3 4 10 Ergonomics requirements Possible relevant factors Easy operation Noise level Physical load Etc bali ee Assigned Compliance VI priority Date Comments ID to level initials ID code Requirement description initials mandatory further details and according the characteristics guidance medium possible changes mentioned in the introduction low PT SRI POT 4 11 Life cycle cost requirements Possible relevant factors Capital expenditures budget Organisations and Management set up expenditures budget Operational expenditures budget Maintenance expenditures budget Author Requirm Description Assigned Compliance VI priority Date Comments ID to level initials ID code Requirement description initials mandatory high dd mm yy further details and according the characteristics guidance medium yy possible changes mentioned in the introduction low Po SRO fo e e T S S SR11 2 SR11 3 157 Appendices
56. displayed By pressing the F11 button on the keyboard the syntax in the 4Dscript window is colored by group This way of displaying makes it easier to check the syntax on consistency In the 2D visualisation window the channels can be shown in order to check the connections There are also atoms parameters without an input check e g in the send to statements percentages of 150 and 10 are accepted When a lot of the same atoms are used in the model and a parameter of all these atoms must be changed it can not be done centrally Contrary to the parameters the behaviour of the atoms can be changed in the mother atom in order to change it in al the atoms in the model Incontrol ED This can be done using 4Dscript Ways of communicating with external applications DDE Dynamic Data Exchange DLL Dynamic Link Library Window sockets ODBC driver database Real time control Socket interface ODBC driver and DLL supported Distributed simulation No features like sharing an event list supported Incontrol ED ED does support TCP IP communication The parameters can be changed during a simulation run by entering the pop up menus If the atoms need a reset in order to calculate something based on the involved parameter the results of the change aren t implemented immediately 1 4 3 Statistical distributions Features discussed include approximating observations values to distributions fu
57. for this master project The methodology is evaluated by confronting employees of Vanderlande Industries with the different aspects of the methodology and the supporting tools Besides the tools are tested against requirements as stated beforehand and are applied in test cases The participation during the development of the methodology resulted in recognition and support of the employees All of them see list of names in appendix C think that the proposed attention for the decision process of the customer the more team based design effort and the quantified justification of the design choices can improve the professional appearance the BHS design process efficiency and the competitiveness of Vanderlande Industries The suggested activities are judged positively Regarding the controlling of these activities some points of attention are mentioned such as the legislation regarding tender procedures the security of information and the importance of not only the horizontal communication within Vanderlande Industries but also the vertical communication The conclusions considering the justification tool are that correct use will improve the quality of designed BHS concepts by structured and agreed upon foundation of design choices both technical and social It guides the user in the analysis documentation and evaluation of the stakeholders network the total set of requirements and the designed concepts The tool content forms preparation mate
58. influence over the cost that will have to be made in the systems life cycle This figure shows that although the cost that have to be made during the conceptual and design phase the sales phase at Vanderlande Industries are relatively low the impact of the decisions made during these phases are of great importance to the total LCC of the system Therefor it is advisable that the engineers of Vanderlande Industries have a feeling for the relationship between their decisions in the sales phase and the impact on the cost that will follow from these decisions Their decisions influence both the cost that have to be made by Vanderlande Industries and that will be passed on to the customer such as R amp D and production cost and the cost that are made directly by the customer such as the operating cost Having an understanding of the life cycle costs LCC of a BHS making a forecast during the sales phase enables the engineers to 1 Analyse and evaluate the differences of the cost effectiveness of two or more BHS concepts The cost effectiveness represents the LCC in relation to the technical characteristics such as performance reliability maintainability quality and producability Blanchard 1991 2 Present well founded quantitative concepts to the customer Present well founded quantitative concepts to colleagues pi Project him herself into the role of the customer understanding the customer s business 5 Converge towa
59. information processing as stated in section 4 3 is approached by the principle of breaking through the walls between departments within the Vanderlande Industries organisation The following philosophies apply to this principle Self regulating teams Instead of working separately the agents salesmen and concerning engineers should work in a team in order to gather document and discuss information This can prevent double work gathering the same information twice and stimulates the equal interpretation of information which results in a smoother adjustment of intermediary products of different departments Considering the sociotechnical design approach these teams must function as semi autonomous work groups Meel van 1994 with not only primary tasks such as calculating a BHS price analysing the dynamic behaviour of a BHS etc but also managerial tasks such as planning and controlling a design effort The we feeling can be enhanced by responsibilities towards each other concerning broader aspects than the aspects directly related to the personal primary expertise only All disciplines represented The team members should represent all disciplines such as sales concepting simulation calculation controls and CAD engineering of a BHS design effort in the Sales phase Early integration of the different experts not only stimulates the we feeling all concerned employees involved right from the start of a project it a
60. meeting overview Including Vanderlande Industries employee and stakeholders ID s date subject results and references 11 Strategy in stakeholders approach The agreed upon approach of stakeholders regarding technology economics management and communication such as involve in process emphasise new technology emphasise other project references emphasise proven technology emphasise good relation emphasise extendability emphasise LCC emphasise low noise offer more then one concept options offer certain quality price balance emphasise or keep silent about certain risks etc 12 General comments All comments about the sales process that can not be classified in one of the previous items including author ID date and comment description 5 4 2 Requirements analysis template Another template introduced in the new design methodology is the requirements template It guides the involved Vanderlande Industries employees in documenting the total set of requirements and constraints that apply to the concerning project The template is divided in five parts introduction general functionality and technology requirements constraints specific BHS requirements and procedural requirements Introduction The introduction of the template contains the characteristics of quality requirements For each requirement entered the involved engineer or sales man can evaluate the requirements quality by the following characteristics Young
61. operation hours 20 0 field at the bottom contains the estimated price of the high level system controls in euro s If the checkbox below is check the result will be visualised in a cumulative graph instead of a bar graph After all fields are Cani eA EA eoo filled as desired the engineer can click the next button in order to get to step 2 shown in Graph cumulative y n LI figure 6 10 Cancel Back Next gt Cra Figure 6 9 First input step window on right mouse click In step 2 the elements which are calculated as a percentage of the capital expenditures are entered The four upper edit fields concern the O amp M setup cost and therefor concern cost that have to be made only once The percentages for consumables and energy are added to the total cost each year of the life cycle this is explained in the hint text that appears if the mouse cursor is placed above the edit field I parameter values or if the elements of CAPEX are not included in the calculation see figure 6 8 clicking next will open the next step window which is He cai bo shown in figure 6 11 Documentation percentage fio OM Equipm percentage fo Initial parts percentage do Consumables percentage Boo Energy percentage fo oo Cancel lt Back Figure 6 10 Second input step capex percentages 86 Chapter 6 Supporting tools In this step step 3 the parameters for the personnel cost calculation during the life cycle of th
62. or the data the graph is based on Rough LCC amounts in Partly The Capital Expenditures are calculated quite accurate see below order to compare BHS and are therefor suitable for comparing concepts The input data concepts necessary for the other elements has to be verified with colleagues in order to found conceptual choices on the results A graph that represents the Yes Besides the total cost per year bar graph or cumulative graph it total cost per year of the life cycle is also possible to display the cost per year for one or a combination of cost elements in the graph Table 7 4 Evaluation results of the calculator tested against the requirements 7 5 2 Verification The verification of the cost calculator is performed in iteration with the making of the calculator The input variables are checked on correctness and typing errors By performing several calculations during the making of the calculator and comparing the results with expected values the calculation logic was checked 107 Chapter 7 Evaluation of methodology and tools 7 5 3 Replicative validation Because of the relevance of the capex Capital Expenditures purchase price of complete installed BHS including high level controls calculation an airport test case is used to validate the calculation performed by the calculator The BHS of airport K ln Bonn in Germany is used because of the availability of both the Capital Expenditures
63. phase of a BHS By joining a meeting of several sales engineers in the German Customer Centre several questions came up such as e Is it possible to rearrange the input configuration around the tilt tray sorter in order to lower the utilisation or to sort even more bags e If case of TUBTRAX how many tubs are necessary in the system And where should tub buffers be placed And how many tubs must they be able to buffer 102 Chapter 7 Evaluation of methodology and tools e Regarding redundancy what are my system performances throughput travel times when a part of the system fails Figures 7 1 7 2 and 7 3 show the three simulation model layouts The first one the model of figure 7 1 was quite detailed and answered questions regarding the travel times of the bags and the utilisation of the HELIXORTER in a satisfying way The travel times were copied in MS Excel to make graphs The results considering the utilisation of the sorter are integrated in the simulation tool itself Building this model required one day for the modelling and another two days for the verification validation and output analysis The Sales and Systems engineers involved in the evaluation were unanimously positive about this building time E Model View lolx Edit view IL Figure 7 1 2D model layout of the first BHS simulation model The second model was built on a high level of abstraction and provi
64. processed by the function Output represents the products of the function Controls are the triggers of the function the influence the way the function is fulfilled Finally the mechanisms represent the required necessities that support the function fulfilment 133 Appendices Function Design and describe system concept Current situation VI strategy VI experience signals from market terminal characteristics customer characteristics terminal environment characteristics x preliminary system requirements gt Design and information request by consultant gt describe system concept m tender document information request by customer gt call for tender gt Vi Employees AO CAD tools Internet amp MS Office Simulation amp Pricing tools Airport database VI systems books VI product data book VI sales reference database 134 Level AO Function Design and describe system concept VI strategy VI experience signals from market terminal characteristics customer characteristics terminal environment characteristics preliminary system requirements Make proposal Proposal information request request form request form by consultant N information request by customer gt LSales r A1 Airport database remarks l colleagues VI experience VI strategy terminal characteristics customer characteristics terminal environment
65. relation between the concerning BHS item and the requirement or constraints is fixed In addition to these defaults the engineer must enter all other relevant codes on which the design 80 Chapter 6 Supporting tools choices are based Based on the combination of applied BHS items and BHS configuration with the concerning requirements and constraints the engineer can individually or together with colleagues evaluate the designed BHS concept 6 3 Simulation tool To make a discrete event simulation model a simulation software package is required Installed on a PC this forms the simulation tool that supports the analysis of the dynamic behaviour of a BHS concept After the description of the requirement on such a tool in sub section 6 3 1 the tool is described in sub section 6 3 2 6 3 1 Requirements on the simulation tool Besides the general requirements as mentioned in section 6 1 interviewing several Sales and Systems engineers revealed additional more specific requirements on the simulation tool The following system performance output requirements for the simulation tool came up 1 Maximum throughput distinguished in transfer terminating and originating baggage flows Utilisation measure of the resources 3 In system times travel times of the bags It must be possible to produce these quantitative output results for different scenarios variance of bag arrivals flight schedules or configuration and different availabilit
66. sub contracters A A2 1 4 gt Readcalfor sort g tender a a call for tender gt gt A2 1 5 137 Appendices Level A2 4 Function Develop concept alternatives Current situation terminal environment characteristics terminal characteristics customer characteristics VI experience VI strategy total system Function requirements Determine ES requirements amp functions system related information A2 4 1 Determine Process Flow locations amp flow diagram BHS functions gt A2 4 2 Material Determine peak AE remarks colleagues MS Office flows rag 9 J a 1 p Determine ee concept line diagrams alternatives gt concepts A2 4 4 y j VI product data book MS Office VI systems books 138 Appendices Level A2 4 4 Function Determine concept alternatives Current situation remarks colleagues terminal characteristics VI experience customer characteristics terminal environment characteristics 4 VI strategy v Material Flow 4 Diagram amp Determine total system check in amp break check in amp break technology o m requirements technology x A2 4 4 1 system related a information 4 Determine re claim amp build up re claim amp build up technology technology A2 4 4 2 j Determine E
67. table and easily exported into Excel Incontrol ED Export to excel is always possible using Copy amp Paste functions A lot of error messages pop up that can be ignored when clicking on reset in order to define the shape of the sorter Incontrol ED The error messages are obviated Now only some tracer messages appear about not connected atoms Not clear how priority is set In default situation most priorities are 1 some 14 674564 etc Incontrol ED Priority set can be given in the sorter atom A025 Tub Station Composition of server and non accumulating conveyor atom extended with tub change capacity bag hr tub length and tub width options by menu In 2D and 3D animation tubs are added A026 Vertical Sorter Includes options like length speed rotate empty y n rotate time Wish possibility to choose from the menu a sorting condition in turns channel 1 channel 2 channel 1 channel 2 etc 191 Appendices Characteristics Remarks Wish possibility to use vertical sorter atom as a vertical merge A027 Table can be filled from which Wish possibility to retrieve the names of the Lead Times atom to which atom the leadtime atoms from a pull down menu new exact has to be measured typing is required Wish possibility to group atoms in the table ofte
68. the BHS design The document hard copy or digital written on the authority of Vanderlande Industries which is sent to the potential customer containing a complete description layout technology controls description CAD drawing simulation report price and terms of delivery of the proposed BHS Vanderlande Industries B V Vil Table of contents Summary Preface Glossary Table of contents 1 Introduction 1 1 Vanderlande Industries B V 1 2 Baggage Handling System BHS 1 3 Report structure 2 Research description 2 1 Initial problem description 2 2 Research objective 2 3 Research scope demarcation 2 4 Research approach 3 Current baggage handling system design process 3 1 Stakeholders involved in the current BHS design process 3 2 Products of the current BHS design process 3 3 Description of the current BHS design process 3 4 Information used in the BHS design process 3 5 Technology used in the BHS design process 4 Problem analysis 4 1 Initial problem verification 4 2 Implications of the desired situation 4 3 What is the underlying problem 4 4 Why is it a problem 4 5 The need for a new design methodology 4 6 Summary 5 A new design methodology 5 1 Way of thinking 5 2 Way of working 5 3 Way of controlling 5 4 Way of modelling 5 5 Summary 6 Supporting tools 6 1 Requirements on the supporting tools 6 2 Design choices justification tool Table of contents vii viii 10 11 11
69. to node atom extended Switch with only rotate when empty option and better 2D 3D animation A012 Similar to composition of Lateral Sink server and sink atom A013 Line Sorter Non accumulating conveyor atom extended with several outlets Added value many discharge conditions by menu rest by 4Dscript Incontrol ED Added value one conveyor with many exit points less conveyors needed in the model A014 Uses attributes of the conveyors Wish Merge atom possible at different Merge of the BAX Suite transport heights via menu now only via atom editor A015 Similar to check in block atom Originating Point A016 Automatic Encoding Station Similar to non accumulating conveyor atom extended by no read percentage option and a bow in 3D animation Added value animated bow in 3D and no 4Dscript necessary for no read percentage option menu controlled No data entry check no read percentage of 150 and 10 possible A017 Screening Machine Similar to non accumulating conveyor atom extended with capacity option 4Dscript field for set screen status option 3 phase failure rate option and a 3D animation The failure rate of screening machines MUST be given 1 9999999999 Wish several options of distributions in a set screen status pull down window instead of only a 4Dscript f
70. tool It is based on a MicroSoft Excel document first of all to keep the barrier to use the tool low every Vanderlande Industries engineer works with MS Excel often Secondly in the current situation Excel is already used to process and document quantitative results regarding cost and performance of a BHS The tool can be stored and maintained on the IT Public Library Vanderlande Industries network and loaded for each project in VI_Projects to make it accessible for all concerning employees VI_Projects is the central storage on the Vanderlande Industries Intranet of project related work documents Figure 6 1 shows the tool in MS Excel the complete layout is shown in appendix E It shows the worksheet named general that contains information like the project name and number the customer s organisation name and a revision table with the author s name date and reason for revision Right below the objective of the justification tool figure 5 4 is integrated in the tool to explain the relations between the worksheets The templates consistent with the terminology of Excel called worksheets named stakeholders requirements and concept can be found at the bottom of figure 6 1 To make it possible to integrate more than one BHS concept there are two copies of the concept worksheet added to the tool The latest worksheet named concept history is added to document the history of concepts Spa Chapter 6 Support
71. traysorter or a Helixorter The component price includes the inducts and chutes so they have to counted in both the model atom and the VI TraySorter not atom A026 VI VertiSorter 1 Added attribute Identification Vertical Sorter LCC_Code A028 VI Start Stop 1 Added attribute Identification and more Accumulating Conveyor LCC_Code realistic length Conveyor 2 Initial length set to 1 5m A014 VI Vertimerge 1 Added attribute Identification and distinction Merge Normal LCC_Code with SideMerge 2 Color and size in 2D view A022 VI EBS 1 Added attribute Identification and High LCC_Code component price calculation Aggregation Tubs which depends on whether Storage 2 On user event added the bags are stored in tubs or menu option stored in tubs or not not Table M 1 The adjustments on the BAX atoms objects 202 Appendices Appendix N Cost estimation guidelines External version CENSORED The numbers in this appendix are hidden and represented as The way the capital expenditures capex are calculated is explained in appendix L The capex are not further detailed in this appendix The labour cost depend on the number of operational hours per year and the cost per employee per hour Concerning the other distinguished LCC elements percentages of the capex are used The following data and sources might be guiding in finding the rig
72. y Design amp Y line diagrams document line and technology gt descriptions Justification tool 144 technology N A2 2 2 incomplete or x ss dissatisfying Fa oie Evaluate amp results comp 3 teos VI systems books_y document line ete dii VI product data book diagram Bd as Evaluate amp Viable line diagrams document alternatives d concepts an p documented amp ees a used information founded gt N A2 2 6 concepts x A results dynamic Determine a simulation gd bi document dynamic simulation behaviour model N_A2 2 4 A ne cata Calculate amp Office too Ny document LCC life cycle cost results N_A2 2 5 j Simulation tool LCC calculator Level N_A2 2 2 Function Design and document line diagrams and technology incomplete or dissatisfying results remarks colleagues terminal environment characteristics terminal characteristics _ customer characteristics VI experience VI strategy Determine material flow check in amp break check in amp break technology diagram technology N_A2 2 2 1 I Determine re claim amp build up re claim amp build up technology technology N_A2 2 2 2 i Determine EBS gt amp HBS EBS amp HBS technology technology N_A2 2 2 3 i Determine t
73. 0 fs ninafrocoinodeodroioi a ba das 1 900 1 234 5 67 8 9101112131415 Year Figure 6 15 The calculation results represented by a cumulative cost graph The cost calculator makes it very easy to zoom in on different life cycle cost elements and to communicate the results with others For instance if only the spare parts are considered the rest of the elements are excluded by not checking the boxes in the submenus that pop up by double clicking the LCC icon After resetting the model the graph as shown in figure 6 16 pops up It displays the costs that are to be expected for each year for spare parts only eo standard graph E 0 x Ele Edit Type Settings e SB efits k Rare Cost per year Figure 6 16 The calculation results represented by a bar graph if only the spare parts are considered Now that the interface is known the content calculation methods of the cost calculator must be found As mentioned before there is hardly any data available concerning life cycle costs of BHSs Therefor rough guiding estimations are made that need to be detailed in the near future The following three estimation methods are distinguished Blanchard Verma Peterson 1995 and applied e Method A Finding the total cost by multiplying the incremental unit cost by the quantity of units involved e Method B Finding some higher level of relationships such as non linear or multivariate relationships e Method C Cost estimatio
74. 2001 Hooks Farry 2001 1 Complete Nothing is missing no to be determined and all conditions under which the requirements stated applies 2 Consistent Does not conflict with other requirements 3 Correct Accurately states a customer need 4 Feasible Can be implemented within known constraints 5 Modifiable Can be easily changed with history when necessary 6 Necessary Documents something a stakeholder really needs 7 Prioritised 67 Chapter 5 A new design methodology Ranked as to importance of inclusion in product 8 Testable Possible to ensure that the requirement is met 9 Traceable Origin source of requirements known 10 Unambiguous Has only one possible meaning interpretation Also included in the introduction is the protocol for coding and documenting different versions of requirements and constraints see chapter 6 appendix E General functionality and technology requirements After the introduction the general functionality and technology requirements are included Each documented functionality requirement owns these attributes author initials requirement ID code requirement description initials of the person organisation to whom the requirement is assigned to compliance level Vanderlande Industries priority and comments The prioritisation of the requirements before spending resources on them offers greater flexibility in tradeoffs design and implementation Hooks Farry 2001 Th
75. 31 Chapter 4 Problem analysis Design choices In the current design process illustrated in the IDEF 0 models of appendix D1 no activity is integrated to document the qualitative or quantitative foundation of the choices regarding the BHS concepts which are made Therefor it is not possible to check whether a BHS concept is designed purely based on expectations or experience of the involved Sales or Systems engineer or on clear foundation The activity actor diagram and the IDEF 0 models confirm that the Sales and Systems engineers design the BHS concepts without integrating quantitative dynamic behaviour and cost aspects So these quantitative arguments are not used in the BHS design process for sure Good fit As mentioned before a good fit should be established by design choices based on the total set of requirements or vice versa Mapping the current situation revealed that the Sales and Systems engineers mainly found their design choices on their own interpretation of the requirements as documented by the customer in the call for tender document The possibility to influence the total set of requirements and wishes convincing the customer about certain advantages of design choices is neglected proves the lack of communication with the customer or his environment Problems allocation The problems occur at different levels and are related to different aspects but also overlap In order to point out in which direction the solutions c
76. 3D model layout window During the actual runs ED offers the possibility to vary the speed of the simulation or to stop for a moment and continue for instance step by step The output of a simulation run can be stored within the simulation model or can automatically be exported to MS Excel or a database ED is also provided with monitoring possibilities which enable the engineer to survey specific performances during the run Existing models or parts of existing models can in most cases be reused when building new models of other alternatives Summarising the ED simulation tool is a graphical oriented simulation package based on objects with attributes and inherited behaviour By dragging the required objects into a model layout connecting them and defining the input parameters via menus it is easy to build a simulation model Its reverse is the restricted level of detail of the model when no actual programming is applied By adding code the behaviour and the menu interface of the objects can be extended to get more detail The animation in both simplified 2D and more detailed 3D makes analysis of bottlenecks flows queues and equipment utilisation possible The performance results can be visualised during the simulation or can be exported to other software 6 4 Cost calculator To support the cost analysis activity of the new design methodology a cost calculator is developed This section also is divided in the requirements on the tool 6
77. 4 1 and the description of the tool 6 4 2 83 Chapter 6 Supporting tools 6 4 1 Requirements on the cost calculator The following characteristics are required for the cost calculator e Easy to use by both experienced and inexperienced Sales and Systems engineers e Calculating the different cost elements should not take to much time e Logical transparent structure to preserve the engineer from thoughtlessly following the calculation results e Extendable the moment additional data is found and approved it must be added to the tool e Security of confidential information e Information must be kept up to date e Engineers must be able to document the results easily The information that must be delivered by the calculator must contain e Rough cost amounts elements as mentioned in the cost breakdown structure of figure 5 5 in order to compare BHS concepts relative and to estimate the impact of a certain change within a concept absolute e A graph that represents the total cost of the system per year of the life cycle 6 4 2 Description cost calculator To keep the calculation of the costs easy and quick work performed in the previous stage of the design process is reused namely the simulation model of the BHS This way for calculation the engineer does not have to re enter all the systems characteristics such as the number length and speed of the conveyors the number and level of screening machines the type of
78. A new design methodology 5 Anew design methodology In this chapter the underlying problems as stated in section 4 3 are tackled At the beginning the solution directions were based on common sense The lack of attention for the customer s decision process should be solved by more external communication analysis of the main process variables and analysis of the involved people The lack of teamwork should be eliminated by a culture switch at Vanderlande Industries from individuals designing parts of the system to a design team responsible for the total project The design activities of the Sales and Systems engineers should include documentation of the design choices and the justification for those choices In order to make this justification clear and judgeable it should be quantified as much as possible Two judge two main characteristics of a BHS being the costs and the performance these characteristics should be quantified in an early stage of the design process These solution directions were discussed with employees and they were asked how they would handle the problems Besides literature was consulted to confirm the usefulness of the solution directions and to obtain new perspectives on the solution field Elaboration of the solutions was discussed with employees of both Vanderlande Industries and the Delft University of Technology The results are gathered in a new design methodology which includes a way of thinking described in sect
79. Arrival flow transfer ratio and transfer matrix what are the destinations of transfer baggage Specific flow of check in and transfer baggage that can not be read automatically working rates of manual coding operations screening rates and the of bags that are accepted after each subsequent level of screening storage strategies storage volumes and required storage retrieval flows Distinction between intercontinental domestic passengers Ratio of high priority baggage late check in or transfer baggage Equipment flow capacity volume throughput per component Eich SE ES ES Eee EA ID to level initials ID code Requirement description initials mandatory high dd mm yy further details and crea Ere mentioned in the introduction sai e C sR PT 4 2 Operation time requirements Possible requirement factors are the number of operational years days per year hours per day and expected occupation of equipment during operation ID level ES ID code Requirement description a mandatory high dd mm yy further details and according the characteristics guidance medium yy possible changes mentioned in the introduction low SR2 1 SR2 2 SR2 3 155 Appendices 4 3 Performance requirements Possible relevant factors In system times divided in different flows divided in different processes such as transport and storage Maximum connection times M
80. BAXSIM That s a library with building blocks atoms for simulation models of Baggage Handling Systems on airports which can be loaded into the main ED library In order to determine the usefulness of both the ED package and the BAXSIM module three simulation models of Baggage Handling Systems were built at two different levels of detail The ED software evaluation which in most cases also implies the BAXSIM atoms is based on the criteria in the simulation software tool selection of Nikoukaran Wintersim 1999 Vendor Criteria related to the evaluation of the credibility of the vendor and to some extend his her software Model and input Issues related to a model its developments and data input Execution Issues related to experimentation Animation Issues related to creation running and quality of animation Testing and efficiency Issues for evaluation of testability debugging power and efficiency of a package Output Kinds of output and included analysis instruments User Needs and circumstances to be able to use the simulation language These criteria are divided in several sections In each section the possibilities of the ED package are subscribed and remarks are added for improvements when the possibilities of the software do not meet the wished requirements of the user Also included are the reactions of Incontrol Enterprise Dynamics further referred to as Incontrol ED on the remarks These reacti
81. BS amp HBS EBS amp HBS technology technology i A2 4 4 3 Determine transport transport technology technology 4 A2 4 4 4 A p Combine _ functions to insa i gt system concept oe Determine sort N gt alternatives gt technology A2 4 4 6 A2 4 4 5 VI product i data book A MS Office amp VI systems books 139 Appendices Appendix D2 IDEF 0 model of the new design functions New situation VI strategy VI experience signals from market terminal characteristics customer characteristics terminal environment characteristics preliminary system requirements gt Design and information request by consultant describe system information request by customer concept gt tender document call for tender gt Vi Employees N_AO ie Internet amp MS Office Simulation amp Pricing tools LCC calculator Justification tool Airport database VI systems books VI product data book VI sales reference database m BHS concept description amp foundation 140 Level N_AO Function Design and describe system concept VI strategy VI experience signals from market terminal characteristics preliminary system requirements information request by consultant information request by customer S VI experience i terminal characteristics vy VI experience VI strategy gt Call for ten
82. CT Waiting times passengers at check in desks max average spread Waiting times operators loaders unloaders identification screener etc Utilisation operators maximum average standard deviation Reliability bags which needed manual intervention to get through the system bags not travelling on same flight as passenger damaged bags mean time between failure maximum time between failure Availability malfunction times unattended standby operating in service downtime see also maintainability Component process times Performance guarantees agreements about who takes the risk in e g throughput required men power and components quality Etc ID der level initials ID code Requirement description initials mandatory high an M details and according the characteristics guidance pi possible changes mentioned in the introduction Po SRI __ O Po SRT PT sa S S S S A O Ek 4 4 Redundancy requirements Possible relevant factors What if situations scenarios what happens and what is the impact on the factors relevant to the requirements Remaining capacity and functionality in failure cases Re routing possibilities Etc Author deg LL Description Assigned Compliance VI priority Date Comments to level initials ID Sr Requirement description initials mandatory high Sa further details and according the characteristics guidance medium possible changes
83. Summary Summary This report forms the completion of a thesis at Vanderlande Industries B V as part of the study Systems Engineering Policy Analysis and Management at the Delft University of Technology Vanderlande Industries supplier of material handling systems wants to enlarge her market share in baggage handling systems BHS and is therefor compelled to reconsider the current design process in the sales phase This formed the lead for the start of this research which was aimed on the following objective Creating a situation at Vanderlande Industries in which engineers design Baggage Handling System solutions based on clear justification of design choices which are well tuned to the total set of requirements and wishes of all stakeholders Based on the implications of this objective the current situation was analysed to define the occurring problems that block the realisation of the objective These problems were identified and can be summarised by 1 Too little attention for the decision process of the customer about which supplier will be awarded with a BHS contract 2 Too little teamwork regarding information processing and evaluation 3 Inadequately justification including documentation of BHS concept design choices After verification of the problems with participation of involved employees solution directions were found and elaborated by consulting literature and discussing subjects with employees These solution directions are
84. The error monitor is not emptied after a message All new and old Wish distinction in the messages are displayed without a distinction error messages between old and new messages 182 Appendices 1 7 2 Multitasking Possibility to execute several tasks at the same time as user for example build a model and run replications with an other Possibilities Remarks Not possible in ED Wish possibility to open more then one model in order to compare model structures etc Incontrol ED However it is possible to change a model during run time without compiling 1 7 3 Interaction Interaction of the simulation model change of the model and continuing the executing of the model Possibilities Remarks By using the Interact Window any 4Dscript statement can be executed during or after a run by clicking on execute The tracer window can be used to write messages to in 4Dscript without stopping the simulation run All parameters can be changed during the run but some of them are only executed on reset e g if the discharge frequency of a tray sorter is changed the number of trays the logic needs the speed of the sorter and the size of the trays too Easy entering of the atom s behaviour via the atom editor Changing the behaviour of the mother results in changes in the behaviour of all the daughters too Changing parameters of atoms means opening them o
85. TrainingValue 1 If true the employees training expenditures will be included in the calculations if false they will be omitted boolean 12 OperatingTeam 1 If true the expenditures on the operating team will be included in Value the calculations if false they will be omitted boolean 13 HandlingTeamValue 0 If true the expenditures on the handling team will be included in the calculations if false they will be omitted boolean 14 Not used 15 MaintenanceTeam 1 If true the expenditures on the maintenance team will be included Value in the calculations if false they will be omitted boolean 16 SpareParts Value 1 If true the expenditures on spare parts will be included in the calculations if false they will be omitted boolean 17 OMEquipValue 1 If true the expenditures on setup equipment will be included in the calculations if false they will be omitted boolean 18 OperationDays 365 Number of days that the BHS is operational per year integer range 0 365 19 EnergyPerc 3 Percentage of the capital expenditures attribute nr 1 that will be 193 Appendices Nr Name Initial Description value calculated for the energy cost per year real range 0 1000 20 DailyHours 20 Number of hours that the BHS is operational per day real range 0 24 21 TrainingPerc 3 Percentage of the capital expenditures attribute n
86. Z Chapter 3 Current baggage handling system design process e Appendices if applicable a planning specifications of the resale equipment offered layout drawings and results of a simulation study proving the BHS meets its requirements 3 3 Description of the current BHS design process The first subsection 3 3 1 of this description of the BHS design process deals with the overall process to clarify the interrelation of the actual concepting activities of the Sales and Systems engineers and the other activities in the sales phase Subsection 3 3 2 deals with the activities of the Sales and Systems engineer in more detail 3 3 1 Current overall BHS design process in the sales phase The scope of this thesis project is demarcated to the sales phase of a BHS In this sub section a activity actor diagram is included in order to place the concepting activity of the BHS in its context The diagram shows the relations in time between the activities of the different disciplines at Vanderlande Industries Besides the main activities of the customer that directly influence the Vanderlande Industries activities are integrated Note that the activities and sequence of the activities as described apply to most projects but each project has its own variations The actors can be found in the upper row of figure 3 5 and all them have their own span of the sales phase the columns First actor is the customer As mentioned in the section 3 1 the customer
87. ack and evaluation activities and for the justification of the design choices that are made An important aspect of the process side is the attention not only for the external communication but also the vertical communication within the Vanderlande Industries organisation involvement of the higher management The role of process manager can be fulfilled by the Project manager If no Project manager is applied in the project the role can be performed by the Manager Sales Engineering regarding the design choices justification and the Area manager regarding the stakeholders and requirements analysis 5 3 2 Support From the macro perspective support must be created for the way of cooperation between Vanderlande Industries and other stakeholders in the decision process of the customer Therefor Vanderlande Industries must communicate a suggested cooperation approach for each stakeholder individually or combined agreements at the beginning of the design effort Regarding the coordination of the processes between the different departments meso perspective the process manager must ensure that the team members and therefor the departments understand and support the way they work together If not another approach must be formulated and documented For both perspectives it is important to get the support of the management of Vanderlande Industries too by communication and involvement From the micro perspective the design process m
88. aining the requirements which the new part of the system should meet When Vanderlande Industries decides to tender for the concerning project an engineer designs a BHS based on the information in the call for tender and his experience The system design lays the foundation of the tender document that is sent to the customer This tender document forms the basis on which the customer decides whether to award the contract to Vanderlande Industries or to a competitor In the phase of evaluation of all the received tenders the customer makes several considerations and chooses a system supplier Vanderlande Industries suspects that an improvement in the tuning of the offered BHS to the considerations of the customer is possible Besides the BHS design choices made during the system development depend on the engineer who designed it and are often not documented and unclear to colleagues Vanderlande Industries therefor beliefs that the development of a BHS is subjective and depends too much on the lack of experience of the engineer Concluding the previous the following problem description divided in two sub problems was defined for this master thesis project 1 At Vanderlande Industries lives the notion that the Baggage Handling Systems offered in the tender documents can be tuned in a better way to the requirements and wishes of the customer and the system s environment 2 The foundation of the choices made during the design of a Bag
89. airport in order to support them during several steps in the purchase process such as defining the future developments and formulate the system requirements e Airlines mainly in the USA owners of the airport terminals e Handling agent independent stakeholder with core business baggage handling e g OGDEN e Third party e g security stakeholder independent stakeholder with core business guaranteeing security on the airport and or in the aircrafts Other external stakeholders no employees of Vanderlande Industries can be of importance during the sales phase such as e Competitors also suppliers of parts of BHS e Business partners e g a company who delivers the system controls e Sub contractors suppliers of intermediary products e Project managers external project managers who are hired by the customer in order to lead the total project e Public authorities on several levels e g the EU prescribing purchase processes the local government prescribing working conditions and authorities enforcing security legislation e Media negative or positive news about e g Vanderlande Industries or a competitor can influence the decision of the customer e Commercial organisations with influence for instance a important customer of the concerning airport e Agents in several areas Vanderlande Industries works via agents who obtain a provision if a system is sold e Financiers e g banks that buy the BHS and rent it to the ai
90. al customer until the moment the customer signs the contract or refuses the proposed BHS So the sales phase is the quotation phase Concepting This thesis focuses on the concepting part of the BHS design A concept of a BHS exists of the description of a BHS by the documentation of the equipment the system layout and often the description of the rough controls of the system The concepting activity is performed by a Sales or Systems engineer see section 3 1 for further detail Vanderlande Industries s capabilities The proposed solutions shall be in accordance with the current or realistic future capabilities of the organisation of Vanderlande Industries and her employees Development time available for a BHS The proposed new way of working shall be in accordance with the time that is available for BHS design in the current and near future 12 Chapter 2 Research description Customer requirements Although the customer and his requirements and wishes plays an important role in this thesis the potential customers are not approached themselves Information about market demands is therefor mainly obtained by interviewing employees of Vanderlande Industries and reading internal documentation Sales Reference Database Implementation The actual implementation of the solutions as introduced in this report is not included in the thesis project to keep the scope of the project in accordance with the time available A brie
91. ales or Systems engineer The history of the total set of requirements must also be included in the analysis Feedback elicitation It is advisable to involve the customer or related stakeholders with influence on the decision of the customer in the design process by regular updates or even presentations if allowed by the legislation regarding public tender procedures If the conditions occur the customer can even join certain team meetings to evaluate intermediary products The information gathered during such feedback moments must be reported to the responsible person agreed upon during the team formation e g the Sales or Systems engineer He she documents this information in a structured way see section 5 4 and 6 2 to make it accessible for all concerned team members 52 Chapter 5 A new design methodology 5 2 2 Way of working a meso perspective The way of thinking from the meso perspective comprehends more teamwork regarding evaluation and information processing which leads to the following activities Team formation The moment Vanderlande Industries decides to make a quotation for a BHS and it concerns a complex system and or customer environment a team must be formed by the Salesman see also the way of controlling section 5 3 The members of this design team should represent all disciplines that can be involved in early or later phases of the design process of the BHS Involvement right from the start will increase
92. an addition of euro meter to compensate curves So the calculator uses the attributes length and speed of the conveyor to calculate the capex Start Stop conveyor A start stop conveyor costs 20 euro per unit So for each start stop conveyor the calculator finds in the simulation model it adds 25 euro to the capex Vertisorter Unit price is 10 euro So for each VERTISORTER the calculator finds in the simulation model it adds the unit price to the capex This sorter always needs 3 start stop conveyors Check In Isle Each desk including desk weighing belt and dispatching belt costs about 20 euro the desk is obtained from a subcontractor approximately euro per desk The collector belt behind the desk costs about 25 euro meter The calculator uses the attributes containing the number of desks and the length of the collector belt 198 Appendices TRIPLANAR A TRIPLANAR flat make up costs 10 euro meter A tilted TRIPLANAR costs 15 euro meter Therefor the calculator uses besides the length an attribute that indicates whether it s a flat or tilted TRIPLANAR Screening machines A screening machine level 1 amp 2 costs 20 euro per unit A level 3 machine costs 10 euro per unit obtained from subcontractors The screening machines require a minimum number of start stop conveyors of 1 and a maximum number of 4 Coding stations A handgun manual costs 10 euro per unit An automated 3 directional sc
93. an be found and which relation the problem has with its environment these different aspects and levels are made explicit Therefor three perspectives are distinguished in order to determine the location of the problem s analogous to Sol 2000a Meel van 1993 e The macro perspective concentrating on cooperation between different organisations in this thesis concentrating on Vanderlande Industries cooperating with the customer and several other external organisations in the sales phase e The meso perspective concentrating on coordinating processes that take place within the boundaries of an organisation in this thesis the different involved departments and Customer Centres of Vanderlande Industries in the sales phase e The micro perspective concentrating on the primary tasks that are performed at work place level in this thesis the primary tasks in the sales phase of the involved engineers sales men and managers of Vanderlande Industries At first this thesis research focussed on the concepting activities of the Sales and Systems engineers a micro perspective because the involved employees of the Systems Group see appendix C thought the problems concentrated there Summarising the underlying problems can only be described by taking a broader view at the sales phase which results in the following defined problems from a macro meso and micro perspective 299 Chapter 4 Problem analysis The problem from a macro perspective
94. anager at Vanderlande Industries must ensure that all team members support the methods and tools that will be used during the design effort Acceptance of the methods and tools will increase the trust in the intermediary design results 62 Chapter 5 A new design methodology 5 3 3 Commitment The process manager must ensure that all design team members keep committed to the team based design effort If the we feeling fails for certain involved people the process manager should found out the reason and discuss this dissatisfaction regarding the teamwork Dissatisfaction can be detected by frequent absence at team meetings or a lack of communication Besides the team it is very important to keep the management of Vanderlande Industries committed to e g by frequently communicating up dates of the design effort or involvement in team meetings or evaluations For some projects external stakeholders such as the customer or a consultant are integrated in the design effort or even the design team at Vanderlande Industries In these cases the process manager must ensure that these stakeholders stay committed by frequent communication and information sharing 5 3 4 Drop out prevention Vanderlande Industries is one of the stakeholders in the decision process of the customer Several stakeholders such as the customer and the consultant of the customer play a crucial role in the information supply for the design process at Vanderlande
95. and conditions for delivery Performance margins level of acceptance Quality uniqueness level of concept Etc GEA RIE eo Assigned Rigidity level VI priority Date Comments to initials ID code Unambigious and complete initials fixed high dd mm yy further details and constraint description flexibel medium possible changes low 3 6 Competition constraints Possible relevant factors Number of competitors Reputation competitors Relationships between competitors and relevant stakeholders Etc Constr ID Description i igidi iori Comments to initials ID code Unambigious and complete initials fixed high dd mm yy further details and constraint description flexibel medium possible changes OW possa ee ee fh Po 86 2 _ S S S S fh Po l ess S T T T T T h 4 Specific BHS requirements 4 1 Flow requirements possible relevant factors Baggage split non conveyable OOG Bag characteristics dimensions weights Expected passenger flow peaks average spread originating terminating transfer Expected baggage flow peaks average originating terminating transfer Flight data aircraft departure and arrival during a peak day number and type of airplanes seats per aircraft aircraft occupancy loading factor average pieces of bags per passenger beside hand held baggage Originating flow arrival pattern of passengers at check in desks
96. and the result must be analysed Determination more runs Based on the analysis results the engineer might be interested in other alternatives of the BHS If so parts of the existing model can in most cases be reused when building new models of other alternatives Documentation and reporting In order to make evaluation in a team possible the engineer must document the results of the simulation runs Besides the results the input parameters used and the assumptions made during building the model should be documented This enhances the understanding and therefor the trust of the team members in the simulation effort when presenting and discussing it Implementation Considering the sales phase of Vanderlande Industries this step should be the choice of the BHS concept or concepts which all team members will work on from that moment on BHS cost analysis In line of the integral design thought the Sales or Systems engineer should integrate the cost aspects in the justification of the BHS concept design To simplify the evaluation of 55 Chapter 5 A new design methodology design choices in the team meetings the engineer must quantify the cost aspect as detailed as necessary depending on the phase of the design process Therefor the engineer must calculate and document if necessary in consultation with a Calculation engineer costs related to the BHS concepts The costs can be divided in several cost elements see section 5
97. anisation of Vanderlande Industries This question is briefly answered in this chapter It is not meant to be an exhaustive plan but offers guidelines for the main aspects of the suggested implementation The first section deals with the nature of the change implementation at Vanderlande Industries organisation Section 8 2 describes how to start the change by testing tools and methodology in a pilot project The final section 8 3 describes the actual implementation and related activities in case the results of the pilot project are satisfying 8 1 Designing versus developing the organisation In the literature a distinction is made between designing an organisation and developing an organisation Twist van Edelenbos 1999 Design implies a radical change of the formal organisational structure by starting from scratch and ignoring the existing structure Development implies a learning aspect meaning an incremental change of the informal organisational structure The approach of the change depends on the characteristics of the situation Twist van Edelenbos 1999 In case of a threatened continuity of the organisation crisis situation and the existence of big conflicts among the employees the design approach is preferred In case the organisation functions quite well but improvements are desired based on a considerable level of agreement the development approach is recommended The characteristics of the situation at Vanderlande Indu
98. anner costs 20 euro per unit The scanning machines require a minimum number of start stop conveyors of 1 and a maximum of 4 depending on the regularity of the supplied baggage flow Traysorter HELIXORTER A traysorter costs 20 euro meter If it concerns a HELIXORTER the price is 25 euro meter Each induct costs 30 euro per unit and each chute costs 35 euro per unit So the calculator uses attributes that indicate the length and the type of the traysorter It also counts the number of chutes and inducts and adds the unit prices to the capex An induction point always needs start stop conveyors maximum of 4 when the maximum capacity is required Traysorter Induct and Chute The induct price of 30 euro per unit and chute price of 35 euro per unit are included in the table twice see also the Traysorter HELIXORTER This is done for programming reasons because the chute and induct atoms can be placed in both the model atom and the traysorter atom VertiMerge A vertimerge costs 10 euro per unit compare with VERTISORTER For each vertimerge found in the model the calculator adds the unit price to the capex A vertimerge always needs 6 start stop conveyors Sidemerge A side merge unit including one start stop frequency conveyor costs 20 For each unit the calculator finds this unit price is added to the capex A minimum of two additional start stop conveyors is required EBS Conveyors Conveyors with loo
99. ansport attribute Name Belt conveyor start stop belt conveyor accumulating conveyor belt curve TUBTRAX BAGTRAX string Length m real Angle real Speed m min real Maximum peak capacity bags hour integer actions Transport bag between two points Object class Process attribute Name EBS lanes EBS rack EBS dynamic screen level 1 screen level 2 screen level 3 manual scan automated scan load unload charge discharge reconciliation string Maximum peak capacity bags hour integer Maximum store capacity number of bags integer Process time sec time actions Process bag 167 Appendices Object class Output attribute Name bin lateral TRIPLANAR string Status open closed string Length m real Capacity number of bags integer Handling time sec time actions Bring bag out of the system Object class Sort attribute Name pusher vertibelt cross belt VERTISORTER tilt tray sorter HELIXORTER TRIPLANAR sorter POSISORTER string Number of inlets integer Number of outlets integer Number of positions integer Length m real Speed m s real Maximum peak capacity bags hour integer Handling time sec time Capacity number of bags integer actions Sort bag in different directions Object class Merge attribute Name side merge vertimerge end merge string Length m real Speed m s real Max
100. as to integrate financing aspects of the BHS too For now the tool includes life cycle cost but not the way these cost are financed According to some experts the financing agreements such as involving a bank in order to buy the BHS and to sell it to the airport after a couple of operational years in order to earn money first get more relevant each day A requirement or constraint table should be added to the justification tool to include this aspect in the requirement analysis It is hard to perform a cost benefits analysis because the benefits of the tool can not be expressed quantitatively The tool improves the quality of the designed concepts realised by structured and agreed upon foundation of conceptual choices based on both content and process aspects which must lead to a better fit of the offered concept to the requirements of the customer s decision makers To implement the tool in the organisation resources such as people PC s and MS Office software are available But in addition to that cost regarding the security accessibility and maintenance of the tool have to be made 7 3 3 Conclusions The justification tool is well received by the employees They are convinced that the correct use of the tool will improve the quality of the designed concepts realised by structured and agreed upon foundation of design choices This foundation contains both technical and social aspects Using the tool means dealing with subjectivity and m
101. ated at reset or during the run can be displayed during the run The simplified graphs in the Monitor atom are refreshed during the run with a user defined interval The graphs created by the Graph atom are only refreshed after double clicking the atom in the 2D window Included in ED are several colour changes when the status of an atom is changed e g when a conveyor is not available the colour of the conveyor turns red By using the Monitor atom the status of each atom can be animated in text or value Queues with a maximum capacity up to 10 display animate the atoms they contain bigger queues display a red bar to indicate the level of occupancy The number of atoms in the queue is always displayed in the 2D window I 7 Testing and efficiency 1 7 1 Verification and validation Includes on line help on line error messages on line tutorial logical error checks syntax error checks and clear error handling Possibilities Remarks If an error occurs while running or resetting a model the error monitor pops Wish if possible more up if it was already popped up the background colour of the monitor is accurate error messages not changed The monitor will list the ID of the involved atom the event the the statement is not correct error occurred on and gives a short description The exact error is not but a bracket missing at the mentioned end of that statement
102. ated simulation projects improve team communication 7 5 Evaluation of the cost calculator The evaluation of the cost calculator is based on a test against the requirements as stated in section 6 4 described in sub section 7 5 1 verification of the calculator 7 5 2 a replicative validation 7 5 3 and an expert validation 7 5 4 Finally the results are recapitulated in sub section 7 5 5 7 5 1 Test against the requirements In table 7 4 the requirements for the cost calculator as stated in section 6 4 are shown in the left column The level of compliance to these requirements including explanation is given in the other two columns 106 Chapter 7 Evaluation of methodology and tools Requirement Com Tool characteristic pliant Easy to use also by Yes Once the engineer is familiar with the ED simulation package in inexperienced engineers order to determine the dynamic behaviour of a concept performing a calculation is very simple by dragging the LCC calculator into the simulation model The input data is entered via menu steps In order to get the required input data colleagues have to be consulted or at least the input data has to be verified Maintaining the calculator requires more knowledge of ED and the 4Dscript ED programming language Performing a calculation Yes Ifthere has already been built a simulation model of the concept should not take too much the only time spend o
103. ategies within the limits imposed by a criterion or set of criteria for the operation of the system Using simulation in the design phase in general means that the engineer has the opportunity to test and communicate a concept of a BHS up front in a computer environment without all the constraints on site and still has all options open for improvements or changes This leads to cost and risk reduction and saves time during the 48 Chapt er5 A new design methodology Figure latter project phases In more detail simulation if used correctly provides the relevant stakeholders with Arsham 2001 1 Advanced optimisation techniques examination of multiple elements simultaneously and track the system performance with respect to e g travel times arrival and exit rates and system utilisation 2 Insightful system evaluations experiments to monitor the systems behaviour with particular configurations of input resource arrangements flow control rules and downtimes or failures 3 An accurate depiction of reality reflects the randomness and interdependencies that system elements share in the complex reality 4 A good visualisation animation of the system makes corrective feedback possible can be used as a presentation tool and offers the possibility to track material flows through the system The results of simulation experiments can be used for quantitative conceptual choice foundations when evaluating BHS concepts Th
104. ately but are grouped in the capital expenditures of the customer Although the actual costs are made by 27 Chapter 5 A new design methodology Vanderlande Industries the customer eventually pays for them in the form of the initial purchase investment capital investment And because of the relative importance of that initial investment to the customer the cost elements are grouped in two periods of the systems life cycle The first period ends when the BHS is installed tested and including the personnel ready for operation this moment is called the hand over and the cost which are made up to then are the total installed cost The second period starts right after the first one and ends the moment the BHS is no longer operational the cost made in this period are the total operating cost The costs of training the maintenance personnel e g although necessary for the maintenance activities during operation are included in the set up costs But the spare parts they use when the system is in operation are included in the maintenance costs Another demarcation is the omission of the system phase out and disposal cost Although the replacement of an old system plays a significant role while in most cases there are requirements considering the operational continuation Putten van 1999 there is a complete lack of data in relation to the complete life cycle cost The use of space is also left out although space is very expensive on the a
105. calculation used for the quotation including the high level controls price and a AutoCad drawing of the layout In figure 7 4 the model layout is shown upon which the cost calculation was made Note that it is necessary to drag the right objects with the right dimensions into the model but that no connections or exact locations are required E g the chutes points where the bags leave the tilt tray sorter in figure represented by blue squares are al grouped at one place in the sorter while in reality they are distributed along the sorter s side Model Layout loj x Ede Yow EBSD SEES SESE ES SES 525550 555555 Sc SES S558 SS SS ES SESS ES SEE ES SS El GSS5 EE SS SEs S5 So SS SESS 6S 55 S35 55655555 S555 85 Se SESS Es SS ES ES SUN see Pi mu i ma 12 902 itom Vi Carousel 19 at 45 000 43 000 G8 3 000 18 000 Figure 7 4 Cost calculations layout model of the K ln Bonn BHS After entering the price of the high level controls system detailed price was available via the input menu of the calculator the capex were given The capex amount calculated by the tool was 5 0 too high The prices of BHS components did not increase for the last five years source Vanderlande Industries JG so inflation can not account for the difference Therefor the capex calculations can be said to be accurate enough to indicate the system price but not detailed enough to use calculation results in detailed external communicati
106. chematic layout of the BHS including physical dimensions which is more convenient than a textual spreadsheet The results are presented as numbers and in two different graphs and can be exported to e g the justification tool Besides the investment costs there are other life cycle cost elements included which in the current stage mainly can be used to elicit attention and discussion These elements are not calculated with enough detail to directly use the absolute results Direct benefits of using the cost calculator e Offers quantified insight in the consequences of changes in BHS concepts for the life cycle costs integrated in the concept design process e Calculations are based on schematic layouts which eliminates the chance of forgetting parts of the system Indirect benefits of using the cost calculator e Offers the engineers who are unacquainted with LCC something to hold on to e Structures team discussions regarding LCC 7 6 Summary In this section the evaluation findings as presented in this chapter are summarised The amounts are confidential The calculation was performed without taking the deviating lifts at the check ins into considerations The price of these lifts subtracted from the detailed calculation performed in 1997 was estimated by JG 109 Chapter 7 Evaluation of methodology and tools The methodology and tools are not evaluated by using them in a real sales phase because of the limited time available
107. ckground information is missing Inexperienced engineers icro j i miss the opportunity to learn from the work performed in earlier projects by more experienced engineers Table 4 3 Consequences of problem 3 What is the problem 4 The Sales and Systems engineers of Vanderlande Industries seldom integrate quantitative results of dynamic behaviour and cost analysis in the BHS design process Considered A Why is it a problem Perspective M More objective quantified foundation of the design choices stimulates an eso i effective and quick team based evaluation of those choices If a BHS gets more complex a static calculation does not offer enough insight in the BHS behaviour This can result in sub optimal design choices and increased Micro chances for BHS concept adjustments in phases after the BHS concepting unnecessary iterations which leads to a longer total development process This can also be the result when taking the cost aspects into consideration only in a final stage of the design process Table 4 4 Consequences of problem 4 35 Chapter 4 Problem analysis 4 5 The need for a new design methodology This research effort is focused on improving the way BHS are designed in the sales phase of Vanderlande Industries mainly by taking a closer look at the information elicitation documentation sharing maintenance and usage Resuming the previous sections the initial ap
108. components that operate together to accomplish a purpose The components of the system can be organisations people machines software and other systems Applying this definition to a BHS the following definition including the function can be defined A baggage handling system is a set of interacting transport sort process store and control components and operators that collaborate in order to control and handle all baggage flows on the airport Controlling and handling takes place from the baggage acceptance locations to the aircraft stands and from the aircraft stands to the baggage delivery to the passenger In case of transfer baggage from one aircraft to the other it provides the control and handling between the aircraft stands According to Vanderlande Industries Bartelet et al 2000 the scope of a baggage handling system can be defined as follows All equipment and personnel that is necessary to handle all baggage excluding hand luggage between the locations of check in re claim and the aircrafts and if required to ensure that all the appropriate bags entering the aircraft are security screened and reconciled with passengers Besides that the BHS ensures effective data collection transmission storage and analysis in order to optimise the system performance In this thesis the scope of a BHS is demarcated to the baggage handling inside the airport terminal building only Transport between the terminal building and the airc
109. constraints Possible relevant factors Availability of space Column grid Free height Building construction Power supply Distances Etc EG RI Assigned Rigidity level VI priority Date Comments to initials ID code Unambigious and complete initials fixed high dd mm yy further details and constraint description flexibel medium possible changes 3 4 Environmental constraints Possible relevant factors Political relations Local wages Unions Employment figures Local philosophy towards security and employment Working conditions legislation Legislation on competition Climatic influences moisture temperature wind sand precipitation BHS market situation Reliability energy supply Media attention Fire hazard regulations Developments in the air transport market Economic development Infrastructure around airport levels Type of airplanes Type of transport between build up and airplane Etc Author Constr ID Description eee Rigidity level VI priority Date Comments initials ID code Unambigious and complete E fixed high a further details and constraint description flexibel medium possible changes low Po CSA Po S84 Po T ess T S T T Eh 154 Appendices 3 5 Vanderlande Industries constraints Possible relevant factors Relation with relevant stakeholders Guarantee philosophy Engineering and delivery times Terms
110. ct helps Vanderlande Industries to recognise changes that have occurred in the relations and structure of the different stakeholders e Linking Knowing most possible relevant interests of all possible relevant stakeholders enables the engineers and sales men and agents to create win win situations or to compensate weaknesses with strengths Awareness and competence regarding customer orientation These soft social interaction process aspects are less tangible then the hard content aspects of a BHS According to Snellen often the legitimacy of a certain solution is more important than the efficiency and effectiveness Enserink e a 1999 With other words the best solution is the one every relevant influential stakeholder can identify himself with and that does not have to be the best solution from an analytical point of view So attention for the customer and his environment is of great importance in the sales phase In table 5 1 the awareness of the Vanderlande Industries employees of the soft customer oriented side is given in relation with the competence in customer focused design The quadrants represent the different phases in the time Competence Competent Incompetent Awareness Aware 3 2 Unaware 4 1 Table 5 1 Competence and awareness of customer focused activities in relation to time Most Vanderlande Industries engineers are now somewhere between phase and 2
111. d are performed by the Sales or Systems engineer If there is a lack of input data for the cost calculation colleagues must be consulted to get reliable and agreed upon results that are documented Evaluate and document Again in an iterative way of working the results are evaluated with colleagues and if applicable with other relevant stakeholders The design team can evaluate the BHS concepts by tracing and approving the relevant requirements for the designed concept characteristics Based on the outcome the quotation strategy is determined The engineer 60 Chapter 5 A new design methodology ends the sales phase by elaborating and documenting the final concept s and by preparing the descriptive text for the tender document 5 3 Way of controlling The way of controlling deals with the managerial aspects of the new design methodology Because of the overlap of the way of controlling from macro meso and micro perspectives these perspectives are not made explicit Table 5 3 shows the relation between the way of thinking way of working and the aspects of the way of controlling as introduced in this section Macro Meso Micro Cooperation of Coordination of processes Primary tasks at organisations between VI departments workplace level Way of Getting grip on the Teamwork regarding Integral justification hinki decision process of the evaluation and information including documentation of thinking customer processing des
112. d by Vanderlande Industries to the potential customer is not chosen and therefor the contract is not awarded to Vanderlande Industries So the Vanderlande Industries engineers should integrate an exploration of the customer s environment and the definition of requirements in an early stage of the sales phase in order to provide quality products as playfully illustrated in figure 5 1 42 Chapter 5 A new design methodology nNZzOoO P IMOO RD FE F DI RI MI O N N QUALITY Figure 5 1 Making quality products starts with good product requirements Hooks Farry 2001 Value by choice Customers evaluate suppliers based on their overall satisfaction with the business relationship A key measure of this satisfaction is the value derived from doing business with a supplier Byrne Markham 1991 Hazelrigg marks that something has a value to an individual if under some circumstances the individual would choose to consume it that is if the individual would choose this thing over other options So value is implied by choice Hazelrigg 1996 Therefor it is important to involve the customer in the design process and create several moments in which the customer s meaning is at least contributory to the chosen direction in the design steps In the ideal situation the customer gets the impression that the offered concept by Vanderlande Industries is partly a result of his her interference In that case the tendency of the cus
113. d fewer mistakes when converting the different products between AutoCad and ED Involvement in BAXSIM library development Vanderlande Industries in the role of potential customer of Enterprise Dynamics is recommended to keep involved in the development of new releases of the BAXSIM library Involvement offers a voice in the matter of which features and functionalities will be added in the near future to the library Besides it offers influence in the terminology used in the library That way the BAXSIM library will keep up to date to the product range of Vanderlande Industries which enlarges it usefulness 9 2 2 Cost aspects of a BHS The purchase price of a complex system can be just a fraction of the total related costs that have to be made during a life cycle of such a system Insights in these total costs can be powerful tools for the customer when evaluating different systems on the criteria of return on investment Vanderlande Industries can exploit the results of the life cycle cost calculations by using them in those situations it positively influences the decision process of the customer In this report a beginning is made to breakdown these life cycle costs in several elements in order to reduce the complexity The following two recommendations are made concerning these costs Research on life cycle cost data to elaborate the cost calculator It should be wise to start research projects to collect and document more detailed LCC data t
114. d the BHS When a container loaded with transfer baggage from one plane to another comes at the airport terminal loaders take care of the feeding of the system load the baggage from the container into the BHS At the different sorting areas unloaders take the baggage off the system into a container belonging to a flight Finally the unloaders take care of the baggage that is out of gauge OOG baggage that is not qualified to enter the main baggage stream in the system because of its dimensions and the non conveyable baggage such as a basketball After it enters the terminal manually or automatically this baggage also has to be taken off the system into containers The total system has to be maintained in order to perform its function over its whole life cycle Therefor maintenance employees interact with the system periodically Finally the BHS manager interacts with the system in order to ensure its functionality 130 Appendices Appendix C Involved employees of Vanderlande Industries Vanderlande Industries employees being interviewed during this master thesis Bruno van Wijngaarden Erik van Rossum Friedrich Alexander Olivier Harm Koster Henk Geurts Jasmien Mertens Marcel Bunkers Peter Hoefkens Rinus Vervoort Roy van Putten Ton Koemans Warehousing amp Distribution Systems engineer Manager Proposal Verification amp Pricing Sales engineer CC M nchen Gladbach Quality amp Service International Sal
115. de Heuvelhof ten 1999 Legitimacy of strategic behaviour depends on justification with regard to the content A creative design process The following design principle of sociotechnical design which can also be applied to BE Meel van 1994 leads in the prescription of the new situation This design principle focuses on the compatibility of the processes and the products of those processes When aimed on designing an organisational structure capable of self regulation based on making use of creative individual capacities the design products then a constructively participating project structure for the actual design project the design process is necessary Meel van 1994 This means aiming at structuring the creative design process rather than at being prescriptive with respect to the content In that design process automated support should free humans from dull and monotonous tasks thereby freeing intellectual capacity for more complex and creative tasks Documentation of design choices justification If the engineers at Vanderlande Industries document their BHS concept justification well structured this can offer the following advantages e Preventing double work There are several engineers involved in the steps from scratch to BHS implementation Therefor it is very well possible that an engineer doubts the design choices made by another engineer in an earlier step and thinks of changing the solution If the engineer in the earl
116. ded the answers about the empty tub management As can be seen the connections between the different areas are represented by a simple network of conveyors There are local areas distinguished with lower conveyor speeds and scaled transit lines between terminal buildings with 103 Chapter 7 Evaluation of methodology and tools higher speed These speeds can be changed for all conveyors centrally just like the initial number of tubs in the central and three local buffers There are monitors connected to the local buffers that display how many times and for how long a bag had to wait for an empty tub Building this model took about two days including optimising the controls So the simulation tool enables the Sales or Systems engineer to answer questions about buffer locations dimensions and numbers of tubs or carts within two days including insights in the results of different control algorithms model view E lol x Edit View Figure 7 2 2D model layout of the second BHS simulation model The third model made of a BHS was able of predicting the maximum possible throughput for two check in islands and a transfer line The distribution over the sorter was changed by different controls and layouts alternatives scenarios This offered very much insight in the system s behaviour Building the model took about one day Changing the controls was easy but changing the configuration of the sorter takes more time because addin
117. del of concepts cost concepts y concepts calculations I Fine tuning concept strategy amp write final documentation Compose tender i i document i I Present offered concepts to customer y Choose supplier Figure 5 3 Activity actor diagram of the new situation in the BHS concept design s5 Chapter 5 A new design methodology Kickoff meeting The moment Vanderlande Industries decides to make a quotation a team is formed and the responsibilities of each team member are documented Also those engineers who will not be busy right from the start of the project e g the simulation and calculation engineer are involved in the team in order to create commitment to the project The sales man makes the first documented stakeholder and requirement analysis results available including a project number Analysis elaboration and asking questions After the kickoff meeting the involved Sales men the Sales or Systems engineers and the Controls engineers together start up a thoroughly analysis and document the stakeholders and requirements When the call for tender is received they document in a team based effort the requirements and discuss the interpretation Communication with the customer official in a question round or by unofficial lobby must clarify the missing parts of the stakeholder and requirements analysis First design round After the analysis results are base lined Sales or Systems engineers the concepting d
118. depends on the number of bags handled by the BHS and their weights Another information system the BHS communicates with is the Airport Time Server All the systems working on the airport are connected to this server in order to synchronise all system clocks and guarantee a perfectly timed cooperation Looking at the human interfaces there are passengers and employees who interact with the BHS The passengers put their bag directly on the system at the check in desk and re claim it at their destination take it off a baggage carrousel There are several employees working with the BHS To start the employee at the check in desk takes care of the registration labelling weighing of the bag and charges it into the system Another interaction of the system is with the coding and security screening employees When the baggage has to be screened for security reasons the most common configuration is a partly automated screening in different levels After the system screened automatically and decides a bag is still suspicious another level is entered where employees judge the X ray pictures and open the bag if necessary Coding baggage is performed to identify the concerning bag e g to determine the route Often this is a fully or partly manual process with employees scanning a barcode on a bag label with a handheld scanner Besides the passengers at the check in desks who bring baggage into the system there are other people and places who fee
119. der gt Appendices New situation remarks customer characteristics Make building CAD concept layout drawing gt Calculate capital terminal environment d a and concept dit characteristics drawi pi expenditures system rawing te remarks Pricing price i CAD Engineer N_A3 3 Engineer N_A6 Peform initial g VI experience actor amp Actors amp i n requirements info pt i FS wet Design controls oe pricing tool 9 i controls architecture Sales Man N_A1 architecture ________ t Controls Engineer N_A4 sbi sare call for tender Justification tool VI experience Airport database Determine detailed dynamic simulation ay system report ae m behaviour imulation remarks Engineer N_A5 remarks colleagues l Simulation tools f VI experience VI experience VI strategy terminal characteristics L di i customer characteristics mpose tender O __ Compos SER terminal environment p document di nt characteristics locume building Salesman N_A7 drawing request J oie MS Office Design system BHS concept concept description amp Systems Sales foundation 5 Engineer N_A2 j Internet amp MS Office VI product data book VI systems books VI sales reference database LCC calculator Justification tool Simulation tool 141 BHS concept description amp foundation Level N_A2 Function Design system concept VI exp
120. dology and the tools apply to the sales phase in general not only for the baggage handling systems Therefor it should be wise to research the possibilities for tailored versions of the process and tools in the sales phase of the other disciplines Warehousing and Distribution Express Services Industry and Manufacturing Industry Research on reusing work in phases after the sales phase Vanderlande Industries is advised to start research on the reuse possibilities of the products of the sales phase in following phases E g the reuse of the model object tree of the simulation tool which contains all objects read components applied in a BHS concept to create a bill of material for the purchase department or to support the planning of the manufacture department Another example is the use of the information in the design choices justification tool in the engineering phase in order to clarify why certain design choices are made and therefor prevent misjudgements Tracking AutoCad Enterprise Dynamics linking The supplier of the ED software mentioned developments regarding the linking of objects in ED with components in AutoCad Vanderlande Industries is advised to keep up to date considering these developments to exploit possible efficiency improvements if CAD 118 Chapter 9 Conclusions and recommendations engineers and Sales Systems or Simulation engineers could exchange intermediary products This could imply reuse of work an
121. e BHS are entered Five functions are distinguished LCC Parameters Step 3 of 4 SIE e Operations manager e Operations employee working in the control room of the BHS Numbers amp wages of operation managers ion e Bag handlers loading unloading bags Gates fe manual coding etc e mist nen e Maintenance man first line non complex ee ore ino There meri maintenance such as oil replacements and visual checks Cost operation manager e Maintenance man second line more Cost operation employee complicated maintenance such as Cost baggage handler replacements and thorough quality Cost maintenance man 1 inspections g Petm ienn For each function the number of people necessary depending on the BHS layout and technology and their labour cost can be entered Cancel lt Back Figure 6 11 Third input step personnel numbers and wages The last input step window shown in figure 6 12 contains the Perrie pee bo Spare parts Z pear percentages of capital expenditures Pacenone ea Lo including overhaul for the spare parts necessary Some Percentage year 3 components of the BHS have to be Percentage year 4 reconditioned or even completely Percentage year 5 replaced after a certain number of Percentage year 6 operational hours In this input step Percentage year 7 the engineer can make estimations Forcentage yart Percentage year 9 of the spare parts cost for each year The life cycle of th
122. e 2D window The atom status percentages can be reported after the run length has passed The structure of the model atom is always given in the model window The model documentation can also be written into a separate file txt by using the Model documentation atom The following properties can be included defined by user atom name mother name container name attributes channels location size and labels 1 8 2 Delivery Creating your own reports with extra information or direct send the output to a printer Possibilities Remarks By using the Summary report atom personal reports can be defined After choosing the atoms to include in the report the following properties can be included current content average content maximum content average stay time input output quantity current atom status and the atom status percentages Besides these properties the analysis start and duration time can be assigned In order to write leadtimes to a table the entry time must be defined in each starting location if the starting location is a source the leadtimes can be defined by the age of a atom which is included in the standard Data recorder atom 1 8 3 Integration Links to other packages to handle the data for example links to planning tools or optimisation programs Possibilities Remarks Optimisation not standard included Incontrol ED ED provides an Optquest link Op
123. e A 3 Organisational chart of Vanderlande Industries Marketing amp Communications Secretariat Facilities Appendices VI Netherlands Belgium amp Luxembourg VI France VI Germany Switzerland amp Austria VI Spain VI United Kingdom 127 GamBit VI Direct Export VI South Africa VI Hong Kong VI U S A Appendices 128 Appendices Appendix B Interaction between a BHS and its environment Figure B 1 illustrates the interaction of an installed BHS with its environment The BHS interacts with the bags as well as with employees the passengers and several information systems The Departures Control System DCS communicates with other airports and is controlled by the International Air Transport association IATA When a bag is checked in the BHS sends a flight registration and the DCS supplies the BHS with a Baggage Source Message BSM The BSM contains a unique 10 digit IATA number License Plate to identify that bag on all airports Besides that IATA number the BSM includes the name of the passenger the flight number s the date the travelling class and the security status of the bag Based on this information the BHS determines the route of the bag through the system The information is also sent to the destination airport s by a Baggage Transfer Message BTM te Pan Management Maintenance Information P an ra System MIS Pd a yst
124. e conceptual model and the information into a simulation model for modelling technique see section 5 4 Verification Before using the model the engineer should check the coding of the model By using common sense while observing the animation of a running model bugs in the input parameters and model structure can be traced and corrected The output has to match with rough estimations e g a static calculation If it does not match as expected the way the results are calculated should be corrected Validation In this step the engineer must make sure that the model reflects the reality in the right way This can be done by changing input parameters and test the reaction of the model Is it the expected reaction Another way of validating the model is by presenting the animation and results to colleagues familiar with baggage handling processes Experimental design Now that the model is ready to produce useful output the engineer has to document the scenarios that have to be simulated Often new combination of scenarios will reveal while analysing earlier runs The engineer also has to decide how long the simulation run will be and when stochastic input is used it is necessary to base the results on several replication runs instead of only one The Sales or Systems engineer can consult a Simulation engineer from the Systems Group if knowledge about certain steps is insufficient Production runs and analysis The actual runs are performed
125. e fourth sub section describes the way the justification of the design choices made during the BHS concepting is modelled This is followed by the simulation model used in the dynamic behaviour analysis activity and finally the structure of the cost breakdown model is discussed which can be used in the cost analysis activity 5 4 1 Stakeholders analysis template To guide a complete stakeholders analysis and the evaluation of this analysis in the new design methodology a template is composed for the documentation of a stakeholders network It guides the engineers and Salesmen in documenting all relevant stakeholders who can have an influence on how the quality of a BHS is experienced By taking all wishes and requirements into consideration a better weighing of pro s and con s of BHS concepts can be made and no important factors are omitted Filling of the stakeholders analysis template will be performed iterative because in the initial contact phase not all the information is available yet The list below contains all items that are included in the stakeholders analysis template Note that for each item several hints are included to guide the filling see section 6 2 1 Initial problem description The initial problem or current required situation as stated by the customer 2 Organisation chart of the customer s organisation Including persons names and communication lines 3 Stakeholders Including ID initials organisation name d
126. e results in combination with the visualisation of concepts enable the engineers to elicit and prioritise the real requirements of the customer while presenting several conceptual options offering choices Next to the results the modelling itself and the animation while running a simulation offers the engineer to get good insight in the system s behaviour and suitability of the system for the airport s process This brings us to the following paradox A simulation analysis can not be performed without the BHS layout but in most cases a good BHS layout can not be designed without a simulation analysis This means that simulation must be integrated in the design process iteration between layout determination and simulation Justification quantification by cost analysis Figure 5 2 illustrates a typical life cycle of a technical system with on the x axis the several phases of the system in relation to the time aspect during its life cycle Cumulative Life Cycle Cost Level of influence over LCC Production Operation Disposal Development ae Design 7 System life cycle phases Conceptual 5 2 Relation between the total Life Cycle Cost and the level of influence over the cost over time Source Ludema Roos 1998 49 Chapter 5 A new design methodology On the y axis of figure 5 2 represented by a discontinuous line the cumulative life cycle cost are shown The continuous line represents the level of
127. e software are supplied on the Internet Planned new versions of ED every year in October updates after 3 and 7 months Object oriented character The atoms have hierarchical features inheritance of behaviour and are partly acting as individual objects In order to achieve total encapsulation additional 4Dscript is required to protect some typical attributes and behaviour of atoms against interference of other atoms e g a screening machine can change the dimensions of a bag etc 1 3 2 Documentation Documentation discusses issues on availability of a manual tutorials examples and troubleshooting guide that make learning a new piece of software enjoyable Possibilities Remarks User Manual Engine describes the functionality of the simulation engine User Manual Tutorial general introduction in building models including a developer part to develop new atoms User Manual 4Dscript Manual gives an overview of all words of the programming language 4Dscript and the syntax rules and common errors User Manual Atom Manual Describes the functionality of the atoms that are part of the ED atom library It also includes sample models Tutorial software integrated and several useful sample models added 1 3 3 Support Support means the availability of experts that can help training maintenance consultancy updates newsletter user group meetings and Internet discussions Possibilities Remarks Qu
128. e supporting tools are the results of several interviews discussions and literature research To decide whether the results will contribute to reaching the desired situation reaching the objective some evaluation activities are performed in cooperation with employees of Vanderlande Industries The first section deals with the methods that were used during the evaluation Section 7 2 describes the evaluation results for the new methodology The following sections describe the evaluation results of the supporting tools being the design choices justification tool 7 3 the simulation tool 7 4 and the cost calculator 7 5 The chapter is summarised in section 7 6 7 1 Evaluation method The new design methodology and the tools have not been applied in a real situation yet mainly because the sales phase of a BHS can take several years while only limited time is available for this thesis project Besides the sales phase is very complex considering the number of involved stakeholders and factors of relevance which makes it hard to test in a simulated situation The new process makes the engineers aware of strategic behaviour of stakeholders but historical data about this soft aspect is not available Therefor the evaluation is separated in the methodology and the three tools and approached as described in the following sub sections 7 1 1 The new design methodology The verification of the methodology was already performed during the deve
129. e system is shi a yearn wee Percent 11 limited to 30 years in step 1 so E Percentage year 12 step 4 offers a maximum of 30 edit sio s i Percentage year 13 fields After entering all necessary E n Percentage year 14 parameter values review is Percentage year 15 Percentage year 16 0 5 button the engineer clicks on the Cancel lt Back Next Finish finish button possible by clicking on the back Figure 6 12 Fourth input step Capex percentages 87 Chapter 6 Supporting tools Enterprise Dynam x After clicking the finish button the message as shown in figure 6 13 is displayed to remind the engineer that the Reset for LCC calculations calculation is only performed after resetting the model Figure 6 13 Reminder message after the last input step After the model reset the cost calculations are made and the results are displayed as shown in figure 6 14 On the left side the input parameters are displayed which were entered in the four steps as mentioned before In the upper row of the blue column on the right the total costs of the BHS as represented in the simulation model are given The total costs are calculated by adding the four amounts right below the total amount these are the four main elements Capital Expenditures Organisation amp Management costs Operational costs and Maintenance costs as distinguished in the cost breakdown structure of figure 5 5 Br Gin yew nani st in ye 8
130. e table below is included in the VI_LCC_Calculator atm to be used in combination with the VI_BAX atm in Enterprise Dynamics simulation software This table contains the data necessary to calculate the purchase prices of all BHS components that are used within a certain system concept Before using these prices read the following remarks All prices are estimated selling to customer prices in euro All component prices are with the controls on PLC level All component prices are without the high level system controls the high level control cost can be entered by right click on the calculator in the ED 2D window All prices are without the platform steelwork Not included in calculator when more then one building level is required 10 up to 15 euro has to be added to the meter prices of all conveyors The required number of start stop conveyors depends on the way the baggage flow is arranged just before the start stop conveyors a steady supply of baggage requires less start stop conveyors If applicable a minimum and maximum number of start stop conveyors are mentioned in the clarification text below The initials refer to the source of the prices JGr Jan Graste MB Marcel Bunkers LCC Name CAPEX1 CAPEX2 CAPEX3 CAPEX4 Code 101 Conveyor belt 10 15 JGr JGr 102 Start Stop conveyor 20 JGr 201 VertiSorter 10 JGr 301 CheckIn Isle 20 25 JGr JGr 401 Triplanar 10 15
131. e total project mainly during the build phase For further clarification of the difference between a Sales engineer and a Systems engineer at Vanderlande Industries figure 3 2 is included The Sales engineer working at a Customer Centre of Vanderlande Industries is responsible for the total quotation made for the customer The quotation is documented in a tender document Of all activities a Sales engineer performs the design of BHS concepts concepting and evaluating can be supported by a Systems engineer The Systems engineers work within the Systems Group which operates as a Staff Department for all Customer Centres In case a Sales engineer lacks the required experience for a BHS project or lacks the time to handle the project the System engineers can support by taking over the concepting part of the sales phase Sales engineer Customer Centre Gather preconditions and requirements Calculate and verify BHS concept price Design BHS concept Write tender me Systems engineer Systems Group Figure 3 2 The main activities performed by the Sales and Systems engineers 19 Chapter 3 Current baggage handling system design process 3 2 Products of the current BHS design process In this subsection the outputs or results of the sales phase are specified which are used directly by customers of the BHS design process or the process participants They are arranged chronologically
132. e were documented the mental model of the current situation the as is situation was translated in a physical descriptive model in order to verify the current processes and requirements The descriptive model made it is easier to understand and communicate verify the current situation Besides that the model of the current situation made it possible to discover problems or aspects of improvement To describe the current situation the work centred analysis framework is used Alter 1996 This framework contains the following elements Customers Products Business process Participants Information and Technology These elements are described in chapter 3 To support the textual description of the element Business process an activity actor diagram was made This diagram shows who which actor performs which activity at what moment in the sales phase including the global sequence of the tasks To increase the insight in the process activities the IDEF 0 method Integrated computer aided manufacturing DEFinition language is used to model the current design process This method is derived from SADT Structured Analysis and Design Techniques and divides a process activity in several sub processes and activities It makes it possible to zoom in at these sub processes as much as necessary to look at them in more detail A more detailed model explanation can be found in appendix D1 Main elements in this phase of the thesis project were com
133. ed justification of design choices the professional appearance of Vanderlande Industries the 96 Chapter 7 Evaluation of methodology and tools design process efficiency and the competitiveness of Vanderlande Industries will improve The involved employees appreciate the objectives of all documentation activities of the new methodology It supports the spread of information among team members it structures evaluation meetings and it guides concerned engineers in founding their design choices on real existing requirements and wishes The simulation and pricing activities moved to an earlier stage of the design process got a positive judgement of the employees too Besides the quantified results they offer additional insight in the consequences of conceptual changes The introduced models to be used in the BHS sales phase are judged positively One remark was made regarding the omission of financing requirements or wishes in the template for the requirements analysis Points of interest regarding the controllability of the new methods are the legislation regarding tender procedures the security of the information that is used during the design effort and the importance of good vertical communication within the Vanderlande Industries organisation 7 3 Evaluation of design choices justification tool The evaluation of the design choices justification tool is performed by testing the tool against the requirements as stated in section 6
134. ed Customer Centres can be found Europe Asia Africa and the United States of America In 2001 Vanderlande Industries B V realised a net income of 16 0 million euro on a net sales of 452 2 million euro This result was reached with 920 employees in total Public Library docnr CP01 06 The clients of Vanderlande Industries can be found in the areas Warehousing and Distribution Baggage Handling Systems BHS Express Services Industry and Manufacturing Industry This master thesis project is executed on authority of the Systems Group which provides technical and commercial support to Customer Centres and Operations in developing system solutions for customers The Systems Group consists of four sub departments e Systems Development e Simulation e Proposal Verification amp Pricing e Knowledge Management For more detailed information about the organisation is referred to appendix A which also includes the organisation chart Chapter 1 Introduction 1 2 Baggage Handling System BHS Because of the central role of the Baggage Handling System BHS in this thesis this section briefly describes its definition subsection 1 2 1 its possible baggage flows 1 2 2 the main processes that take place 1 2 3 and the components of a BHS 1 2 4 1 2 1 BHS definition To determine the definition of a BHS first of all a definition of a system is given According to Alter Alter 1996 a system is defined as A set of interacting
135. ee Figure 3 4 A Line Diagram of a baggage handling subsystem VI internal drawing technique Tender document The tender document is the official quotation that is given to the customer Based on this document mostly in combination with a presentation the customer evaluates the Vanderlande Industries offer in comparison with the competitors Based on this evaluation the choice is made which supplier will be awarded with the contract The following topics are discussed in a common tender document Problem and solution description including the bag dimensions capacities flow diagrams building description operational area and constructional circumstances System functions functioning of the offered system including advantages Mechanical materials general characteristics of the mechanical materials offered Controls describing the control configuration including aspects as supply voltage software observations interfaces PLC control and product identification Project management planned activities and products Installation preconditions and size of delivery of the assemblies Commissioning including description of commissioning acceptance criteria first take over and final hand over After sales service recommended spare parts service training and documentation Pricing summary of the price calculations of the quotation Terms and conditions validity of the quotation terms of payment guarantee etc D
136. eeks but can be rescheduled if necessary When possible relevant stakeholders outside Vanderlande Industries should be invited to join certain evaluation meetings see also previous comments on feedback elicitation During these meetings not only the completeness and correctness of the information the BHS design choices are based on is evaluated but of course also the choices themselves When the stakeholders and the requirements for that moment are documented properly and the first design choices regarding the BHS concept are made these decisions can be evaluated All team members representing all disciplines and aware of the total set of agreed upon requirements have their own point of view what results in an integral BHS concept design effort The results of the evaluations have to be documented Besides the minutes of meetings the results regarding the design choices and their foundation have to be documented in a structured consistent way these templates will be described in section 5 4 53 Chapter 5 A new design methodology 5 2 3 Way of working a micro perspective The main thought for the new situation from a micro perspective is the integral justification and documentation of the design choices made in the BHS design process This implies the following activities BHS design choices justification and documentation The Sales engineer or Systems engineer see section 3 1 for clarification must document the desi
137. eer can enter the elements of the costs that will be included in the calculations Figure 6 8 shows the submenu of the O amp M set up cost By checking the boxes the engineer can choose whether documentation training O amp M equipment or the initial spares should be included VI LCC Calculator1 E Documentation Vv lt l OM Equipment LI Initial Spares Vv Figure 6 8 Choice window of the O amp M set up which elements to include in the calculations After defining all elements to be included the engineer can give a right mouse click on the LCC icon to start the input steps The first step that appears is shown in figure 6 9 When the mouse cursor is placed above an edit field a hint text appears to explain in more detail which parameter is entered If the engineer enters values that are out of range an error message will pop up and give the possible range The allowed ranges are included in appendix J describing the attributes of the calculator 85 Chapter 6 Supporting tools LCC Parameters Step 1of4 In this step the name of the calculator object Main parameters and if desirable the icon can be changed In the three edit fields in the middle the total Atom name VI LCC Calculator time cycle of the system must be entered Icon depending on the number of years the number of days per year and the number of hours per day the system will be operational The edit Life Cycle Years fi 5 Days of operation 365 Daily
138. el document that offers templates for supporting and documentation the stakeholders analysis and the requirements analysis 9 Chapter 6 Supporting tools Besides it includes a template to support the making and documentation of design choices regarding a BHS concept In addition to that it offers insight in the relations between the stakeholders the requirements and the design choices that are made The simulation tool is a existing graphical oriented simulation software package of Enterprise Dynamics ED including the so called BAXSIM library containing objects tailored to baggage handling systems It supports the Sales and Systems engineer to determine the quantified performance of a BHS concept on a rather high level of abstraction It also offers insight in the dynamic behaviour of designed BHS concepts which enables the engineer to compare different alternatives The cost calculator is based on the same simulation package ED and supports the Sales and Systems engineer in making a quick quite accurate estimation of the investment costs of a BHS concept Besides it offers the possibility to get a feeling of the other elements of life cycle costs of a BHS The Knowledge Management team of Vanderlande Industries will have the responsibility for maintaining the tools and making them available for the users 92 Chapter 7 Evaluation of methodology and tools 7 Evaluation of methodology and tools The new methodology and th
139. em have to be described by multiple perspectives In the following tables the answers to the why question are given for each stated problem Besides answers in the business economics field there are several answers related to management in relation networks Bruijn de Heuvelhof ten 1999 33 Chapter 4 Problem analysis What is the problem 1 The employees of Vanderlande Industries who are involved in the sales phase of a BHS pay too little attention to the complex context of the decision process of the customer and therefor possibly not make the best of their chances to influence that decision Considered Why is it a problem Perspective If the dynamic arguments multiformity between organisations but also within organisations and interdependencies of different stakeholders are unknown in the decision process of the customer it is not possible to predict the reaction on a offered BHS concept e g aversion to the proposed system from Macro hidden and therefor not involved stakeholders Besides it is not possible to exchange weaknesses with strengths to create win win situations or to lobby in the right way This lack of grip on the sales decision process of the customer can lead to a stagnating or even decreasing number of system orders which threatens the continuation of the company Not knowing who the real decision makers are including their requirements in Mi a customer organisation or an t
140. em sa i A F nar Was or Airport nae Administration J System FIS j y mE 7 ee arl a f oe N Control System Airport Time DCS E oe Pe Baggage Handling System Coding Ba operator Security screen operator Passenger Check in Maintenance operator operator un Loader BHS manager Legend BHS Information system interface BHS Human interface BHS baggage interface Figure B 1 The interaction of a BHS with its environment The Flight Information System FIS supplies the BHS with the flight schedule and information about planes that arrive or depart Based on this information the BHS allocates flights to the baggage collecting points and supplies the routing information of the baggage through the system The information sent and obtained from the Management Information System MIS depends on the requirements of the concerning airport It 129 Appendices supplies the management with information such as numbers of bags that are handled in a certain period that justifies their decisions on high level airport control Sometimes there is also a separate Maintenance Management System MMS installed to provide the management with information which is necessary to plan maintenance activities such as the number of operational hours of components The Airport Administration bills the airlines for their usage of the BHS The amount
141. employees on completeness During this evaluation several managers of Sales and Systems engineers stressed that they were looking for a structured consistent and uniform way of gathering relevant information based upon which BHS concepts can be designed The offered templates can replace all kinds of personal checklists and form a good basis that if necessary can be tailored to each specific project The only remark made regarding the completeness was the lack of requirements considering the financing of a BHS costs are integrated but not the way these costs are financed According to the employees the cost breakdown structure of figure 5 5 offers enough elements of the life cycle costs of a BHS for this moment It can be used as a steppingstone on which further details can be applied in the near future The object model of a BHS offers enough detail right division in object classes and attributes to quickly represent a BHS concept of Vanderlande Industries It enables the engineers to build a model by placing and connecting components based on thinking in flows as they are used to do 7 2 5 Conclusions Partly due to the participation during the development of the new methodology lots of aspects of the design methodology are recognised and supported by the employees The need for more attention for the political aspects of selling a BHS is confirmed by all involved employees Combined with a team based design effort and quantifi
142. environment characteristics i terminal characteristics Collect info from Internet VI Network amp sub contractors N_A2 1 2 additional info Internet VI systems books VI sales reference database Exchange knowledge with additional VI knowledge gt gt gt p ala Perform amp results actors amp gt colleagues N_A2 1 3 gt Read call for tender call for tender gt N_A2 1 5 documented customer requirements Communicate gt with customer N_A2 1 4 expressed customer requirements 143 document actors ene amp requirements ees analysis N_A2 1 6 Justification ie S tool incomplete or dissatisfying Evaluate results correctness gt completeness agreed upon analysis results actors amp ui requirements N_A2 1 7 analysis Justification tool Building gt drawing request Level N_A2 2 Function Develop test and document concepts agreed upon results actors amp requirements analysis Determine amp document MFD N_A2 2 1 A incomplete or dissatisfying results remarks colleagues terminal environment characteristics terminal characteristics customer characteristics VI experience VI strategy Appendices New situation diagrams and material flow di iagram 7 LE Yy
143. epartment person s name function telephone number and e mail address 4 Stakeholders characteristics Comments about the stakeholders that should be shared with other colleagues such as experience with Vanderlande Industries relationship level of BHS knowledge etc 5 Stakeholders objectives and perspectives The fundamental objectives stabile in time mostly abstractly formulated of the stakeholder and the concrete objectives concrete issues for this project And what is the perception of the problem and solution of the stakeholder depending on e g the cultural background position ambition fundamental objectives available vocabulary what can be discussed and individual frame of reference selective perception 6 Stakeholders means The means both formal and informal the stakeholder can deploy in order to reach the objectives technical juridical social or economical And is the stakeholder a formal informal or no decision maker in the project 7 Stakeholders interdependencies The way the involved stakeholders are interdependent e g on resources information relations both formal and informal and balances of power 66 Chapter 5 A new design methodology 8 Communication agreements The agreements made regarding communication 9 Meetings overview Including Vanderlande Industries employee and stakeholders ID s meeting date meeting subject results and references 10 Other communication than
144. epts The development IDEF 0 level N_A2 2 begins by defining and documenting the required functionality and baggage flows Then for each functionality area the potential technology must be determined After documentation of the conceptual systems another evaluation round can be performed with colleagues to discuss the designed concepts in relation to the requirements on the system Also the relevant stakeholders outside Vanderlande Industries can be involved in this evaluation if allowed by the legislation regarding public tender procedures Note that the results of the stakeholders analysis can be unpleasant for some stakeholders for instance some personal characteristics and objectives Therefor it is preferable only to lift some elements out of the analysis when directly evaluated with people outside Vanderlande Industries Determine and document dynamic behaviour If viable BHS concepts are selected e g two options completely compliant to the customer requirements and one smarter option not fully compliant the dynamic behaviour if point of discussion is determined see sub section 5 2 4 The required level of detail to obtain the right information can be discussed with a Simulation engineer After running scenarios and analysing the output the results are summarised and documented including the layout of the concept Calculate and document costs To evaluate the concepts regarding cost cost calculations not too detaile
145. erefor the templates for the stakeholders and requirements analysis and the template for the documentation of a BHS concept are integrated in the tool The tool must stimulate the Vanderlande Industries employees to integrate the process side of the complex sales phase with the content side It must form a guideline for the exploration of the behaviour strategy and position of different stakeholders in a complex environment Regarding the requirements analysis it has to be applicable for all possible BHS systems It must be a comprehensive checklist to ensure completeness of the requirements Besides all requirements must be grouped in their proper context Regarding the documentation of a BHS concept the tool must stimulate the Vanderlande Industries Sales and Systems engineers to define the design choices they made in a clear and complete way including the foundation Next to the general requirements as mentioned in section 6 1 additional requirements are introduced when assigning the main features of Requirements Management to the justification tool According to Young a sophisticated requirements tool is able to facilitate requirements elicitation help with prioritising of requirements provide traceability of requirements throughout the development effort and allow for assignment of requirements to sub sequence releases of system products Young 2001 These requirements are also captured in the management requirement tool evaluati
146. erience terminal characteristics customer characteristics terminal environment characteristics c actors amp Gathers N requirements info document call for tender information N_A2 1 Internet VI systems books VI sales reference database A Appendices New situation S building m gt drawing remarks request colleagues agreed upon VI strategy results actors amp requirements l analysis N documented amp romane Develop test amp N founded colleagues C document concepts VI strategy gt concepts l incomplete or dissatisfying N_A2 2 Analyse amp N results A j evaluate J justification tool PANERA VI product A evaluation data book itself and content esille colleagues MS Office N_A2 3 concepts VI strategy VI systems A ji books Choose amp h LCC calculat i chosen system ET 2 T A Mace document concept s Simulation too Na gt concept s S N_A2 4 Elaborate amp document final PHS concept description amp concept s foundation N_A2 5 MS Office Justification tool 142 Level N_A2 1 Function Gather and document information actors amp _ gt requirements info xe Appendices New situation Communicate with sales man N_A2 1 1 mental problem model Justification tool proposal request form customer characteristics terminal
147. ers suitable for the conceptualisation steps in the sales phase see below the description of three models that were built The flow aspect makes it easier to understand what happens in the model because the bags can actually be traced through the model The object aspect makes it possible to easily exchange extend and reuse parts of models The objects offer enough openness for further programming detail e g acceleration of conveyors However this requires more knowledge of the package and 4Dscript the ED programming language 101 Chapter 7 Evaluation of methodology and tools Execution Regarding the execution of simulation runs ED offers the possibility to run the model at different speeds and to predefine multiple runs including run length and initial start up period Animation The 2D animation of ED is very simplistic but offers enough detail to get a good insight in the behaviour of the system and the baggage flows The status of an object can be represented by colours Tables and graphs can be shown during a run The 3D animation is generated automatically and offers more presentation and validation power than the 2D layout The AutoCad drawing of the terminal building can be used as background of the animation Missing are standard drawing features like lines and coloured shapes which could support the engineer in arranging the models in a convenient way Testing and efficiency Although not very precise the error mes
148. erver different dimensions have to be modelled without the occupancy and sink atoms Wish display the occupancy of the carousel server in 2D windows Shadow in 3D view is incorrect when carousel is rotated A007 Similar to queue and server Added value histogram of waiting times Check inBlock atom extended with attribute average waiting time and histogram of waiting time Wish show the occupancy of the check in server in 2D windows A008 Not available in the standard Curved Non Logistics Suite Accumulating Conveyor A009 Similar to composition of non Added value no 4dScript necessary to Manual Encoding accumulating conveyor and define two process times and per interval Station server atom extended with 2 number of bags and the occupancy rate process times with chance and interval table with number of bags and occupancy instead of average over all occupancy rate of normal server atom 188 Appendices Characteristics Remarks A010 Similar to non accumulating Shadow in 3D view is incorrect when Fast Non conveyor without the number of conveyor is rotated Accumulating animated supports but extended Conveyor with some attributes necessary Capacity is calculated wrongly when not for the merge atom using the physical length option Incontrol ED the calculation problem is worked on A011 Similar
149. es engineer International Sales engineer CC M nchen Gladbach Systems engineer Manager Simulation Systems engineer CAD engineer Simulation engineer Controls engineer Vanderlande Industries employees also involved in the evaluation Carlo Boeijen Ernst Iedema Gijs Bartelet Hans Bodewes Jan Graste Marnix Rutten Robert van Ree Roland van den Bergh Sjouke Tjalsma Toin Aarts Ton van Wieringen Sales engineer Benelux Sales engineer Benelux Systems engineer Manager Systems Group Sales engineer Benelux International Sales engineer International Sales man Benelux Area manager International Manager Sales engineering International Quality amp Service International Systems engineer 131 Appendices 132 Appendices Appendix D1 IDEF 0 model of the current design functions Model explanation The box contains the name of the Controls function the ID of the function and the ID of the employee who fulfils this function If a grey triangle is Activity ai shown in the upper right corner of Inputs gt gt Outputs the box the function is further Employee ID ID detailed divided in several functions The ID of these detailed functions refers hierarchical to the Mechanisms function they were derived from e g A2 4 is derived from A2 The arrows represent the interfaces of the function with its environment Input represents the physical products that are
150. ese years the Vanderlande Industries sales department should already get a grip on the situation by making people familiar with the name Vanderlande Industries and knowing who is who including the different relationships and interdependencies So the sales man needs to start the analysis of the different stakeholders and their requirements in a early stage because often there are only two months left after the call for tender is obtained to design the BHS and write the tender document 56 Chapter 5 A new design methodolo NEW SITUATION Customer Getin EPS tae Perform stakeholder amp potential suppliers requirements analysis Write Call for Tender Elaborate and document stakeholders i and requirements analysis Ask questions i i Develop test and ail a i document concepts xploring controls i pi i architecture Draw terminal layout I Il Analyse and document first results rough concepts Sales s Evaluate the completeness and correctness of the design information and design choices phase 7 7 7 I Analyse physical Analyse physical I limitations I limitations i l I I I Exploring controls Develop test and architecture I I document concepts i l j i Analyse and document results different concepts Evaluate and choose concept offer strategy Write final Building modular Make modular documentation for pesiar Corro s i Paayan Nitra simulation mo
151. esign choices that are made in the design process of a BHS The Sales and Systems engineers of Vanderlande Industries seldom integrate quantitative results of dynamic behaviour and cost analysis in the BHS design process General solution directions Based on common sense and a literature study solution directions are distinguished to solve these problems An analysis of the involved stakeholders including their interests and perceptions offers the opportunity to handle the aspects of a complex stakeholders network and to predict or even influence the strategic behaviour of stakeholders Enserink e a 1999 The dynamic requirements of these stakeholders on a system 115 Chapter 9 Conclusions and recommendations should be identified in an early stage and have to be tracked and traced through the design effort in order to ensure a good fit between system and requirements Hooks Farry 2001 Attention for the strategic behaviour of stakeholders should not go without justification with regard to the content Bruijn de Heuvelhof ten 1999 Documentation of the reasons why certain technical choices were made offers efficiency benefits in the design effort and allows structured and unambiguous usage of this knowledge by other colleagues when operating in the social network To quantify and enlarge the insights on which the justification of design choices is based automated tools can be used Simulation studies on a computer
152. esigned by Vanderlande Industries Therefor all these components are documented including their functionality see appendix G Building a simulation model during the sales phase requires system representations on a level of abstraction which is global enough to prevent the engineers and customers from getting lost in details and detailed enough to design valuable system concepts To reduce complexity details of the components are omitted which do not contribute to the insight in the systems behaviour Based on their functionality the components are grouped in so called object classes The object description technique means the definition of objects by identifying their attributes and 70 Chapter 5 A new design methodology actions Bots et al 1997 The objects the building blocks for the simulation model represent a part of the BHS and together they form the total system Appendix H shows the object model which contains all required building blocks They are grouped in the classes Input Transport Process Sort Output Controls and Employees 5 4 6 Cost breakdown structure In the literature a difference is made between the costs involved with a system during its life cycle from the customer s point of view and from the producer s point of view Ludema Roos 1998 In this thesis the costs included in the cost analysis refer to the Costs of Ownership being the costs from the customer s point of view In order to
153. essar Necessary documents something customer really needs Prioritised ranked as to importance of inclusion in product Testable possible to ensure that the requirement is met Traceable origin source of requirements known Unambiguous has only one possible meaning interpretation Note that it is possible that the customer doesn t realise the total set of his requirements in the first phase of a project Talking with the customer about the aspects of a BHS pointing out the results for certain implementations and iteration in the requirements elicitation process helps determine the real set of requirements By communicating it can also become clear that the constraints as set up at the start of the project will change Filling in this template is a iterative process The ID Code is composed as follows Example SR2 4 SR Requirement characteristics possibilities FT Functionality or Technology requirement CS Constraint SR Specific Requirement PR Procedural Requirement 2 4 Second section fourth requirement When requirements are changed the original version must be kept By inserting a new row just below the original requirement and adding an extra number behind the code the history is documented SR2 4 2 Specific Requirement second section fourth requirement and version two The sources as mentioned for each requirement in this document assigned to refer to the stakeholders mentioned in the worksheet named Stake
154. ethodology and tools Engineers do not want to document information if the documentation is the only objective document only to document Therefor the reason why the information must be documented must clearly be communicated during team meetings In the new methodology the documented information forms the foundation for structured evaluations and supports all team members to be up to date the moment a meeting begins Therefor there is a responsibility towards the other team members to keep the documentation up with the work Sharing and evaluating information in a team means that more people are acquainted with information that could be of value for the competitors of Vanderlande Industries This understanding of course is the responsibility of each employee of Vanderlande Industries individually but it can be advisable for the process manager to stress the importance of delicate information usage Also regarding the documentation of objective or subjective information delicacy can be important 7 2 4 Evaluation of the way of modelling The models as introduced in section 5 4 have to represent the real situation in the sales phase on such a level of detail that on one hand all users of the models can extract the information they need but on the other hand composing the models will not take too much time Therefor the introduced templates for stakeholders and requirements analysis and concept documentation are judged by the involved
155. ey depend on the dynamics of the sales phase e g stakeholders who enter or leave the sales process changing political situations intermediary evaluations etc However the inter colleague evaluations have to be performed therefor it is wise to document agreed upon evaluation moments in the sales phase These moments can be rescheduled when necessary 58 Chapter 5 A new design methodology Concept offer strategy choice After iteration in designing and evaluating concepts a moment will come to choose the concept concepts or the concept strategy that will be offered to the customer In almost all situations Vanderlande Industries must offer at least one concept that is fully compliant with the official requirements as stated in the call for tender Otherwise Vanderlande Industries enlarges the risk of being excluded from the list of potential suppliers based on non compliancy If Vanderlande Industries beliefs a concept can be offered to the customer that is not fully compliant but will in the eyes of Vanderlande Industries satisfy the needs of the customer in a better way this concept can be offered together with the fully compliance concept This way the customer can justify to the outside world further cooperation with Vanderlande Industries based on the fully compliant concept but can also discuss the potential better option Vanderlande Industries may also choose for offering a concept strategy for instance modular concept
156. ey are grouped per functionality area and are divided in check in transport sorting make up break HBS EBS controls consolidation and other Constraints The constraints in the requirements template are grouped in 1 Existing BHS constraints 2 Knowledge constraints 3 Terminal building constraints 4 Environmental constraints 5 Vanderlande Industries constraints 6 Competition constraints The only differences between the attributes of the functionality requirements and the attributes of the constraints are the requirement ID that is replaced by a constraint ID and the compliance level that is replaced by a rigidity level Specific BHS requirements The specific BHS requirements are divided in 1 Flow requirements 2 Operation time requirements 3 Performance requirements 4 Redundancy requirements 5 Flexibility requirements 6 Conveyability requirements 7 Controllability requirements 8 Maintainability requirements 9 Safety requirements 10 Ergonomics requirements 68 Chapter 5 A new design methodology 11 Life cycle cost requirements The attributes of these requirements are similar with the attributes of the functionality requirements Procedural requirements The final part of the template contains a checklist for procedural requirements e g the tender document content and layout the project planning relevant legislation concerning tender procedures etc 5 4 3 BHS concept description template
157. eyor desks and Collector conveyor length A009 VI Manual 1 Added attribute Identification Manual Coding Station LCC_Code Encoding Station A010 VI Belt 1 Added attribute Identification Fast Non Conveyor LCC_Code Accum Conveyor A014 VI SideMerge 1 Added attribute Identification Merge Normal LCC_Code A016 VI Automatic 1 Added attribute Identification Automatic Coding Station LCC_Code Encoding Station A017 VI Screening 1 Added attribute Identification Screening Levell amp 2 LCC_Code Machine A017 VI Screening 1 Added attribute Identification and distinction 201 Appendices Original New Adjustments Reason for adjustment atomname atomname Screening Level3 LCC_Code with VI Screening Levell amp 2 Machine 2 Color in 2D view A019 VI TraySorter 1 Added attribute Identification Sorter Chute LCC_Code Discharge A020 VI TraySorter 1 Added attribute Identification Sorter Induction LCC_Code Induction A024 VI TraySorter 1 Added attribute Identification and Tray Sorter LCC_Code component price calculation Helixorter which depends on the NrChutes number of chutes the NrInductions number of inducts and 2 On reset event added counting function for the number of inducts and chutes in the TraySorter atom 3 On user event added menu option Helixorter or whether it is a normal
158. f a conveyor loop in which the baggage is continuously circulating The bags enter and leave the EBS by VERTISORTER s In case of automatic lane storage see figure 1 8 each conveyor lane contains bags with a STD within a certain period of time So the lanes are emptied one after the other with e g an interval of half an hour In the left lanes configuration a recirculation lane is integrated in order to recirculate baggage from a storage lane from which one or several item has to be released onto the sorter for instance because of a change in the corresponding flight In the right configuration the sortation to the different lanes is done directly from the sorter and in case of recirculation the sorter itself is used Chapter 1 Introduction recirculation storage lanes storage lanes Figure 1 8 Two configurations for EBS in lanes Storage of baggage in high racks by means of several cranes offers more flexibility because of the possibility of random retrieval Such a configuration of EBS is mainly used in BHS with high volumes that requires thousands of bag positions Security screening and scanning components Security screening and identification equipment is not build by VI Usually sub contractors supply these components Security screening usually referred to as Hold Baggage Screening HBS because it concerns bags loaded in the plane s cargo hold is applied to detect explosives and can exist of several leve
159. f implementation plan is included in chapter 8 2 4 Research approach The research activities are shown in the rectangles in figure 2 1 which represents their rough sequence In reality there were many iterations because of the participating approach of the research involved employees are listed in appendix C Next to the activities the products of the activities are shown including the reference to the chapter of this report in which they are described Initial problem description ch 2 Make leas descriptive conceptual model a gt l Descriptive conceptual model ch 3 Find real problem i Problem description ch 4 Make an prescriptive conceptual model He i Prescriptive conceptual model ch 5 Develop supporting tool t Supporting tools ch 6 Evaluate solution A i Evaluation results ch 7 Write ai implementation plan Implementation plan ch 8 Figure 2 1 Research activities and products 13 Chapter 2 Research description Make descriptive conceptual model The project started with talking to the employees who were interested in the problem and especially its solution and getting acquainted with the world of baggage handling systems by reading internal documentation professional literature and visiting the Internet This way the problem was explored creation of a mental model After the initial problems and objectiv
160. fit between them Total set of requirements and wishes The concerned engineers have to be acquainted with the total set of requirements and wishes by e Identification of potential stakeholders persons or sub organisations who can introduce requirements and or wishes e Identification of the requirements and wishes of those stakeholders e Prioritation of those requirements and wishes 30 Chapter 4 Problem analysis Design choices The concerning engineers have to record the design choices they make including the justification for those choices Clear justification implies unambiguous if possible quantified justification Good fit A good fit means the BHS is saleable the customer prefers a contract with Vanderlande Industries to a contract with a competitor and achievable for Vanderlande Industries from business economics knowledge and capacity point of view There are two ways to achieve a good fit the design choices are based on the total requirements set or the total requirements set must be based on the design choices With these notions in mind the current situation is analysed to find the underlying problems of the initial problems 4 3 What is the underlying problem A closer look at the current situation as described in chapter 3 is taken to determine the underlying problems regarding the total set of requirements and wishes the design choices and the good fit as stated in the previous section Total set
161. g inducts and or chutes is complicated If the configuration alternatives are known at the moment the sorter is modelled the extra needed inducts and chutes can already be included in the model which reduces the required modelling time Model View jo x Edt yew Figure 7 3 2D model layout of the third BHS simulation model 104 Chapter 7 Evaluation of methodology and tools In order to represent the BHS in a right way the completeness of the simulation tool regarding the components which are applied by Vanderlande Industries in BHS solutions is evaluated table 7 3 Object class Completeness BAXSIM library version 1b in ED Input Nothing missing Transport The instance BAGTRAX is not included according to the supplier available in the latest version of the library Instead of the attribute maximum peak capacity the objects have the gap length attribute in combination with speed the same functionality Process The instance EBS can be represented but without the distinction between lanes racks or dynamic EBS The instance Screen can be represented but without the distinction between levels 1 amp 2 or 3 Reconciliation can not be represented Output Nothing is missing Sort The instance tilt tray sorter can be represented but without the distinction between the normal sorter and the HELIXORTER The instances pusher vertibelt and cross belt can not be represented The
162. g deals with the managerial aspects of the methodology It includes planning and feedback and determines in which ways various persons and groups should interact Way of modelling The way of modelling defines the design products or intermediate results of the methodology and the way they are represented in terms of modelling formalism A good and sound design methodology can be defined as a methodology which addresses explicitly the way of thinking working modelling and controlling and is supported by a set of automated tools in a coherent and consistent manner Meel van 1993 This analytical framework is used in a prescriptive way The four ways of the new BHS design methodology are described in the chapter 5 Chapter 6 deals with the supporting tools 38 Chapter 4 Problem analysis 4 6 Summary The problem analysis can be summarised by the following The initial problems as stated in section 2 1 can not quantitatively be proven to exist because of the lack of the required information Both problems are recognised by all employees who were involved in the master project see appendix C for names The objective as based on these initial problems implies e Familiarity with the total set of requirements and wishes knowing who the potential stakeholders are what they want and how the requirements and wishes relate to each other e Unambiguous if possible quantified documented design choices made by the Sales and
163. g the way BHS are designed at Vanderlande Industries could imply changing parts of the organisation To cope with possible resistance 36 Chapter 4 Problem analysis and to implement changes in the right way this field of knowledge must be included in the problem tackling activities Concurrent Engineering defined as a design perspective on making the designers aware of all aspects involved in the life cycle of the system such as quality cost planning and user requirements Ludema Roos 1998 A broad view on the system requirements up on which the BHS concepts are based on means integration of the thoughts of Concurrent Engineering in the design process At the start of this project no one could tell what the solution of the problem would look like and which people in the organisation would participate in developing the solution or the solution itself The most directly concerned engineers in the Systems Group thought of a new way of designing supported by information and communication technology ICT The nature of the problems as stated in the previous sections differ and concern the communication culture at Vanderlande Industries and the BHS design methods Combined with the thought of introducing supporting technology an integral approach was necessary with attention for the organisation the processes and the tools In order to structure such a wide spread solution a BHS design methodology is developed A design methodology ca
164. gage Handling System is often unclear and depends too much on the engineer who is involved ics Chapter 2 Research description 2 2 Research objective Based on the problems as mentioned above the following project objective is defined Creating a situation at Vanderlande Industries in which engineers design Baggage Handling System solutions based on clear justification of design choices which are well tuned to the total set of requirements and wishes of all stakeholders 2 3 Research scope demarcation The main initial constraints on the project were given by the period within which the project had to be performed and the subject scope that had to be within the scope of the study Technology Policy and Management Further demarcation to the solution space was necessary in order to reduce the complexity of the problems and to create controllability of the project The following initial demarcations applied Baggage Handling System Although Vanderlande Industries supplies more material handling systems besides the BHS such as Express Parcel Systems only the BHS is taken in consideration in this thesis Besides only BHS for mid range airport terminals are included mid range terminals deal with 2 up to 15 million passengers a year Sales phase This thesis focuses on the sales phase This is the phase from the first trigger that starts Vanderlande Industries spending time on developing a BHS for a potenti
165. ge handler in euro real range 0 1000 33 NrMaintMenFirst 4 Number of maintenance men first line necessary at one time when the BHS is operational real range 0 1000 34 MaintManFirstCost 50 Hour wage of a maintenance man first line in euro real range 0 1000 35 NrMaintMenSecond 1 Number of maintenance men second line necessary at one time when the BHS is operational real range 0 1000 36 MaintManSecond 150 Hour wage of a maintenance man second line in euro real range Cost 0 1000 37 SpareParts1 0 Percentage of the capital expenditures that will be calculated for to To the spare parts during the first second and third year including 39 SpareParts3 overhauls real range 0 1000 40 SpareParts4 Vary Percentage of the capital expenditures that will be calculated for to To from the spare parts during the fourth to thirtieth year including 66 SpareParts30 0 5 to 4 overhauls real range 0 1000 67 ControlsEuro 800000 Purchase price in euro of the system controls this price will be included in attribute 1 integer Table J 1 The attributes of the cost calculator 194 Appendices Appendix K Calculation steps of the cost calculator Legend Reset y __ Internal decision of the calculator without influence Set all LCC of the engineer calculation results a g to zero Decision determined by the engineer y Y Ca
166. gn teams working on specific projects was judged as a good change The integral quantitative justification of the design choices made by the Sales and Systems engineers was supported by all involved employees Several employees stressed that the relevance of the quantification of the design choices justification should be determined for each project specifically A good balance between the project time available and the time spend on the quantification must be found 7 2 2 Evaluation of the way of working The way of working regarding the communication of Vanderlande Industries employees with the stakeholders including documentation of the results of this communication is supported by all interviewed employees They confirmed the need for a structured way of working including moments of evaluation and reflection on the designed concepts and the information they are based on This was illustrated by described situations in which the involved people take a quick decision in an early stage of the project in order to start with the real design work as soon as possible Later it appeared that the information the decision was based on was out of date and crucial for the success of the offered concept 94 Chapter 7 Evaluation of methodology and tools The employees also support the team formation including the documentation of the responsibilities It will improve efficiency because the same work will not be done twice everybody aims for t
167. gned BHS concepts and the information he she uses during the design process in a structured and consistent way This enables the colleagues to judge the considerations made by the engineer The engineer must quantify his her concept choices justification as much as possible see also following subsections to support quick and structured team evaluation afterwards A checklist supports the engineer to integrate many disciplines in the design choice justification The documented concepts including justification offers the experts of all disciplines to check the engineer s reasoning and to prepare themselves for evaluation meetings BHS dynamic behaviour analysis In the line of integral design and quantification of design choices justification the Sales or Systems engineer must integrate a simulation study when static calculations do not answer all questions regarding performance or system behaviour necessity of the simulation study can be determined in consultation of a simulation engineer As stated by Banks a thorough simulation study contains the following steps Banks e a 1999 1 Problem formulation The engineer is already involved in the stakeholders and requirements analysis and the conceptual choices that are considered therefor the uncertainties can be defined and documented 2 Setting of objectives and overall project plan The engineer must determine the objectives of the simulation study These are the questions to which the answers
168. hanges exceptions etc yyy frequency deadlines intermediary products 9 Meetings overview Who spoke to whom when what were the subjects and the results holder initials initials dd mm y subjects of meeting main results minutes of meeting document name 151 Appendices Requirements worksheet The characters of the requirement or constraint ID code refer to FT Functionality or technology requirement CS ConStraint SR Specific Requirement PR Procedural Requirement The table as shown for the check in functionality is repeated for transport sorting make up break HBS EBS controls consolidation and other 152 Appendices Man IRTA ETTI INDUSTRIES Requirements documentation Document objective Support the process of complete and consistently requirements elicitation and documentation Content 1 Introduction 2 General functionality and technology requirements 3 Constraints 4 Specific BHS requirements 5 Procedural requirements 1 Introduction The following characteristics can be used to identify real quality requirements Complete nothing is missing no to be determined and all conditions under which the requirements applies stated Consistent does not conflict with other requirements Correct accurately states a customer need Feasible can be implemented within known constraints Modifiable can be easily changed with history when nec
169. he same objectives there will be less iterations in the design process and the evaluation can be performed quicker and more structured This will also improve the professional appearance of Vanderlande Industries because there will be no misunderstandings among VI employees and no double questions will be asked Besides the lobby stakeholders and requirements analysis and the feedback activities will enable the employees of Vanderlande Industries to approach the right people at the right moment with the right arguments They will also be able to link the right solutions to the right interests etc The employees recognise that the quantified justification of the design choices will support the team evaluations They are convinced that it offers salesmen and engineers persuasion power when presenting solutions The analysis of dynamic behaviour and costs and the relations between the BHS concept and its environment offer the Sales or Systems engineer a wider insight to base their design decisions on 7 2 3 Evaluation of the way of controlling In this sub section several remarks regarding the controllability of the new methodology are given First of all now is the right moment to implement the new methodology because the management of Vanderlande Industries is aware of the introvert culture at Vanderlande Industries and is eager to change that The cooperation of the management is also required because of their important role in the lobby activitie
170. heck in desk isle Check in desk isle Weighing Labeling Identification Checking dimensions Dispatch Tipping Transport Input Transfer Transfer loading Identification Weighing Checking dimensions Transport Claim carrousel Arrival carousel Loading Transport Belt conveyor Belt conveyor Transport Start stop belt Start stop belt conveyor Queuing conveyor Transport Accumulating Accumulating conveyor Transport conveyor for tubs Hold baggage Transport Arrange a uniform flow of baggage Belt curve Belt curve Transport baggage 2 dimensional Tub conveyor TUBTRAX Transport baggage in tub DCV BAGTRAX Transport baggage in cart Tub loading Load Load bag in tub Tub unloading Unload Unload bag from tub Cart loading Load Load bag in cart Cart unloading Unload Unload bag from cart Carrier load Charge Load tub in carrier Carrier unload Discharge Unload tub from carrier Reconciliation Reconciliation Match passengers and baggage going into plane Process Handheld scanner Handheld scanner Identify bag Automated scanner Automated scanner Screening level 1 Screening level 1 Check bags for explosives or drugs Screening level 2 Screening level 2 Screening level 3 Screening level 3 Baggage storage EBS lanes Temporarily store and release bags Baggage storage EBS rack Baggage storage EBS dynamic p t 0 Appendices continuation General name VI name Functionality Object class Pushe
171. her 3 Cost effectiveness To what extent fulfils the system its function in a desired way against the lowest possible life cycle cost 3 1 Throughput Possible descriptions Flow throughput divided per source such as check in transfer other terminal and terminating Flow throughput per system component Description in words graphs flow layouts etc Comments Description Comments regarding the throughput description specification of the throughput capacities Requirements and or constraints concerning the throughput capacities Requirem Description Compliance VI Priority Assigned Organsiation MAG constr level to ID code Requirement constraint Mandatory High initials Organisation name Person name description guidance medium low SR1 1 0 0 0 0 N A SR1 2 0 0 0 0 N A SR1 3 0 0 0 0 N A N A N A N A N A N A N A N A N A N A N A This combination of description table and relevant requirements table is repeated for all cost effectiveness elements Below only the hint text for each element is shown 3 2 In system times Possible descriptions Average maximum minimum times divided by flows Description in words graphs histogram etc 3 3 Resource utilisation Possible descriptions Percentages busy stand by off per component group Content in nr of bags per interval Description in words graphs histogram etc 159 Ap
172. hird party organisation with great influence can icro Lia lead to tuning the BHS characteristics or peripheral events to the wrong requirements which can result in losing the contract award Table 4 1 Consequences of problem 1 What is the problem 2 The employees of different departments and Customer Centres of Vanderlande Industries who are involved in the sales phase of a BHS do not work as a team regarding The elicitation interpretation and documentation of information regarding the total set of requirements on a BHS Structured evaluation of design choices made in the BHS design process Considered 5 Why is it a problem Perspective This can result in damaging the professional appearance of Vanderlande Industries by Macro 1 Asking the same questions to the customer more then once redundancy 2 Different interpretation of the same information by employees communicated with the customer 3 Different BHS concept solutions for more or less similar situations Without team based information elicitation work can be done twice inefficient M Inconsistency in the interpretations and documentation of the information also eso F el aenst 5 DIE results in inefficient cooperation of the involved engineers by misfits of intermediary products lack off an equal goal The Sales or Systems engineer founds his choices made in the BHS design Mi process only on his own assumptions expectations
173. holders 2 General functionality and technology requirements Keep the entered requirements in accordance with the characteristics mentioned in the introduction 2 1 Check In functionality and technology eee ade ID to level initials ID code Check in functionality required initials mandatory high dd mm yy further details and e ra If yes certain technology guidance medium possible changes required BB FT1 1 Walk through check in desks Mandatory 16 5 2002 MF saw walk through including elevators check in on K ln Bonn Airport Po ro o o S e T Po Po o o S T T LC ST 153 Appendices 3 Constraints The limitations to the solution scope 3 1 Existing BHS constraints dismantle integrate or reuse existing BHS sub systems or controls Author Constr ID Description Assigned Rigidity level iori Comments to initials ID code Unambigious and complete initials fixed i further details and constraint description flexibel i possible changes 3 2 Knowledge constraints Level of technical know how of e g the handling controls and maintenance employees working with the BHS Constr ID Description Assigned Rigidity level iori Comments to initials ID code Unambigious and complete initials fixed i further details and constraint description flexibel it possible changes 3 3 Terminal building
174. ht percentages to use Note that these are very rough estimations that always have to be verified Training cost There is no data available Depends on the chosen training facilities The concept train the trainer costs less labour hours than the train all involved employees concept Documentation cost There is no data available Again the number of hours spend on documentation depend on the complexity of the system and the required documentation detail O amp M equipment cost The equipment necessary to use and maintain the BHS depends on the systems complexity A small system with standard components will need no special equipment More complex components and therefor higher capex require special and therefor more expensive equipment Probably the relation between the capex and the cost of setup equipment will be an S curve source AAa setup equipment cost capex Figure N 1 Relation between setup equipment cost and capex Initial spares cost A system with a lot of different BHS components requires many different initial spare parts The more unity in the components the less different spare parts necessary The following graph shows a relation between the percentage of the capex needed for initial spare parts and the capex source document 06320 005141 HKo Based on this graph the following assumptions can be made towards the initial spare cost 203 Appendices Capex lt euro in
175. ible solution directions from getting awarded with increase quality systems the stakeholders view point commission decreasing the nr increase market share of mis connected bags etc 6 Stakeholders means What means both formal and informal can the stakeholder deploy in order to reach the objectives technical juridical social or economical And is the stakeholder a formal informal or no decisionmaker in the project Stake Formal Informal Date Means holder decision decision initials ves no yes no dd mm y such as provide information men power knowledge funds or set in yyy jurisdiction authority relations persuasiveness exercise a veto lodge a notice of objection status compulsion blackmail etc E sf AT T r r Fr_rTr rr r r 7 Stakeholders interdependencies In what way are the involved stakeholders interdependent e g on resources information relations both formal and informal and positions of power Stake Stake Date Nature of interdependency holder holder initials initials dd mm y e g financially information gathering possible future cooperation formal or informal yyy relations authority 8 Communication agreements What are the agreements made regarding communication VI Stake Date Agreements Comments holder initials initials dd mm y Contact persons addresses contact c
176. ice This part of the solution considering the activities related to attention for the decision process of the customer the teamwork regarding information elicitation and evaluation and documented justification of the design choices is mainly formed in Veghel Parts are results of interviews with employees of the Veghel office and therefor it should prove its benefits in a world outside Veghel The Customer Centre in Germany or Spain is recommended to start the pilot project because according to the Management of the Systems Group these Customer Centres have a relatively open mind towards new more customer focused activities The employee who will play the role of process manager can introduce the new methodology at the CC and start up the pilot Again the BHS to be developed should imply a certain level of complexity towards the stakeholders network in order to reveal the benefits of the methodology and tool 8 3 Actual implementation If the results of the pilot projects are satisfying the new methodology can be introduced in the whole Vanderlande Industries organisation Because of the learning aspects of the process it is very important that the participants have an understanding of and appreciation for the methods and tools that are used during a project and afterwards to institute continuous process improvement CPI Mayer 2001 So the new methodology and tools should be explained to all involved Vanderlande Industries empl
177. ick respond on questions asked by e mail Internet possibilities Incontrol ED Meetings can Update downloads be scheduled 173 Appendices Possibilities Remarks Technical support FAQ Tips amp Tricks for registered users under construction Nov2001 WebEx online meetings for registered users facility implemented on website but no meetings planned yet Nov2001 Incontrol ED MyPlant has a section for ED Incontrol ED has experience with projects at Schiphol Airport so knowledge of BHS is available Incontrol ED Incontrol Enterprise Dynamics has a large experience in the simulation of Baggage handling systems at Schiphol Airport so knowledge of BHS is available to a high level Incontrol ED additional services consultancy and training basic and advanced Incontrol ED develops an Education Suite easy to use modelling objects for queuing cases Potential user group meetings organised e g The European Simulation Conference 1 3 4 Pre purchase Pre purchase facilities include demo disks free trials and on site demonstrations Possibilities Remarks Evaluation version of ED can be downloaded up to 20 atoms can be saved no connections with external programs possible from the Internet Incontrol ED Connections with external software possible in evaluation version of ED 4 0 Trial period of simulation software is possible by means of s
178. ield Wish possibility to set failure rate to 0 189 Appendices Characteristics Remarks A018 Sorter Curve A019 Wish distinction between the sorter Sorter Discharge induction atom and the sorter discharge atom in the view channels screen layout Wish automatically height adjustment to the height of the tray sorter atom 4Dscript at reset event handler Wish possibility to set a certain distance between discharge point and decision point of discharge no discharge reality 2 3 metres in front of discharge point A020 Sorter Induction Wish distinction between the sorter induction atom and the sorter discharge atom in the view channels screen layout Wish automatically height adjustment to the height of the tray sorter atom 4Dscript at reset event handler Induction frequency can only be given in time between two inductions Wish option to give the number of trays that must pass before another induction can be accomplished A021 Sorter Scan A022 Storage with the following In 3D animation no bags are shown and in High Aggregation options store capacity store time 2D only 1 bag is shown Storage 4Dscript inbound capacity and outbound capacity In 2D Incontrol ED All atoms in the storage are animation the contents number accessible with the atom editor of bags the current utility and the a
179. ier step has documented what went wrong when trying these changes the other engineer will not try it again e Enabling reuse of work If the conditions requirements and constraints are known that applied to a certain earlier designed BHS parts of this design can be reused in new BHS e Learning individual engineers By reading the foundation of the design choices made by experienced engineers less experienced engineers can learn from their knowledge e Learning the Vanderlande Industries organisation 47 Chapter 5 A new design methodology Discussing the justifications of design choices made by individual engineers enables all Vanderlande Industries engineers to grow towards all agreed upon best practise design choices sharing knowledge e Offering transparency inside Vanderlande Industries Transparency of the design choices results in less time necessary to evaluate concepts with colleagues and better possibilities to take over someone else his work e Offering power of persuasion A complete justification of a concept supports the engineers who present the concept to the customer in reacting on questions and defending certain choices without the responsible engineer attendant e Preventing routine based design Justification forces the engineers to explain why certain choices were made The engineers can then be challenged by colleagues to defend their routine reasons during an evaluation meeting e Preventing gold plate
180. ign choices Lobby BHS design choices justification Way of Stakeholders analysis Team formation amp documentation A Requirements analysis Team based evaluation BHS dynamic behaviour analysis working SO a Feedback elicitation BHS cost analysis lt _ Process manager _ gt lt Commitment gt Way of lt _____ Drop out prevention _____ controlling lt Support lt Responsibilities division amp documentation Table 5 3 Relations between the way of thinking working and controlling Note that the way of controlling as described in this section is meant for the managerial aspects once the new design methodology is implemented at Vanderlande Industries The aspects regarding the implementation are dealt with in chapter 8 5 3 1 Introduction of a process manager A new role is introduced in the BHS design effort at Vanderlande Industries the role of process manager The process manager s main job from macro and meso point of view is to find the right balance between the process and the content side during the design effort see also the strategic behaviour paradox as stated in section 5 1 3 legitimacy of strategic behaviour depends on justification with regard to the content The process side refers to the decision process of the customer The content side refers to the BHS concept the configuration the used technology performance etc
181. imulation model window from the Enterprise Dynamics application The concerning engineer enters the requirement or constraint ID code in the white left column Then automatically the other related information is displayed obtained from the Stakeholder and Requirements worksheet 158 Appendices Some default ID codes are given in the tables They refer to relation between the concept and the requirements that exist for certain 2 Technology specification 2 1 Check in technology Author _ Technology Comments initials specification of the applied check in technolo Comments regarding the check in technolo BB 50 walk through check in desks combined with 25 Stainless steel covers Weighing belts included elevators type X1200 from subcontractor TD Requirements and or constraints concerning the check in technology Requirem Description Compliance VI Priority Assigned Organsiation Person constr level to ID code Requirement constraint Mandatory High initials Organisation name Person name description guidance medium low FT1 1__ Walk through check in desks Mandatory High MF FT1 2 0 0 0 0 N A N A N A N A N A N A N A N A N A N A N A N A N A N A This combination of description table and relevant requirements table is repeated for the following technology transport sorting make up break HBS EBS controls consolidation and ot
182. imum peak capacity bags hour integer Handling time sec time actions Merge bag from different directions 168 Appendices Object class Bag attribute Bag number integer Time in time Time out time Standard Time of Departure time Flight code string Out of gauge yes no boolean Status screening not screened level screened level 2 screened level 3 screened string Status EBS yes no boolean Baggage category originating transfer destinating string actions Object class Controls attribute Price real actions Control the BHS Object class Employee attribute Function integer Labour cost per hour real actions 169 Appendices 170 Appendices Appendix I Enterprise Dynamics and the BAX Suite evaluation Supplier Incontrol Simulation Software b v Maarsen Based on ED Version 3 4 and BAX Suite Version 01 b I 1 Introduction This appendix evaluates the usefulness of the software for building simulation models of Baggage Handling Systems in order to obtain information about the dynamic behaviour of the system It is based on a stand alone installation with a hardware key with code ZWBXO Enterprise Dynamics and Airport Suite are trademarks of Incontrol Simulation Software b v in Maarssen The Netherlands The Enterprise Dynamics Airport Suite is a library of simulation objects made for the airport industry One of the modules is ED
183. ineers VI project manager Purchasing Planning Pricing Customer Centres Etc ID Organisation name Department Person Function Telephone amp e mail initals initials name department name person s name function name telephonenr amp e mailaddress Operations il i Manager Operations 150 Appendices 4 Stakeholders characteristics Comments about the different stakeholders that should be shared with the VI colleagues Stake Comment holder initials initials dd mm y good relations with who VI employees consultants competitors etc earlier yyy experiences with VI level of BHS knowledge conventional in front with high tech etc 5 Stakeholders objectives and perspectives What are the fundamental objectives stabile in time mostly abstractly formulated of the stakeholder and what are the concrete objectives concrete issues for this project And what is the perception of the problem and solution of the stakeholder depending on e g the cultural background position ambition fundamental objectives available vocabulary what can be discussed and individual frame of reference selective perception Stake Date Fundamental objectives Problem and solution Concrete objectives holder perception initials dd mm y mission e g continuation profit describe the problem and objectives in this project e g yyy good name trust customers poss
184. ing and controlling Macro Meso Micro Cooperation of organisations Getting grip on the decision process of the customer Way of thinking Lobby Stakeholders analysis Requirements analysis Feedback elicitation Way of working Coordination of processes between VI departments Teamwork regarding evaluation and information processing Team formation Team based evaluation Primary tasks at workplace level Integral justification including documentation of design choices BHS design choices justification amp documentation BHS dynamic behaviour analysis BHS cost analysis 4x__Y Process manager _____L__ gt lt Way of Commitment lt Y Y Drop out prevention ___ gt controlling p lt Stakeholders Way of analysis template modelling Requirements analysis template Support Responsibilities division amp documentation BHS concept justification BHS concept description template lt __ design choices gt lt Simulation model gt Cost breakdown structure Table 5 4 Relations between the way of thinking working controlling and modelling 65 Chapter 5 A new design methodology The first two sub sections discuss templates to structure the stakeholders and requirements analysis Sub section 5 4 3 discusses the template to document a BHS concept in a structured way Th
185. ing tools Man Den ianve UDUVERE Supporting the design of VI Baggage Handling Systems Project name Doo o o Customer s organisation name s __ Project number Eye in accordance with the VI guideline sales document numbering 8 2137 0139 G Author Date Reason for revision initials dd mm yyyy Document objective The objective of the tool is to support the VI employees in 1 Performing and documenting a stakeholders network analysis 2 Eliciting prioritising and documenting the total set of requirements on the future BHS 3 Objectively founding the designed BHS concepts by documenting each part of the concepts in relations to the requirements that apply to that specific part evaluate determine assigned to satisfies needs based on justify Figure 6 1 The general worksheet in the justification tool Stakeholders worksheet The stakeholders worksheet contains edit fields for the items of the template for the stakeholder network analysis as described in sub section 5 4 1 It guides the engineers and sales men in documenting all relevant stakeholders who can have an influence on how the quality of a BHS is experienced By taking all wishes and requirements into consideration a better weighing of pro s and con s of BHS concepts can be made and no important factors are omitted Filling of the worksheet will be performed iterative because in the initial contact phase not all the informati
186. initial requirements can be formulated even before the design team at Vanderlande Industries is formed These requirements have to be documented by the Salesman The moment a Sales or Systems engineers starts working on the project he she accounts for the requirements analysis All changes or additions in the requirements discovered by others have to be documented by the responsible Sales or Systems engineer In comparison with the stakeholders analysis the documented results form preparation information for the team meetings and the composition and evaluation are guided by a sound requirements analysis template Feedback elicitation The process manager is responsible for the delegation of adjustment and frequency of the feedback activities including structured sharing of the results It is advisable to document the obtained feedback via one person e g the Salesman Team based evaluation The process manager is responsible for frequent and structured team based evaluation moments Especially in case of a very dynamic environment regularly recapitulation of the information the design effort is based on is necessary Templates can quicken and guide the structured evaluation activities BHS design choices justification and documentation The Sales and Systems engineers have to document their justification of the design choices they make during the sales phase A template for complete documentation of the choices enables the team membe
187. ion 5 1 a way of working section 5 2 a way of controlling section 5 3 and a way of modelling section 5 4 as described in the section 4 5 of the previous chapter The findings are summarised in section 5 5 5 1 Way of thinking The way of thinking describes the underlying philosophy of the methodology Again the macro meso and micro perspectives are applied to allocate the new way of thinking Table 5 1 shows the main elements of the way of thinking which are elaborated in the following sub sections Stake holder Stake holder J take holder Cooperation of Coordination of processes Primary tasks at organisations between VI departments workplace level Way of Getting grip on the Teamwork regarding Integral justification decision process of the evaluation and information including documentation of thinking customer processing design choices Table 5 1 The way of thinking 41 Chapter 5 A new design methodology 5 1 1 Way of thinking a macro perspective The main philosophy regarding the macro perspective is getting a grip on the decision process of the customer in which the supplier is chosen who will be awarded with the contract The following notions form this philosophy Focus on the customer s needs As stated in chapter 4 the organisation of Vanderlande Industries is too much focused on the technical side of the Sales phase Too little attention is spent on the decision process side of the Sales
188. ion of methodology and tools Requirement Com Tool characteristic pliant clarification captured in blue areas containing the hint text No graphical representation of relations in tool included Maintain a common Yes The justification tool is used and filled by sales men and engineers reusable repository data They and also other Vanderlande Industries employees such as models source pricing engineers can reuse each other s work Besides the stored information can be used in future projects Support team collaboration Yes The tool enforces the involved people to discuss the content and to gear the missing information gathering activities The information recorded in the tool is spread before each meeting which enlarges the efficiency of the meetings Enforce the correct Partly By combining the requirements including their source and priority application of methodology with the designed concept characteristics a well organised concept and methods evaluation is possible The tool does not implicit enforce the involvement of colleagues in the evaluation nor does it enforce a method to gather the required information Maintain an enter once use Yes Once the information is documented all involved employees are often approach in data able to use it The different concepts are based on one and collection therefor consistent set of stakeholder and requirements analysis information Ens
189. ir functionality can be simulated with the object lateral Merge The instances vertimerge and end merge can not be distinguished The functionality of the instance side merge is missing in the library can be represented by splitting the conveyor to which is merged in two conveyors Bag Nothing missing Controls High level controls object is missing Employee Available in the standard ED logistic library Table 7 3 Completeness evaluation of the BAXSIM library The objects included in the ED simulation package and the BAXSIM library are compared with the object classes and their instances of a BHS as defined in appendix H The level of detail of these objects is tuned to the minimum required insights and simulation results in the design phase of a BHS concept The distinguished object classes are represented in the left column of table 7 3 The right column contains the comments regarding the completeness of the BAXSIM library Most of the BAXSIM library objects are more detailed than the required level of detail in the design phase Although not necessary for the behaviour study of a concept it does provide more detailed layouts and animation that can enlarge the trust in simulation models To get the whole library on this level of detail the vertimerge pusher and vertibelt should be added to the library 105 Chapter 7 Evaluation of methodology and tools 7 4 3 Conclusions Summarising the ED simulation
190. irport site According to the experienced engineers the space is in most cases already reserved for the BHS the moment Vanderlande Industries receives the call for tender Mainly in countries with humid heat when an air conditioning is required the cubic metres of space are relevant Accept for this remark this aspect is not taken into further consideration The following financial aspects are in consultation with the involved engineers also excluded in this cost calculator start up structure e Interest e Inflation the value of money has to be discounted for the time e Learning curves experience in a certain application field could result in less cost in the remaining years of use 5 5 Summary In order to structure the compound solution to the defined problems a new design methodology is developed It came into being by interviewing employees and consulting literature on the defined problem areas This methodology that must help Vanderlande Industries to reach the stated objective can be visualised by the table 5 5 SD a A new design methodology Chapter 5 holder Cooperation of organisations Getting grip on the decision process of the customer Way of thinking Lobby Stakeholders analysis Requirements analysis Feedback elicitation Way of working 4___ Process manager _ Way of gt Commitment Drop out prevention ___ gt Coordination of processes
191. iscipline start developing BHS concepts further detailed in section 5 2 5 This is done in close consultation with the Controls and CAD engineers who start working on possible control architectures and the terminal building layout In the mean time the Salesmen and Agents stay involved in the customer s environment in order to detect relevant changes in participating stakeholders and their requirements on the BHS When different concepts are designed they are evaluated by the team based on their relations with the stated documented and agreed upon requirements In some cases e g when the European legislation regarding public tender procedures applies no or very little contact with the customer is allowed Questions may be asked to the customer but only if officially written down and the answers will be sent to all competitors In such situation it can be preferable not to involve the customer officially because it might result in competitors copying the solutions of Vanderlande Industries While evaluating different BHS concepts the involved Vanderlande Industries employees must also discuss and tailor the content of the checklists to the specific project Following design round s Then a new design round can be performed Note that filling maintaining and evaluating the stakeholders analysis the requirements analysis and the designed concepts will be an iterative process These activities can not be fixed scheduled up front because th
192. istics documented amp founded gt concepts Justification tool VI strategy ti Evaluate correctness amp gt completeness justification tool _ itself ey N_A2 3 1 x Evaluate correctness amp M gt completeness tool content FN N_A2 3 2 A Evaluate amp document each j XX gt concept according bi o ao requirements N_A2 3 3 ii MS Office 147 incomplete or dissatisfying results evaluation results concepts Appendices New situation Appendices 148 Appendices Appendix E The design choices justification tool layout The BHS design choices justification tool exists of a MS Excel document containing five different worksheets named General Stakeholders Requirements Concept and Concept History excluding the two copies of the Concept worksheet The General worksheet contains a template for general information including tool objective see below and the Stakeholders worksheet contains information about the customer and the future environment of the BHS The Requirements worksheet offers a template for the total set of requirements on the BHS and the Concept worksheet contains the template to describe the designed BHS concept The history of the concepts is documented in the final worksheet In this appendix the different worksheets are shown and if necessary provided with a brief explanation To save space some tables are shor
193. itial spares of capex euro lt Capex lt euro initial spares of capex Capex gt euro initial spares of capex Initial spare parts a percentage capex x1 000 000 euro gt Figure N 2 Relation between the percentage of capex for initial spares and capex Consumables cost Based on calculations for one project the consumables cost about of the capex per year source document CAAS T3BHS amp TBS version 1 AAa Energy cost There is no data available Estimation based on studies performed by RvP is of capex per year source RvP Spare parts cost The first years after the start up and test period of the BHS hardly any spare parts are necessary Most BHS components have a technical life time from to operational hours source document 1 6320 03346 Hko Transform this in a life time in years Example Life span 35 000 hours Operational days per year 365 Operational hours per day 20 of time in operation 80 Results in a technical life time of 35 000 365 20 80 100 6 years This means that the required number of spare parts will increase after approximately 5 years and peak after 6 years This cycle will repeat itself and therefor another peak can be found after approximately 12 years If for some reason the use of the system is less than the mentioned 20 hours per day the pattern will shift further in time An estimation of the total percentage
194. ity option from the main menu allows the user to fly through the 3D model It is also possible to follow a certain atom through the 3D model by using the Camera atom and to change the shadows of the atoms by using the Light atom Scrolling through the models by dragging with the mouse If both mouse buttons are used in the same time it is possible to zoom in and out If unintentionally an atom is selected which happens very often when zoomed in by clicking even near the atom it is moved through the model instead of moving through the model it self 1 6 5 Animation development Includes issues such as ability to create and import icons quality of icons and collection of animation icons 181 Appendices Possibilities Remarks ED contains some simple icons that will do in models with high and medium level of detail See section 1 6 2 importing icons 1 6 6 Running Animation events during the run show or hide changes of animation Possibilities Remarks The slide control function allows the user to adjust the simulation speed to the ideal observation speed By changing the colour of atoms after a certain assignment by adding 4dScript it is easy to follow individual atoms in their way through the model During the run the 2D and 3D windows can be opened and closed Opening these windows results in a drastic decrease of the run speed Every table that is cre
195. l building an AutoCad drawing is made AutoCad is completed with Villa an application containing building blocks of BHS components to generate a bill of material AutoMod To proof the BHS is compliant with the required performance the flow oriented simulation package AutoMod is used by the Simulation engineers Pricing Tools The Pricing engineers calculate the price of a system supported by three applications based on FileMaker Pro e CCP Conveyor Calculation Program equipment prices only e SCP System Calculation Program project related labour cost e PPS Project Pricing Sheet prices as charged to customer Lotus Via the Lotus Notes Desktop application each workstation is connect to several communication and planning features This application also offers the entrance to the Vanderlande Industries Public Library database Vanderlande Industries Product Data Book and Vanderlande Industries Sales Reference Database 28 Chapter 4 Problem analysis 4 Problem analysis Finding the right solution to the right problem is impossible without a clear idea of the problem the context and the solution direction Sol 2000b Therefor the initial problems as stated in section 2 1 are verified in the first section of this chapter Section 4 2 describes the implications of the new situation if the desired objective of section 2 2 has to be reached With these notions in mind two questions were answered to clarify the real problems
196. lculation step performed Find first BHS i by the calculator component in Find next atom in model model T AS aca No Component e sl ui found ho internal D e z Calculate total Yes operations and No y maintenance cost ring lif Add high level Calculate during life cycle i IgIeve j component capex controls cost to tota Std add 16 total capex capex y Calculate Operations and Maintenance cost for each year Yes Include O amp M set up cost in LCC Calculate O amp M Add O amp M set up setup cost of cost and Capex to capex first year cost Include Capex in LCC Include Maintenance cost in LCC Yes Calculate s Maintenance cost Yes et total capex to of capex and zero personnel per year la tt y Include Yes Calculate total LCC Operations by adding all cost cost in LCC Y Calculate No Operations cost y of capex and personnel per year Display results values and graph Figure K 1 The calculation steps of the cost calculator 195 Appendices 196 Appendices Appendix L Internal table of the cost calculator External version CENSORED The prices mentioned in this appendix are imaginary prices only Th
197. lopment In iterative steps new elements or parts of the methodology were checked on realism and rationality The evaluation considering the quality and viability of the methodology is based on the reactions of several experienced Vanderlande Industries employees when confronted with the new methodology see appendix C Some evaluation meetings were group wise up to four attendants some were individually They work in different Customer Centres different departments disciplines and different management layers Some of them were already involved in the development of the new design process Others had nothing to do with the development up to then Their remarks are grouped in remarks related with the way of thinking working controlling and modelling 7 1 2 The supporting tools The design choices justification tool is tested against the requirements as stated before in section 6 1 and 6 2 1 Besides the tool is presented to the employees involved in the evaluation to gather their judgement whether the tool will help reaching the objective On non participating basis the simulation tool is evaluated based on criteria for simulation 93 Chapter 7 Evaluation of methodology and tools software as stated by Nikoukaran Nikoukaran et al 1999 Besides the tool is tested against the requirements as defined in chapter 6 on the simulation tool which includes the making of three simulation models of different airports to judge the tool fr
198. ls namely Level 1 Automated check by a smart X ray device Level 2 An operator analysis the X ray reproduction Level 3 Automated check by a CT machine Level 4 An operator searches by hand with the passenger present Level 5 The bag is destroyed Scanning identifying the baggage label is done manually by handheld scanner or automatically by an infrared scan device above a conveyor belt both reading a bar code Control components In order to control the baggage flows there are three control systems integrated in a BHS namely e Baggage Destination System BDS e Baggage Routing System BRS e Programmable Logic Control PLC The BDS receives the flight schedule and chute allocation from an external information system see figure 1 9 It also receives the Baggage Source Messages BSM and Baggage Transfer Messages BTM from a world wide information system see appendix B for further details about interfaces with a BHS These messages contain information of the bag a unique License Plate a passenger name a flight number etc Based on this information the BDS is able to link a destination code to a License Plate of a bag So when the BRS sends a License Plate the BDS returns the destination code for the 9 Chapter 1 Introduction concerning bag Based on this code configuration and status of the equipment the BRS determines the routing of the bag through the system This route is sent to PLC level that is the l
199. lso offers a broader insight in consequences of design choices which enriches the evaluation moments Supporting information system Such a group wise BHS design effort can be supported by an information system that enables the concerning employees to access the gathered information stored in one and therefor consistent document It can also improve the communication between the team members and offer the possibility to carry out a variety of tasks at one workstation Although the Vanderlande Industries network Intranet offers the possibility to share information with different departments this cooperation is not structured integrated in the design process 46 Chapter 5 A new design methodology 5 1 3 Way of thinking a micro perspective The main underlying philosophy to solve the two problems from the micro perspective section 4 3 is the integral if possible quantitative justification including documentation of the design choices This philosophy is a compound of the following thoughts Strategic behaviour paradox The way of thinking from a macro perspective mainly deals with strategic behaviour in a complex network of different stakeholders with different objectives and means And although the engineers in the current situation focus too much on the system s content only that content is essential for success meaning selling BHS This is the strategic behaviour paradox as stated by De Bruijn and Ten Heuvelhof Bruijn
200. luminated which supports the stakeholders and requirements analysis the team based evaluations and the documentation of BHS concepts and their design justification Section 6 3 describes the evaluated simulation package Enterprise Dynamics that supports the analysis of the dynamic behaviour of BHS concepts The final section 6 4 deals with the developed cost calculator that supports the engineers in performing a cost analysis 6 1 Requirements on the supporting tools While performing the new or adjusted design activities the employees can be supported by new tools The general requirements on these tools are described in this section First of all there are some requirements given which were found in the literature and apply to supporting tools according the Business Engineering design perspective According to Mayer the most powerful tool supports integration of the information in the different methods supports automatic drawing of the graphical display of a view and supports the generation of quantitative analysis results or process implementations directly from the methods Mayer 2001 This leads to the following requirements that also apply to the tools in this thesis e Enable efficient and effective knowledge capture e Use graphical representations for clarification of communication e Maintain a common reusable repository data models source e Support team collaboration e Enforce the correct application of methodology and meth
201. lumn are atoms of the ED BAXSIM module of the ED Airport Suite The referred atoms in the second column exist in the Logistics Suite of ED Atom Characteristics Remarks The BAX Atom Contains the atoms for modelling BHS Version 01 b A001 Not intended to drag into a model AtomAttributes 187 Appendices Characteristics Remarks A002 Similar to product atom Double click on the Baggage atom results Baggage extended with extra attributes in error message see Incontrol ED bug already fixed A003 Similar to source atom Baggage Generator extended with bag dimensions and color percentage OOG internal arrival table of baggage nr of bags with attributes per time interval excel database data link A003 Baggage Generator FS Similar to Baggage Generator but instead of arrival table of baggage an arrival patterns table of passengers nr of passengers per time interval relative to STD and a flight schedule table Incontrol ED Baggage can be generated according to a flight schedule FS and passenger arrival patterns Incontrol ED Provides a link with Excel or a database to read data from either baggage data or flight schedule data See also example model A005 Similar to source atom Baggage Source A006 Composition of conveyors Added value in case several carousels with Carousel curved conveyors s
202. me department name person s name function name telephonenr amp e mailaddress FlyHappy Airport Operations Manager Operations Flight FlyHap com Figure 6 2 The stakeholders identification input table Requirements worksheet The requirements worksheet guides the involved Vanderlande Industries employees in documenting the total set of requirements and constraints that apply to the concerning project Similar to the introduced template for requirements documentation the worksheet is divided in five parts introduction general functionality and technology requirements constraints specific BHS requirements and procedural requirements In figure 6 3 an example is shown of a documented functionality requirement Each requirement has attributes such as author initials and priorities to link the requirements with the stakeholders of the previous worksheet and to prioritise them The initials of the author and ID code of the requirement help tracing the requirement through the project The prioritisation of the requirements before spending resources on them offers greater flexibility in tradeoffs design and implementation Hooks Farry 2001 In the example engineer BB has record a requirement assigned to MF MF has stated that this requirement is mandatory in the BHS concept The priority of Vanderlande Industries regarding this requirement is high result of the team based evaluations 79 Chapter 6 Supporting t
203. mouse monitor resolution 1024x786 minimum and keyboard Pentium II processor minimum necessary memory hard disc 50Mb and 32Mb RAM 1 9 2 Operating system Desired operation system to run the simulation language Possibilities Remarks Windows 95 NT Incontrol ED ED Version 4 0 requires Windows 98 ME or 2000 186 Appendices 1 9 3 Network version Possibility to use network licences Possibilities Remarks Yes 1 9 4 Required experience Assumed preliminary knowledge before starting to use the package Possibilities Remarks User interface is written in English Because of the graphical model building ED is mastered by beginning engineers easily 1 9 5 Financial Costs of the package hardware and learn time Possibilities Remarks ED 3 year contract periods 1 technology license 7 500 Euro per year 1 user license 2 500 Euro per year Includes maintenance and helpdesk 1 9 6 Security device Hardware dongle software number Possibilities Remarks Evaluation Version for free up to 20 atoms can be saved no connections with external programs The normal versions are protected by hardware keys and licence numbers 1 10 BAX Suite atoms For ED BAXSIM a tutorial atom reference and sample models are available Case studies and further information can be found on www EnterpriseDynamics com and www AirportSuite com The atoms mentioned in the first co
204. munication modelling and iterations Find real problem The first activity of the problem analysis was verification of the existence of the initial problem as stated by the Systems Group of Vanderlande Industries The confirmation was only qualitatively found while interviewing employees of different departments of Vanderlande Industries see appendix C Quantitative confirmation could not be found To find the real underlying problems the implications of introducing the desired situation at Vanderlande Industries were mapped Based on these implications an analysis of the descriptive models of the current situation and interviews with the different employees lead to redefinition of the problems For these problems the question Why is it a problem was answered to communicate and therefor verify the problems and to show the necessity of solving these problems Make prescriptive conceptual model The search for possible solutions was mainly based on information gathered when talking to the involved engineers literature studies exchanging thoughts with suppliers of supporting tools and discussions with employees of the Delft University of Technology First all information together formed the to be situation in mind Thoughts and ideas were communicated with stakeholders of the thesis project and their remarks were integrated this mental to be model Prescriptive conceptual models of the new to be 14 Chapter
205. n the times from all the check in blocks to all the carousels are required Wish possibility to export all leading times for further calculations not only a histogram is wanted also maximum minimum mean etc A028 Similar to accumulating Accumulating conveyor extended with Conveyor attributes necessary for the merge atom A029 Similar to curved accumulating Curved conveyor extended with Accumulating attributes necessary for the Conveyor merge atom A030 A non accumulating conveyor Shadow in 3d view is incorrect when Buffering Belt atom extended with a stop conveyor is rotated Conveyor function A031 Similar to sink atom Sink Sample Models D Double click on Baggage atom in Model Layout window results in error message 1 Atom A002 Baggage10 ID 175 onuser gt No atom currently selected setatt 1 ptv c atombyname A001 AtomAttributes library 2 Atom A002 Baggage10 ID 175 onuser gt No atom currently selected execonuser atombyname A001 AtomAttributes library Incontrol ED Bug is fixed 192 Appendices Appendix J Attributes of the cost calculator The following table contains the list of attributes of the cost calculator filename VI_LCC_Calculator atm VI_BAX atm in Enterprise Dynamics simulation software Besides the attribute to be used in combination with the file named number and name the initial values and a shor
206. n be collected on a TRIPLANAR as described above Other components are the lateral and the bin In case of a lateral the bags is put on a straight conveyor belt that accumulates the bags It is possible for the operators who work at the conveyor belt to activate the belt in both directions automatically to grab the bag and put them in the right container In case of a bin the bags are dropped and slide down to the end of the bin and stay there until the operator puts them into the concerning cart see figure 1 7 It is hard to put more than one cart around a bin so in principle no manual sorting will take place Figure 1 7 Several bins with a baggage cart in front of them Storage components According to Vanderlande Industries Bartelet et al 2000 early baggage can be defined as the bags that are introduced in the system for which the destination bin lateral or TRIPLANAR is not yet open As mentioned in sub section 1 2 3 these bags can be stored in an Early Baggage Storage EBS for a certain period of time In general one of the following 4 EBS alternatives is applied e Manual storage and retrieval e Automatic dynamic storage e Automatic storage in lanes loose baggage totes or carts e Automatic storage and retrieval system with cranes In case of a manual storage and retrieval EBS the bags are taken out of and replaced in the main flow by operators They are stored in containers or racks The automatic dynamic EBS consists o
207. n be defined as a coherent set of activities guidelines and techniques that can structure guide and improve a complex design process Meel van 1993 Using a framework for the methodology made it possible to comprehend all the different parts of the solution and to attribute them to a logical setting The introduced distinction between the micro meso and macro perspective used for structuring the occurring problems chapter 4 is completed with another analytical framework to structure the solution the methodology and supporting ICT tools According to this framework shown in figure 4 1 a design methodology is characterised by a way of thinking controlling working and modelling and can be supported by automated tools Sol 2000b Gone Chapter 4 Problem analysis Way of thinking rr oF 4 Way of controlling a N Way of working Way of modeling framework dimension Support Figure 4 1 The framework a design methodology and its support Meel van 1993 Way of thinking The way of thinking describes the underlying philosophy of the methodology It can be seen as the filters through which the reality is observed and interpreted Way of working The way of working consists of the tasks of the methodology that have to be performed such tasks can also be referred to as steps of activities Way of controlling The way of controllin
208. n by expert opinion the experts in this thesis were Vanderlande Industries engineers from Pricing Maintenance Simulation and Concepting 89 Chapter 6 Supporting tools The estimated results considering the cost elements that are distinguished in the cost breakdown structure can be divided in three groups of estimation accuracy The first group of costs are the capital expenditures capex costs of a completely installed BHS including high level controls These costs can be estimated in adequately accuracy by using estimation methods A B and C The second group the personnel cost depend on the country and environment in which the BHS will operate and will therefor be estimated for each situation separately For the third group the rest of the elements there is hardly any data available In consultation with the experts Vanderlande Industries engineers these cost elements are calculated as a percentage of the capex which can be modified in the input menu steps as mentioned earlier The cost calculator content can be adjusted or extended if new data is found The moment the engineer clicks the reset button the cost calculator takes several calculation steps appendix K contains a diagram that represents these steps In a loop function the calculator finds all BHS components objects present in the simulation model and adds their components based capex to the total capex amount Because of the relevance of the capex several elemen
209. n detailed description of the offered systems by describing the main applied system components such as sorter and transport type and the number of check in desks only The starting conditions of the BHS projects and the foundation of the choices made during the design were not documented So this confirms the existence of the first part of the problem The second part of the problem choices depending on the concerning engineer could not be verified because of the lack of documentation Interviewing employees of Vanderlande Industries revealed that they endorse that the design choices are founded subjectively and without documentation The employees explain the inadequate filled templates by the lack of objective of the documentation They do not want to document in order to document without further reason In conclusion also the second problem is recognised by the employees of Vanderlande Industries 4 2 Implications of the desired situation The objective based on the initial and recognised problems as stated in section 2 2 reads as follows Creating a situation at Vanderlande Industries in which engineers design Baggage Handling System solutions based on clear justification of design choices which are well tuned to the total set of requirements and wishes of all stakeholders The implications of such a situation are described regarding three aspects the total set of requirements and wishes the design choices and the good
210. n predefined steps and templates it is aimed on dealing with subjectivity and multiple perceptions of reality The templates integrated in the justification tool form a bridge between the tangible content site and the intangible process site of the BHS sales phase By guiding the documentation of the stakeholder and requirement analysis in relation to the concept characteristics a well structured evaluation tool comes into being It offers not only the opportunity to evaluate and justify the concepts themselves but also the information the concepts are based on The requirements as stated in a call for tender for instance can be approached in different ways In Eastern Europe the supplier of the BHS determines the way the requirements 99 Chapter 7 Evaluation of methodology and tools have to be interpreted The customer only tests the concept against international standards e g the noise level standards In Western Europe the customer determines the way the requirements are interpreted The standards are only guidelines and in most cases expensive so interpretation of the requirements in a creative way can save money If all involved Vanderlande Industries employees are aware if these interpretation differences achieved by completing and sharing the tool content in a team based effort the chance of offering the right system to the right customer gets bigger The only wish regarding the current content of the tool w
211. n the calculation is verification time for the time input data If no simulation model is required a calculation also implies dragging all concept objects into the model with the right physical dimensions no connections or logic needs to be entered For a mid range airport system this will take approximately 1 5 hour which is satisfying Logical transparant Partly By menu options the structure of the LCC elements that are taken structure into considerations is clarified To find out how the calculation of the Capital Expenditures is performed it is necessary to read the 4Dscript of the calculator including the hint text or to read the explaining appendices K and L of this report Extendable Yes By adding 4Dscript the menus and calculations can be extended Security of confidential Yes The way the calculations object prices calculation steps are information made are not shown in the results no content of the tool is shown Information must be kept Yes The results must support team based evaluation of concepts and up to date the information they are based on This also implies an evaluation of the tool itself A documented maintenance procedure must secure that extensions changes are integrated in the tool Documenting the results Yes Itis possible to copy and paste the model layout of the calculator must be easy in the justification tool including input data Besides it is possible to copy and paste the total cost graph
212. nction The last three functions can be carried out by the belts Transport components The transportation of the bags between the different areas of a BHS is supported by transport equipment Vanderlande Industries developed the following transport equipment for baggage handling see figure 1 3 e Conveyors with loose baggage e TUBTRAX tubs which can be placed on conveyors e BAGTRAX carts tubs with wheels that can be placed on rails high speed transport e COMBITRAX which is the same as BAGTRAX but the tub can be separated from the carrier Chapter 1 Introduction b TUBTRAX Loose Baggage a d COMBITRAX c BAGTRAX Figuic 1 5 LUC UALSPULL CQUIpiltcit UL V dLUCLIALUT iudustries Sorting components In order one baggage flow into two or more flows sorting components are added to a BHS Three examples of important sorting components are the TRIPLANAR the HELIXORTER and the VERTISORTER Sorting by a TRIPLANAR is a way of manual sorting A TRIPLANAR is a round carousel conveyor from which the operators can pick baggage with a certain destination label see figure 1 4 Figure 1 4 A TRIPLANAR for manual sorting Chapter 1 Introduction A HELIXORTER exists of a loop with extended trays see figure 1 5 A baggage item can be dropped off at a certain point by tilting the concerning tray It can handle a lot of destinations and depending on the configurati
213. nctions available number of distributions seed values for conditions and random generators Possibilities Remarks ED includes an input analyser that can read from a ED table or an Excel sheet It calculates the best distribution fit including the parameters All common distributions are available in ED by 4Dscript The seed value for the 100 random generators can be set in the main menu 1 4 4 Coding aspects Possibility to enlarge the flexibility by adding user code to the simulation model 177 Appendices Possibilities Remarks The 4Dscript overview can be chosen from the main menu in order to support writing 4Dscript code Every behaviour decision rule etc can be modified by extending the Wish same edit possibilities existing 4Dscript or define new routines When default 4DScript is changed of text in the 4Dscript e g set the send to percentage 75 to channel 4 the default value must window as Microsoft Word be selected first in order to be able to remove or change it not required to select first Every atom owns event handlers like on entry and on reset that can be modified in the parameter menu 1 4 5 Queueing policies Available queueing methods like FIFO LIFO minimum value and maximum value Possibilities Remarks Besides some included sorting controls such as FIFO LIFO sorting by label and random the sorting control can also
214. nd previous projects While doing so the engineer often talks with colleagues to exchange knowledge If the mental system model implies a certain technology that Vanderlande Industries does not manufacture and must be integrated in the BHS potential sub contractors are approached for possibilities and prices Normally the customer finishes the call for tender see section 3 2 a couple of weeks after the start of the sales phase at Vanderlande Industries The moment the call for tender arrives at Vanderlande Industries the requirements as stated in the call for tender together with the other collected information form the system related requirements and peripheral information Once the engineer has an overview of the available information he she has a conversation with the customer in order to elicit lacking information Then with all information in mind the actual design starts Based on the required functionality of the BHS the engineer draws possible Process Flow Diagrams being the connections between and the sequence of the different functionalities Then after adding the peak material flows to the PFD s the engineer chooses the technology that should be used for each distinguished functionality These choices start with the check in and break technology because often the customer requires certain technologies for these areas After that often in iterative steps the technologies are chosen for the reclaim build up EBS and HBS functi
215. nd going through the minutes of meetings and intermediary products the performed activities can be compared with the activities as described in the process models If the real activities differ from the suggested activities the reason s for this deviation must be found Were process descriptions clear Were all elements of the way of controlling effective Do all employees recognise the benefits of the new approach Was the time available in the pilot project sufficient for all activities Etc e Did the involved employees use the introduced tools in the correct manner By interviewing the involved employees and taking a closer look at the products results of the usage of the tools correct use can be assessed If the tools were not used in the way as described in this report the reasons for this deviation must be found Was the training sufficient Did the tool enforce a correct use Did the time necessary to use the tool exceed the available time Was the user interface adequately Etc e Did the new methodology result in clear justified BHS concept choices A possibility to find the answer to this question is to compare a BHS concept including accompanying documentation as designed in the current situation with the designed concept of the pilot project An employee who was not involved in the design of one of the two concepts should judge the clearness and completeness of the justification of the design choices that were made Does the conce
216. ne for one The hierarchy doesn t apply on the parameters Reading the labels of atoms by using the tools menu and the option view Wish possibility to double atom labels or by a right mouse click in the modeltree If more atoms are click on a baggage or in another atom they can not be distinguished product atom in the 2D view Reading the attributes by using the atom editor no distinction possible in order to see the labels and between the baggage atoms e g attributes Incontrol ED It is now possible to double click on a baggage atom in order to see the attributes The simulation can be stopped and continued during the run see explanation of Run Control Window in section I 5 6 Speed Control 183 Appendices 1 7 4 Step function Running the model event by event lets the user observe the changes in each state Possibilities Remarks Step function is integrated in the Run Control Window see section 1 5 6 Speed Control 1 7 5 Backwards clock Running the model backward would help debug the errors which occurred during the model normal run and which the program did not detect or could not stop at the time Possibilities Remarks Not possible in ED 1 7 6 Breakpoints Possibility to stop the model at any given moment piece of code or condition Possibilities Remarks By adding 4Dscript the simulation can be stopped at a certain time not included as
217. ng models at a high and middle level of abstraction When a very detailed model is required the possibilities of using 4Dscript are infinite but that takes a lot of time 1 6 2 Icons Libraries with standard icons to be used possibility to read CAD drawings bitmaps and OLE objects Possibilities Remarks Enterprise Dynamics supports jpg wmf and bmp formats for 2D Future wish not only visual images These images can be used as background or visualise any object in link but also a functionality the simulation model link between e g AutoCad and ED objects Imported icons for atoms do not scale when zooming in or out Wish use same scale rate for icons as atom it self VRML objects can be imported and connected to atoms for a VR representation Other objects can also be imported and activated in run time e g Powerpoint slide shows sounds 1 6 3 Screen layout Includes issues such as graphical representation of the model on the screen and showing multiple views of the model Possibilities Remarks Creating a model in the 2D model layout window results in a schematic animation of the model When running the model the atoms and atom flows are animated in a simplified way e g the content of a queue is displayed as a bar graph if capacity lt 10 In the 3D window and virtual reality window a more realistic reproduction is automatically generated 180 Appendices
218. ntres were founded throughout Europe Since 1986 Vanderlande Industries also founded Customer Centres in Hong Kong South Africa and the U S A In 1988 the company s name became Vanderlande Industries In addition GamBit GmbH a German software company specialised in Warehouse Management Systems was integrated into the group in 1997 Organisational structure Figure A 3 shows the organisation chart of Vanderlande Industries The organisation can be divided into four branches The departments in the Operations branch work directly on projects while the Group Activities departments have a more supporting task within these projects The other two branches are the Customer Centres in a European and a non European branch Developing markets This master thesis project is executed on authority of the Systems Group emphasised with a bold border in figure A 3 which is part of the supporting department Group Activities The Systems Group provides technical and commercial support to Customer Centres and Operations in developing system solutions for customers The assistance takes place in both the pre contract phase and the execution phase on issues as design training simulation pricing and presenting ideas to customers The Systems Group consists of four sub departments e Systems Development e Simulation e Proposal Verification amp Pricing e Knowledge Management These sub departments are inter related and together they provide the follo
219. o exploit the benefits of LCC calculations The percentages of the capex as integrated in the current version of the calculator may be replaced by costs based on separate components just like the capex Cooperation with an airport to collect data and to find new correlations is advised Besides these new correlations could offer the opportunity to make dynamic cost calculations valuable An example of such a dynamic calculation based on the results of a simulation run is calculating failure costs by distinction of maintenance personnel cost and costs related to bags that do not fly with the passenger they belong to too late for the aircrafts departure Extension of the design choices justification tool During the final evaluation of the design choices justification tool an Area manager placed a remark regarding the financing of a BHS The tool only involves the costs that are related to the BHS not the way these costs are financed Vanderlande Industries is advised to start research on the relevance of this aspect and on how to implement this in the tool 119 Chapter 9 Conclusions and recommendations 120 References References Literature Alter S Information systems A management perspective Second edition Menlo Park The Benjamin Cummings Publishing Company 1996 Banks J et al Discrete event system simulation Second edition Upper Saddle River Prentice Hall Inc 1999 Bartelet G et al
220. ods e Maintain a capability to export to other software tools e Maintain an enter once use often approach in data collection e Ensure legitimacy of the tool the user must understand and appreciate the tool content application and handling In addition to these requirements the following wishes were made known during the interviews and came into being while the project progressed e Logical and transparent structure e Clear user interface easy to use also by inexperienced engineers e Extendable adjustment to dynamic environment must be possible 75 Chapter 6 Supporting tools e Ensure security of the data that can be of use to the competitor s e Ensure the tools to keep up to date Besides these requirements on the tools in general specific requirements apply to the different tools Each of the following sections starts with a sub section to describe these specific requirements 6 2 Design choices justification tool The design choices justification tool supports the following activities of the new design methodology e Stakeholders analysis e Requirements analysis e Team based evaluation e Documentation of BHS concepts including justification of the design choices First the specific requirements on this tool are described In sub section 6 2 2 the tool is described 6 2 1 Requirements on the design choices justification tool The tool is based on the templates and relations as shown in figure 5 4 Th
221. of BHS concepts Computer Aided Design The document hard copy or digital written on the authority of the customer s organisation which is sent to the potential BHS suppliers and contains the requirements on the BHS sometimes detailed to layout level and peripheral conditions which the suppliers have to meet in order to be in the race for the contract awarding Capital Expenditures the purchase price of a completely installed BHS Customer Centre The composition activity of BHS concepts Cost of Ownership Customer Relation Management Artificial persons in private or public law with the funds to pay for the BHS project and its end product Although a party becomes an actual customer the moment a delivery contract is signed the term customer in this report is used for both the potential and actual customer Early Baggage Storage Hold Baggage Screening Integrated computer aided manufacturing definition language Life Cycle Cost A schematic representation of a BHS containing the processes and their connections sequence Material Flow Diagram Process Flow Diagram Proposal Request Form Employee of a Customer Centre of Vanderlande Industries responsible for the composition of the tender document made for the customer including the actual BHS design Systems Engineering Standard Time of Departure Employee of the Systems Group Staff department of Vanderlande Industries among other things able to support a sales engineer in
222. of capex needed for spare parts including overhauls for one project over 16 years is source document 1 6320 03346 V HKo According to RvP this will be more for a average project estimation of over 20 years 204
223. of requirements and wishes Interviews with employees revealed that the employees who are involved in the design process of a BHS see section 3 1 often not exactly know who the real decision maker s is are in the customer s organisation Besides the arguments used by the decision makers to decide which supplier will be awarded with a contract are often unknown Several employees stressed that often the roles of other stakeholders in the decision process of the customer the process in which the customer decides which BHS supplier will be awarded with the contract were crucial to the decision that was made and that Vanderlande Industries payed too little attention to these external influences The activity actor diagram of the current situation figure 3 5 confirms a lack of attention for the customer s organisation and its environment The customer is not involved in the actual BHS design process at Vanderlande Industries After some question time regarding the call for tender document the customer is not contacted anymore until the designed BHS is completed and presented Taking a closer look at the IDEF 0 models appendix D1 of the current situation reveals the lack of the following aspects regarding stakeholders and requirements identification including questioning the priority e A structured approach e A structured documentation e Inter disciplinary communication of results e Multi disciplinary evaluation of results
224. oftware rental Incontrol ED organises hotel seminars for interested people I 4 Model and input 1 4 1 Model building This section discusses issues related to creating and manipulating models Some of the issues considered are graphical model development coding creation of reusable components libraries errors and suggestions during creation Remarks Possibilities No undo redo function Wish an undo redo function is a must for building models without frustration Not possible to open two or more models separately at the same time in order to compare or copy several model parts directly Wish possibility to open more than one model at the same time ee ES o Appendices Possibilities Remarks Incontrol ED It is possible to open a second model in an open model in a container or by merging two models The atoms automatically connect when created The auto connect function built in standard behaviour of all atoms is in most cases unwanted sequence of building a model almost never equals the sequence of the routing Incontrol ED It can easily be switched off Reading the names of the attributes of the atoms in the atom editor table is limited to 10 characters Wish an adjustable column width in the attribute table to the wideness of the name of the attribute Incontrol ED Is already implemented in ED 4 Building a model means d
225. om an user point of view The cost calculator in conclusion is tested against the requirements as defined in chapter 6 A separate verification is performed and the validation exists of a replicative validation and an expert validation A test case of a BHS is performed to evaluate the calculator quantitatively in the replicative validation In the expert validation employees are confronted with the tool and their judgement is recorded 7 2 Evaluation of the design methodology The evaluation results are grouped by the four ways of the methodology framework see table 6 1 Sub section 7 2 5 recapitulates the findings of this section 7 2 1 Evaluation of the way of thinking All interviewed employees recognised the urgency to spend more time on the decision process of the customer It became clear that the factors such as personal preferences and relationships between different parties were of overriding importance in the decision making process of the customer about who should be awarded with the order All employees agree on the statement that the new methodology will strengthen the professional appearance of Vanderlande Industries and that the chances to get awarded with a contract increase by broadening the knowledge with process aspects and therefor base the offered BHS design on a more complete set of requirements Regarding the coordination between different disciplines of the elicitation and evaluation of information the formation of desi
226. ommunicate striking news if those conditions occur Stakeholders analysis To get a grip on the decision process of the customer Vanderlande Industries must be acquainted with all stakeholders attendant The stakeholders analysis starts long before the actual decision to quote is made and a team is formed It can take years between the moment a first trigger is received that a certain potential customer will need a BHS and the moment BHS suppliers are contacted In this period the Salesman if applicable in cooperation with a local Agent must map and document the different players that could be of relevance in the future decision process of the customer Main player of course is the customer s organisation itself Things to consider are the organisation structure names of important persons the balance of power rights of ownership company missions etc Besides of all relevant stakeholders their characteristics objectives and means to reach their objectives should be analysed The structured information document can be used and shared at the team formation to inform all members 51 Chapter 5 A new design methodology During the total design process the analysis of stakeholders continues Changes or afterthoughts should be communicated with the responsible team member e g the Salesman to be added to the analysis Before a team meeting the analysis results can be send to all members to keep everyone at one line Requiremen
227. on Sales Reference Database Vanderlande Industries did not win all contracts for the projects the company made a quotation for So you can say that the fit between system and requirements as stated in the problem can be better But is that not always the case Is it not so that things can always go better Yes but interviewing employees of different departments see appendix C revealed a recognised air of superiority at Vanderlande Industries when cooperating with external organisations In former projects BHS layouts designed and proposed by the customer were put aside in the sales phase and Vanderlande Industries designed another better in the eyes of the engineers solution for the customer s problem Projects were also lost because the BHS was tuned to the requirements of the wrong non decision making people of the customer s organisation In conclusion the 29 Chapter 4 Problem analysis first problem as stated is recognised by the interviewed employees of Vanderlande Industries The second initial problem as stated by the Systems Group reads as follows The foundation of the choices made during the design of a Baggage Handling System is often unclear and depend too much on the engineer who is involved To verify this problem the documentation of former projects was examined VI_Projects Sales Reference Database It appeared that these templates were only filled partly and that they contained a no
228. on criteria used by the International Council on Systems Engineering INCOSE 2000 being the possibility to e Identifying prioritising and hierarchically grouping the requirements 76 Chapter 6 Supporting tools e Keeping up the history of the changes of the requirements e Seeking certain sets of requirements bi directional from the requirements towards the systems concept and v v e Supporting group wise usage security base lining e Viewing the relations between requirements and system concepts in both text and graphical way e Visualising the differences between two versions of requirement sets e Generating of reports e Performing a validation by checking whether all requirements are consistently related to the concept e Proving the concept is compliant with the requirements 6 2 2 Description design choices justification tool This subsection describes the BHS design choices justification tool by highlighting the basic layout function and content For more details is referred to appendix E which contains the total layout of the tool As mentioned before the justification tool depends on three templates e The stakeholders template model used when analysing the stakeholders network e The requirements template model used when analysing the total set of requirements e The BHS concept template used when documenting the BHS concept Because of the relations between these three templates they are integrated in one
229. on is available yet Each item is 78 Chapter 6 Supporting tools provided with hint text see example figure 6 2 to support the filling of the template for more details is referred to appendix E 3 Stakeholders Not only those stakeholders that are intentionally selected and activated and thus more closely involved in the design process but also the indirect involved stakeholders who can play an important role such as blocking or promoting a solution Think of Airport authorities Airport employees levels management operations maintenance contracting finance etc Airport operators Main contractors Consultants Airlines Architects Project managers external Handling agent independent party with core business baggage handling e g OGDEN Competitors Agents working for VI or other stakeholders Partners mostly Controls Sub contractors Security stakeholder Shop owners Government different levels EU National District Local Passengers Media Commercial organisations with influence for instance large customer of airport Agents VI colleagues management Salesmen Area managers Sales engineers Systems engineers Simulation engineers CAD engineers Controls engineers Contracting Mechanical engineers R amp D engineers VI project manager Purchasing Planning Pricing Customer Centres Etc ID Organisation name Department Person Function Telephone amp e mail initals initials na
230. on of the chutes exit points it has a high capacity Figure 1 5 A HELIXORTER for automated sorting Figure 1 6 shows a schematic picture of a VERTISORTER It has two positions up black conveyors and down red conveyors The blue conveyors are not part of the VERTISORTER The baggage item arrives on the blue conveyor on the left If it has to go to the upper conveyor on the right the VERTISORTER will be in the black position If it has to go to the lower conveyor on the right the VERTISORTER will be in the red position Notice that in this case the upper red conveyor is lifted so large baggage items can also go to the lower conveyor Figure 1 6 Schematic illustration of the VERTISORTER side view for automated sorting Merging components A merge component is a reversed way of sorting from two directions to one direction Most common is the side merge where a conveyor ends at the side of another conveyor or sorter in that case the merge is called a induct By using the VERTISORTER of figure 1 6 in the opposite direction it can also be used as a merge component In that case it is called a Vertimerge Build components At the build area or make up area the baggage is taken off the BHS and stacked in carts or containers for transport to the aircraft Therefor the bags are collected in a way the Roi Chapter 1 Introduction operators can easily grab them and put them into the cart The bags ca
231. onality Finally the transport and sort technology is chosen The combination of all mentioned technologies forms the BHS concept drawn in a Line Diagram and accompanied with a describing text In several stages the engineer discusses concepts with colleagues and during these discussions choices are made which configuration of BHS technologies will be offered to the customer The moment the concept is selected the engineer elaborates the Line Diagram and the technology description that will be integrated in the tender document 3 4 Information used in the BHS design process In this section the information used in the sales phase is discussed First data information and knowledge are distinguished according to the definition of Alter Alter 1996 Data Facts or images that may or may not be relevant or useful for a particular task Information Data whose form and content are appropriate for a particular use 26 Chapter 3 Current baggage handling system design process Knowledge Combination of instincts ideas rules and procedures that guide actions and decisions Data forms the base of information and knowledge is needed to extract the right information from the data and to use information effectively Data used in the sales phase Besides general sources such as the newspaper the engineers also use data obtained from more Vanderlande Industries specific activities such as searching on the Internet for project relevant info
232. ons 108 Chapter 7 Evaluation of methodology and tools However each user of the cost calculator must be aware of the way the calculation is made before using the results calculation rules are included in appendix L in order to recognise and integrate deviating situations in the calculation 7 5 4 Expert validation While evaluating the cost calculator with Vanderlande Industries employees it became clear that in this stage the calculator is a powerful tool regarding capex calculations In contrary to a calculation in a spreadsheet the calculation is based on a layout including physical dimensions This is much more convenient and especially when the simulation model is already built faster For now the calculations of the other life cycle cost LCC elements can only be used in a guiding way to make the engineers familiar with different LCC and to elicit and encourage discussions with colleagues about in order to elaborate the LCC knowledge All employees find the chosen diversion of the costs in the elements as shown in the cost breakdown structure in figure 5 5 offers enough detail to distinguish different concepts for now and the near future It offers a framework in which new knowledge can be stored 7 5 5 Conclusions The cost calculator enables the Sales and Systems engineers to easily via menus calculate a reliable estimation of the investment costs of a BHS The calculation can be performed very quickly and is based on a s
233. ons are added to the remarks and are written in italic 171 Appendices Chapter I 2 describes the concept ED is based on the atom Chapter I 3 up to I 9 deal with the criteria as introduced above The final chapter I 10 deals with the suggestions for improvement of the atoms of the BAX Suite specifically I 2 Enterprise Dynamics the atom concept The atom is the most important thing in Enterprise Dynamics ED The atom s main characteristics are e It has 4 dimensions location and speed in space x y z and dynamic behaviour in time e Everything is an atom the model the BAX Suite etc e Every atom can contain other atoms e It can inherit from other atoms e It can be created and destroyed e tcan be moved from one atom into another The atoms are hierarchically structured At the top of the tree is the main atom Normally the main atom will contain at least three atoms the application atom the library atom and the model atom The library atom generally contains a number of atoms with predefined functionalities to be used when building a model All atoms have the same structure with the following characteristics e Description and identification Name ID Color Icon Info Mother e Display settings defining the animation of the atom e Channels number of input and output channels e Behaviour defined behaviour at the event handlers e Attributes e Table each atom has its own data table e Spatial location
234. ools BB FT1 1 Walk through check in desks MF Mandatory High 16 5 2002 MF saw walk through including elevators check in on K ln Bonn Airport Po PoP Po _ S T S LI I Ds _ _LG_L_L__L ___ Figure 6 3 Check In functionality and technology requirements input table Concept worksheet The concept worksheet contains again similar with the template described in the way of modelling the concept layout the technology specification the cost effectiveness and possible references Each item is provided with an input table to specify the designed concept concerning that item including author initials and comments see upper table in figure 6 4 50 walk through check in desks combined with 25 Stainless steel covers Weighing belts included elevators type X1200 from subcontractor TD PO Figure 6 4 Check in technology specification and justification table In the left white column of the lower table figure 6 4 the engineer can fill in the ID codes of the requirements and constraints that apply to this BHS item The tool than automatically displays the corresponding requirement constraint description the compliance level the Vanderlande Industries priority the initials of the source of the requirement or constraint and the name of the corresponding organisation and person These are obtained from the Stakeholder and Requirements worksheets There are some default requirement and constraint codes entered in the tables because the
235. options A modular concept offer is compliant to the requirements but also includes defined omissions or extensions regarding technology and or functionality together with a cost benefit analysis BHS concept elaboration When the choice based on team discussion is made which concept strategy to offer the engineers start fine tuning the concept s and writing the final documentation The Controls engineers will start designing the control system and the Calculation engineer will make detailed selling price calculations based on the CAD drawing of the concept made by the CAD engineer The Simulation engineer will build a detailed model of the concept in order to proof the customer that the claimed performances can be met Tender presentation Based on the outcomes of the different engineering activities there is a latest opportunity to adjust certain parts of the system concept before the results are gathered in the tender document and if permitted presented to the customer The moment the customer decides who can be the supplier the build phase starts not included in figure 5 3 In this phase the Vanderlande Industries project manager should elicit evaluate and document feedback from the customer and make sure that this information reaches the concerning engineers 5 2 5 The new BHS design process of the Sales and Systems engineer This subsection contains the textual description of the new design procedure of the Sales and Sys
236. or their time knowledge and or moral support they invested in me and my project To start with I would like to thank Ton van Wieringen and Edwin Valentin for being a member of the examination board During the entire project they have supplied me with annotations on intermediary products and guiding comments I also want to thank the other two members of the examination board Professor Sol and Marcel Ludema for the required critical notes on interim reports Furthermore I would like to thank all employees of Vanderlande Industries that were involved in my project in some way and especially my colleagues of the simulation department They were always available for help and they not only formed my oracle but also gave me an enjoyable time at Vanderlande Finally last but not least I thank family and friends and especially my girlfriend Susie for their continuous support during both good and rainy days Veghel June 2002 Tjipke Lemain Preface Vi Glossary BHS BHS concept BHS design CAD Call for tender CapEx CC Concepting Coo CRM Customer EBS HBS IDEF 0 LCC Line diagram MFD PFD PRF Sales engineer SE STD Systems engineer Tender document VI Glossary Baggage Handling System A description of a BHS consisting of documentation of the applied equipment types the system layout a line diagram and often a rough controls description The composition analysis and evaluation
237. orting tools as introduced in this thesis will solve the defined problems The methodology is based on the thought of a better mix between technical content aspects and social process aspects in the BHS sales phase at Vanderlande Industries Table 9 1 shows the main elements of the new methodology in relation to each other and the developed and or evaluated supporting tools 116 Chapter 9 Way of thinking Way of working Macro sae holder Stake holder Stake holder Cooperation of organisations Getting grip on the decision process of the customer Lobby Stakeholders analysis Requirements analysis Feedback elicitation Conclusions and recommendations Coordination of processes between VI departments Teamwork regarding evaluation and information processing Team formation Team based evaluation Primary tasks at workplace level Integral justification including documentation of design choices BHS design choices justification amp documentation BHS dynamic behaviour analysis BHS cost analysis Process manager _________ gt lt Commitment gt Way of Drop out prevention ___ gt controlling lt Suppo lt Responsibilities division amp documentation BHS concept description template lt Simulation model gt Cost breakdown structure Stakeholders analysis template BHS concept design
238. owest level of control It controls the equipment of the BHS in other words it starts and stops a conveyor sets a sorter in a certain position etc In order to do this the scanning and tracking equipment sends the ID information of the concerning bag and its speed and location BSM lt a flight schedule gt Baggage Destination System BDS 2 lt a chute allocation BTM A license destination plate y system Baggage Routing System BRS 4 configuration and i status license routing plate y Programmable Logic Control PLC equipment ID location speed control BHS equipment Figure 1 9 Three levels of control systems in a BHS For more detail on interfaces with the BHS controls e g by the Management Information System MIS is referred to appendix B 1 3 Report structure After this introduction chapter 2 starts with the description of the research approach Chapter 3 maps the current situation in the BHS design process Based on this as is description the problems are analysed in chapter 4 Chapter 5 deals with these problems by suggesting a new design methodology based on solutions as revealed during interviews and studying literature To support the employees of Vanderlande Industries in the new design methodology tools are introduced as described in chapter 6 The total package of methodology and supporting tools is evaluated in chapter 7 In chapter 8
239. oyees to gain support commitment and a social basis for the new situation It offers the breeding ground for continuous learning and implementation of improved process aspects 113 Chapter 8 Suggested implementation plan The following implementation activities have to be controlled by employees responsible for the implementation members of the Knowledge Management team e Introduce the way of thinking of the methodology in the organisation e Write procedures for the forming of design teams e Write procedures for the division of responsibilities tasks and authorities of the members of a design team minding the management of the balance between process and content e Create and maintain formal communication channels e Write procedures for decision making activities minding the evaluation moments e Register the new tools e Write procedures concerning the accessibility of the tools e Write procedures concerning the maintenance extension and security of the tools e Arrange the proper training for the involved employees regarding new activities and tools e Arrange frequent evaluation and feedback moments for the new process and tools 114 Chapter 9 Conclusions and recommendations 9 Conclusions and recommendations This chapter summarises the findings of this master thesis and includes some recommendations for further research resulting from this thesis The first section 9 1 starts with the conclusion
240. package in combination with the BAXSIM library offers the Sales and Systems engineer a useful tool to justify conceptual choices regarding configuration and technology It is detailed enough to give insight in system behaviours and answers questions concerning the system performances If very detailed models are required e g including acceleration and decelleration of the conveyors photocells to determine whether a bag is sorted out or not etc it is possible to program it in ED by experienced users but it might be wiser to build the model in AutoMod AutoMod is used by the simulation department of Vanderlande Industries and offers more detail through programming code The cost of the introduction of ED at the engineers workplaces will exist of software licenses possible hardware upgrades and training time Building simulation models requires time of the engineer The benefits of using ED by the Sales and System engineers can be diverted in Direct benefits of using the simulation tool e Optimisation of the BHS design improves the purchase price performance ratio and therefor the level of competence with competitors designs e Accurate and insightful system design eliminates unnecessary rework costs Indirect benefits of using the simulation tool e Accurate system depiction ensures valid decision making information e Improved system performance improves customer satisfaction e Increased understanding of the system behaviour e Integr
241. packed together and integral elaborated into a new design methodology supported by new tools The new design methodology is based on the thought of a better mix between technical aspects and social aspects to realise a better understanding of the real requirements on a BHS concept in the sales phase at Vanderlande Industries by 1 Getting grip on the decision process of the customer corresponding activities are lobby stakeholders and requirements analysis and feedback elicitation 2 Teamwork regarding information processing and evaluation corresponding activities are team formation and team based evaluation of information and designed BHS concepts 3 Integral justification of the design choices including documentation corresponding activities are quantified justification documentation and simulation and costs studies The main aspects that are advised to control the new design approach are the introduction of a process manager and the division and documentation of responsibilities during the design effort To support the employees in their activities three tools are introduced 1 The design choices justification tool developed a MS Excel document containing templates for the stakeholders network analysis the requirements analysis and the documentation of a BHS concept including justification of the design choices iii Summary 2 The simulation tool existing software of Enterprise Dynamics including the BAXSIM library
242. pendices 3 4 Redundancy Possible descriptions Description in words how to deal with scenario Results in performance per scenario Description in words graphs histogram etc 3 5 Maintainability Possible descriptions Maximum time to repair mean time to repair Spare parts usage Maintenance control system Training requirements Back up system International remote Description in words graphs histogram breakdown structure etc 3 6 Reliability Possible descriptions Mean time between failure Maximum time between failure Description in words graphs breakdown structure etc 3 7 Availability Possible descriptions Percentage of time the system will perform its function Description in words graphs breakdown structure etc 3 8 Flexibility Possible descriptions Modular BHS composition possibilities Extendability future flexibility Phaseability Down gradeability Description in words layouts etc 3 9 Controllability Possible descriptions Tracking and tracing Management information System status information Interface with existing other software Failure modes Routing and balancing Peak shaving Description in words layouts etc 3 10 Safety Possible descriptions Emergency stops Danger detection Fencing Fire protection not only in a technical way but also in a human way e g fire escape routes operators Risk Analysis results Description in words layout
243. phase So the engineers of Vanderlande Industries should work less system focused and more customer decision process focused Satisfying your customer s needs starts with knowing your customer his business processes and his environment Hazelrigg 1996 That way you are really capable of judging your BHS concept through the eyes of your customer and therefor realise a better fit of the offered concept with the wishes of the decision stakeholders You are also better capable of showing your customer or another relevant stakeholder that you care about his business and that you think along with them in order to find the best baggage handling solution in the eyes of the influential stakeholders Requirements definition The definition of requirements starts with studying the customer his business and the environment Otherwise the real requirements for the requested solution for a problem can never be determined In that case chances are big that the system development starts from the wrong point and ends in a system that does not meet the total set of requirements Several levels of risk are distinguished in such a situation Hooks Farry 2001 e Extra design time is required e Wrong controls or drawings are made e Wrong products are manufactured e Wrong products are delivered to customer In the situation of Vanderlande Industries there is a risk added to the top of this list being the possibility that the system offere
244. proach of the problems considering the primary concepting tasks of the Sales and Systems engineers only the micro perspective will not result in complete elimination of the problems The solution must be found by an approach that integrates the micro meso and macro perspectives The stated problems not only have a hard rational side the BHS equipment and configuration the tender document offered to the customer etc but also a soft intangible side customer personal preferences hidden assumptions double entry agendas the engineers job satisfaction etc As mentioned in section 3 1 a lot of stakeholders can be involved in a decision process of the customer All stakeholders have their own objectives and they are interdependent in different ways with a continuous changing level of certainty This multiformity setting in a dynamic environment such as the airport business Sulzmaier 2001 combined with the technical complexity of a BHS makes the Sales phase at Vanderlande Industries complex To find an appropriate solution to the problems several fields of knowledge have to be covered such as Customer Relation Management CRM because almost all information needed in the design process at Vanderlande Industries must be obtained from communication with the customer and his environment Systems Engineering SE defined as the effective application of scientific and engineering efforts to transform an operational need into
245. pt documentation of the pilot project offer a better insight in the foundation of the concept With other words does the documentation answer in a structured way the questions why certain choices are made Does the concept documentation offer the possibility to trace all assumptions in order to reuse parts of the work done in the pilot project for other BHS projects Etc e Is the designed concept in the pilot project well tuned to the total set of requirements and wishes Although it is not possible to examine the correctness and completeness of the set of requirements afterwards a lot of stakeholders are not to be contacted anymore it can be compared with the official reasons why a customer did or did not choose Vanderlande Industries to be the supplier at the end of the sales phase In some situations lobby activities after this decision of the customer could possibly reveal other non official reasons and requirements An evaluation team must be formed to determine whether the expected changes did occur Advised members of such a team are employees related to Knowledge Management with contacts at all different departments related to the BHS sales phase This evaluation team should eliminate the current uncertainties and communicate the intermediary evaluation results towards the potential users in order to create support for 112 Chapter 8 Suggested implementation plan and understanding of the new methods and tools In case the
246. r 1 that will be calculated for the training cost real range 0 1000 22 DocumentationPerc 1 Percentage of the capital expenditures that will be calculated for the documentation cost real range 0 1000 23 O amp MEquipmPerc 2 Percentage of the capital expenditures that will be calculated for the setup equipment cost real range 0 1000 24 InitialSparesPerc 3 Percentage of the capital expenditures that will be calculated for the initial spares cost real range 0 1000 25 SparePartsTotalPerc 0 Percentage of the capital expenditures that will be calculated for the spare parts during the total life cycle real range 0 1000 26 ConsumablesPerc 0 03 Percentage of the capital expenditures that will be calculated for the consumables oil filters etc cost per year real range 0 1000 27 NrOpManagers 1 Number of operation managers necessary at one time in the control room when the BHS is operational real range 0 100 28 OpManagerCost 100 Hour wage of a operation manager in euro real range 0 1000 29 NrOpEmployees 2 Number of operation employees necessary at one time when the BHS is operational real range 0 1000 30 OpEmployeeCost 60 Hour wage of a operation employee in euro real range 0 1000 31 NrBagHandlers 14 Number of baggage handlers necessary at one time when the BHS is operational real range 0 1000 32 BagHandlerCost 40 Hour wage of a bagga
247. r Diverter Parallel Pusher Plough Vertibelt Divide one baggage flow into two Cross belt Cross belt baggage flows Vertical sortation unit VERTISORTER Tray sorter Tilt tray sorter Divide one or more baggage flows Sort HELIXORTER into two or more baggage flows Carrousel TRIPLANAR sorter Shoe sorter POSISORTER Side merge Beltjunction 45 Vertical merge Vertimerge Consolidate two baggage flows Merge End merge End merge into one baggage flow Induction Induct Chute Chute Guide baggage by gravity Bin Bin Collect baggage Spur Spur Collect baggage Output Arrange baggage flow by gravity Lateral Lateral Collect baggage Arrange baggage flow Control system Controls Control the total BHS Controls Maintenance man First line maintenance Perform basic visual maintenance man activities Maintenance man Second line maintenance Perform specialised maintenance specialised man activities Employee Baggage handler Baggage handler Handle bags Operations manager Operation manager Manage the BHS operations Operations man Control room employee Control the BHS Table G 1 The components of a BHS and their functionality 166 Appendices Appendix H Object model of a BHS Object class Input attribute Name check in isle belt conveyor loading TRIPLANAR flat make up string Number of desks integer Maximum peak capacity bags hour integer Handling time sec time actions Introduce bag into system Object class Tr
248. r process that takes place at the moment the bags are put into containers in the build area Reconciliation is the linking of a bag loaded and the passenger boarded for a particular flight It is getting more and more usual that all departing baggage is to be reconciled with departing passengers The loading information of the baggage including the container can be recorded This way the airline checks whether the right bags travel with the right passengers and detects suspicious situations in case the passenger of a loaded bag does not show up In the different processes the BHS interacts with its environment Besides handling the bags the system communicates with several high level information systems and interacts with not only the passenger but also the scan screen and check in operators the 4 Chapter 1 Introduction maintenance and loading operators See appendix B for more details of the interaction between the BHS and its environment 1 2 4 BHS components In this subsection the common components that are applied in a BHS are briefly described divided in check in transport sorting merging build storage security screening and scanning and control components Check in components The check in components consist of a desk including the integrated conveyor belts The main functions carried out at the check in desk are data entering weighing labelling and inducting the baggage The desk operator carries out the first fu
249. r the user is sure when a model is saved and there are atoms in the model atom that are not present in the library 175 Appendices Possibilities Remarks atoms loaded in the library the concerning atoms lose all their behaviour and attributes If after that the model is opened with the necessary atoms in the library the concerning atoms are still completely empty Hierarchical tree structure of the model and library Additional atoms can be loaded into the library one for one Wish possible to select more atoms at once in order to load them into the library Incontrol ED Multiple atoms can be joined in one atom and then saved and loaded E g all the ED BAXSIM atoms can be loaded together Selection of more than one atom in the model layout view is only possible by using the Atom Manipulator atom Wish possibility to select e g by mouse in combination with Ctrl key more than one atom e g in order to move them Graphical oriented The routing through the model is given by connecting the atoms with channels which increases the building speed of small models When the model gets more complex zooming in is required in order to distinguish the different channels This is a limitation especially when the atoms that have to be connected are distant Keeping the overview of the model s atoms with the view channels option on is hard By using the Atom Manipulator atom
250. raft stand is not integrated because Vanderlande Industries does not supply equipment for this part of the baggage handling Terms used in these previous definitions are clarified in the two following subsections 1 2 2 Baggage flows In order to illustrate the possible baggage flows in a BHS figure 1 1 is included The baggage flow entering the system at landside area of the terminal building to which the public has access to at the check in desks is called the originating flow This flow is transported to the airside to the area build or make up where the baggage is stacked at containers or carts These containers are transported directly to the departing aircraft Chapter 1 Introduction reclaim Landside originating destinating Airside flow terminating flow transfer flow AO a ll i 1 DEPARTURE ARRIVAL Figure 1 1 Baggage flows in the BHS In the opposite direction the containers arriving by aircraft are transported to the terminal building and unloaded and sorted at the break area A part of the baggage flow goes to the reclaim area to be collected by the passengers This is called the destinating or terminating flow The other part of the baggage arriving at the break area goes to the build area to be stacked on containers again the transfer flow The mix of terminating and transfer flow depends on the type of the airport hub or final destination feeder 1 2 3 BHS processes Figure 1 2 illustrates the most
251. ragging and dropping atoms from the library into the model layout Because of the use of atoms building objects the modelling speed can be high Based on the enter once use often concept atoms and thus models can be reused Building a model is a combination of behaviour programming and menu options In these menus 4Dscript programming options are possible in the standard on entry and on exit menu fields It is possible to edit or create atoms by using the atom editor When double clicking on event handlers the software asks if you want to get the inherit code Answering yes overwrites the code given in by hand The code typed in an event handler field is also deleted if the tree is refreshed before the atom in the library is clicked When the behaviour of an atom is changed it has to be saved before closing ED otherwise the changes are not saved When a model is opened and saved without the necessary Wish if there is new code entered ask whether this can be deleted first Wish if there is new code entered ask whether this can be overwritten first Incontrol ED In version 3 5 it is also possible to activate the changes by clicking on the Apply button in the atom editor not just by clicking in the library Wish message when ED is closed and there are atoms in the library that have been changed Now the changes are not saved only when file Save atom as is used Wish ask whethe
252. ransport gt transport technology technology Combine amp N_A2 2 2 4 document functions to R system concept Determine sort technology alternatives technology N A2 2 2 6 VI product Nee ee MS Office data book J Justification tool VI systems books 145 Appendices New situation line diagrams gt and technology descriptions Level N_A2 2 4 Function Determine amp document dynamic behaviour viable line diagrams gt Determine required information N_A2 2 4 1 Simulation tool Model requirements N l Build simulation model N_A2 2 4 2 simulation model incorrect model A Validated and verified simulation model Validate and gt verify the model N_A2 2 4 3 A Determine Parameter value gt parameter value of scenarios y N_A2 2 4 4 Perform model Output gt runs _ N_A2 2 4 5 A Analyse output N_A2 2 4 6 Results ft a MS Office amp 146 Summerize results in justification tool N_A2 2 4 7 ni justification tool Appendices New situation simulation model results dynamic simulation Level N_A2 3 Function Analyse and evaluate justification tool itself and content remarks colleagues VI experience terminal characteristics customer characteristics terminal environment character
253. rds more standardisation by designing concepts containing less different component types which results in less spare part storage and less controls development 6 Understand the relationship between their decisions and the cost drivers of other departments getting acquainted with the processes at other employees who are also involved in the same BHS project The importance to Vanderlande Industries of LCC is also increasing considering the observed trend of total BHS packages These packages consist not only of the design manufacturing and installation of the BHS but also include maintenance and operation contracts In these cases Vanderlande Industries needs an overview of the expected LCC in order offer realistic contracts Supporting technology In agreement with the BE paradigm consideration of possible supporting information technology is integrated in the new design methodology see chapter 6 5 2 Way of working The way of working describes the activities that should be performed in the new methodology These activities are consistent with the way of thinking as described in the 50 Chapter 5 A new design methodology previous section Table 5 2 shows the activities in relation to the way of thinking In the first nine subsections those activities are described that are new or that need extra attention In subsection 5 2 4 the new overall design process is described which includes the discussed activities follo
254. re made concerning research on the cost aspects of a BHS e Research on life cycle costs data to elaborate the cost calculator e Research on extension of the design choices justification tool with financing aspects iv Preface Preface In front of you lies a true milestone This report not only constitutes the completion of my study of Systems Engineering Policy Analysis and Management at the Delft University of Technology but also the end of my life as a student Ready for the next phase This report contains the findings during my master thesis at Vanderlande Industries B V Although I have used company related terminology I have tried to keep the report accessible for interested people without any prior knowledge of baggage handling systems For those who want to get an idea of the performed research and the outcomes at a glance an executive summary is included at the beginning of the report Because I have aimed my research mainly on matters that could be improved in the current situation at Vanderlande this report might give the reader the idea that a lot of things are badly organised within the Vanderlande organisation Hereby I want to emphasise that there are also a lot of things going very well something what is underlined by the confidence in the Vanderlande by many regular customers While going through each phase of the course that led to this report I have been supported by several people I want to thank these people f
255. rent situation in the BHS concept design 24 Chapter 3 Current baggage handling system design process A sales phase at Vanderlande Industries starts at the moment Vanderlande Industries is contacted by the customer in some cases Vanderlande Industries contacts the potential customers on there own initiative The Salesman of the concerning Customer Centre starts gathering and supplying information from and to the customer in order to get an idea whether Vanderlande Industries could and should be the supplier for the requested system If Vanderlande Industries wants to tender put effort in offering a system for a certain price to the customer the Salesman starts gathering information about the required characteristics of the system The Salesman writes an internal document the Proposal Request Form PRF with the main system requirements and sends it to a Sales engineer of the concerning Customer Centre The PRF enables tracking and archiving the project activities under the same project number The Sales engineer starts gathering information and requirements too and starts configure BHS concepts In a meeting with the customer questions can be answered regarding the requirements as stated by the customer When the experience of a Sales engineer in the BHS field is not sufficient to handle a complex project a supporting Systems engineer of the Veghel office is requested to help configuring the BHS concept see figure 3 2 of section
256. rial for meetings and enables engineers to reuse or learn from earlier work The simulation tool is useful to support the justification of conceptual choices regarding configuration and technology It offers enough detail to get a better insight in the BHS behaviour and related performance Therefor it enables the engineers to optimise designed concepts which improves the competitiveness of the Vanderlande Industries solution By offering insight in an early stage of the design process rework in latter stages can be prevented Next to better founded decision making the dynamic depiction of the system offers a good communication tool to discuss BHS concepts To conclude the cost calculator enables the Sales and Systems engineers in easily and quickly calculate a reliable estimation of the investment costs based on a schematic layout The results are presented in numbers and graphs and can easily be exported and communicated The calculation tool supports the engineer in comparing different concept alternatives regarding the defined life cycle cost elements The elements other than the investment costs are mainly applied to elicit attention for and discussion about these aspects of costs The calculations are not detailed enough to use the absolute numbers 110 Chapter 8 Suggested implementation plan 8 Suggested implementation plan How to implement the new methodology and tools as introduced in the previous chapters in the current org
257. ring test and production facilities Subsidiaries can be found in France Spain Germany Great Britain Hong Kong South Africa and the U S A Besides these so called Customer Centres there are several agents located all over the world coordinated from the head office by the VI International Group Figure A 1 Integrated syste m approach of Vanderlande Industries Service Manufacturing The clients of Express Services 1 T Vanderlande Industries can be as found in the areas Warehousing and Distribution Baggage Handling Systems Express Services Industry and Baggage Handing Manufacturing Industry figure Distributi A 2 VI Public Library 2001 WW This report is about Baggage Handling Systems at airports Figure A 2 Percentage of new orders per business area 1997 2001 excluding UPS contract History In 1949 the Industry and Trading Company E van der Lande was established in Veghel The Netherlands At that time the company was aimed at weaving looms and other machinery for the textile industry Soon the emphasis was put on material handling systems and the name changed to Machinefabriek E van der Lande 125 Appendices A joint venture was established with Rapistan Inc in 1963 and the name became Rapistan Lande The company became the exclusive licensee of the Rapistan products for The Netherlands Belgium and Luxembourg Because of this partnership the company grew and the first Customer Ce
258. rmation such as terminal characteristics reading specialist literature and talking to other engineers It mainly concerns data like the market situation customer information competitor s products and potential subcontractor s products Information used in the sales phase The guiding information source for the Vanderlande Industries engineers is the call for tender obtained from the customer As mentioned before in the previous section the content of the call for tender documents vary brief extended performance equipment specification If the quantity of information is limited the engineers have a lot of degrees of freedom in the BHS design Sometimes the quantity of information is enormously and therefor becomes data to certain engineers In that case the required information must be filtered out The information that can be found in a call for tender often includes a problem description the required functionality the terms and conditions and drawings of terminal building and sometimes a possible solution Vanderlande Industries engineers can review previous sold projects in the internal Vanderlande Industries Sales Reference Database This database contains the main system characteristics which technology and with what throughput capacity and the selling price of earlier designed BHS They also have access to the Vanderlande Industries Product Data Book that contains the technical specifications of all possible Vanderlande Industrie
259. rport e Architects the architect s of the airport terminal building e Customs security enforcement Note that a competitor can be a sub contractor a partner or even a main contractor in another project Besides the external stakeholders there are several stakeholders to be distinguished within Vanderlande Industries who all contribute to the processes at Vanderlande Industries during the sales phase such as e Vanderlande Industries higher management 18 Chapter 3 Current baggage handling system design process Area manager managing several Sales men of a Customer Centre CC Sales engineering manager managing several Sales engineers of a CC Salesmen direct contact with the customers stationed in the CC Sales engineers developing concepts for customers of certain market area e g Germany or South Africa composing the total tender document including pricing and terms and conditions stationed in the CCs Systems engineers supporting the Sales Engineers in developing concepts stationed in Veghel Simulation engineers evaluating the dynamic behaviour of system concepts mainly stationed in the German CC and in the Veghel office CAD engineers drawing the BHS and terminals in AutoCAD Controls engineers developing the controls of the BHS R amp D engineers Mechanical engineers Calculation engineers checking and making calculations of the BHS prices Vanderlande Industries project manager managing th
260. rs to study on the choices and the information they are 64 Chapter 5 A new design methodology based on e g just before an evaluation meeting This way all team members are acquainted with the progress and can call the concerning engineer to account for incorrect or incomplete justification BHS dynamic behaviour analysis The dynamic behaviour analysis can be part of the justification of the design choices If such an analysis is required determined by the Sales or Systems engineer in consultation with a Simulation engineer or and by other team members to complete the justification template of the BHS concept the Sales or Systems engineer is responsible for all steps as mentioned in sub section 5 2 8 Cost analysis Similar to the dynamic behaviour analysis completeness and correctness can require integration of cost analysis results in the justification of a BHS concept So this is also the responsibility of the concerning Sales or Systems engineer checked by the team members during evaluation moments 5 4 Way of modelling The way of modelling describes the types of models substitutes for the complex reality and techniques that form the intermediary results of the BHS design effort Besides the existing modelling techniques of the current design process see section 3 2 new models are applied in the new activities and described in this section Table 5 4 shows the new models in relation with the way of thinking work
261. rtation A transfer flow Sorting S S m HBS M pali Merging Hold baggage screening Early baggage storage outbound flow inbound flow Figure 1 2 Basic processes and sequence in the BHS Following the inbound flow meaning the bags arriving by aircraft and brought into the terminal building the first process the bags undergo is sorting at the break area Here the transfer flows are separated from the terminating flows The terminating bags are sent to the reclaim carousels where the departing passengers pickup their bag The transfer flows are merged to one flow and then depending on the airport safety philosophy screened by X ray machines to detect explosives After screening the bags are sorted again In case there is a period of several hours between the two transfer flights of a bag it is taken out of the main flow and sent to the EBS Otherwise the bag goes directly to the build area and is sorted into the different containers Besides the processes as mentioned in the figure above there are other processes that can appear in the BHS of airports Scanning for instance is done at several places in the system depending on the size of the system and the level of automation in order to identify the bags going through the system This identification can among other things be used to link security screening results to bags or to track and route the bag through the system Reconciliation is anothe
262. s Section 9 2 contains the recommendations 9 1 Conclusions The conclusions of this master thesis comprehend the following Initial problem verification The existence of the initial problems as stated by the involved employees of the Systems Group could not be confirmed by a quantitative analysis because of the lack of relevant data Therefor the initial problems were verified by interviewing employees of different departments of Vanderlande Industries All interviewees recognised the initial problems Underlying problems Analysis of the current situation in the BHS sales phase based on implications of the stated objective revealed the following underlying problems 1 2 3 4 The employees of Vanderlande Industries who are involved in the sales phase of a BHS pay too little attention to the complex context of the decision process of the customer and therefor possibly not make the best of their chances to influence that decision The employees of different departments and Customer Centres of Vanderlande Industries who are involved in the sales phase of a BHS do not work as a team regarding e The elicitation interpretation and documentation of information regarding the total set of requirements on a BHS e Structured evaluation of design choices made in the BHS design process The Sales and Systems engineers of Vanderlande Industries do not adequately document their quantitative or qualitative foundation of the d
263. s So not only horizontal communication is required but also a good vertical communication within the Vanderlande Industries organisation in order to make the best out of the lobby activities E g if the higher management comes to certain conclusions based on informal communications these findings have to be feed back to the design team With respect to the legislation regarding public tender procedures some caution is recommended towards the communication with the customer If a public company within the European Union invites companies to tender they are obligated to write down the official criteria the choice of supplier will be based on and to send the answers on questions asked by a potential supplier to all competitor suppliers Therefor from the moment the customer releases the call for tender it could be necessary to arrange if possible a mix of official and unofficial meetings lobby Another point of attention is the area of tension between the time that must be invested in the stakeholder and requirement analysis and the time available in the sales phase The process does not offer guidelines for the percentage of the total sales phase time that should be spend on the analysis and therefor improving the quality of the systems fit to the environment This percentage will differ for each project depending on the complexity of the stakeholders field the environment and the offered system 95 Chapter 7 Evaluation of m
264. s etc 3 11 Ergonomics Possible descriptions Noise level Physical load Description in words graphs etc 3 12 Life cycle cost Possible descriptions Capital expenditures equipment and controls Organisations and Management set up expenditures training documentation Set up tools initials spares Operational expenditures management operating and handling team energy Maintenance expenditures maintenance team and spare parts usage Description in words LCC calculator graphs tables breakdown structure etc 4 References references to CAD drawings simulation models price calculations text documents call for tenders tender documents etc Document name Description Where to find 160 Appendices Concept history worksheet PP PS PTs INDUSTRIES This table is repeated for 5 concepts 161 Appendices 162 Appendices Appendix F Cost Breakdown Structure Total system cost Research and development Program management Investment Advanced R amp D Engineering design System engineering Electrical design Mechanical design Reliability Maintainability Human factors Producibility Logistic support analysis Manufacturing e Manufacturing engineering e Tools and test equipment e Fabrication e Assembly e Inspection and test e Q
265. s components and most components of subcontractors Finally they can consult the Airport Database that contains the main operational numbers of all airports in the world such as the number of passengers per year the number of terminals the number of check in desks etc Knowledge used in the sales phase Based on the Vanderlande Industries strategy the engineers apply their experience while taking actions and making decisions They are supported by the Vanderlande Industries Public Library that is accessible from all workplaces and contains procedure guidelines Besides they can find design procedures and best practises concerning technology in the Vanderlande Industries System Books composed by the Knowledge Management Team of the Systems group supported by other departments 2 a Chapter 3 Current baggage handling system design process 3 5 Technology used in the BHS design process This section describes briefly the most important technical tools that are currently used in the sales phase see also the IDEF 0 models of the current situation in appendix DI These applications are to be used on stand alone or network computers MS Office including Visio MS Word is the standard for reports MS Excel is used for static calculations of capacities MS Explorer is used to obtain information from the Internet MS Visio a graphical application is used to draw PFD s and Line Diagrams CAD Tools To proof the system will fit in the termina
266. sages that pop up when bugs are found in the entered logic support debugging Further validation and verification support is offered by the animation and the possibility to monitor the basic utilisation characteristics of all objects such as throughput average content maximum content and status percentages Output Concerning the content the standard output delivered by ED covers the data needs of the engineers except for one issue The travel times of bags in the model are represented as histogram data only number of bags per interval of time while in some cases the average and maximum travel time is required too Regarding the presentation of the output it is too much spread through the model For now the easiest way of grouping the results is by copy and paste the data from the ED tables into MS Excel User To work with ED only a couple of days are necessary to learn the basic features So the package is ideal for engineers with no or little simulation experience 7 4 2 Test against the requirements As described in section 6 3 1 the Sales and Systems engineers require insights in the performance of BHS concepts regarding maximum throughput utilisation measure of resources and travel times of bags To evaluate the simulation tool from this user point of view three simulation models were built of BHS in different levels of detail The objective was to answer questions the engineers often have and which play an important role in the design
267. se baggage cost 10 euro meter one bag takes 1 meter and conveyors with tubs cost 15 euro meter one tub takes 1 2 meter Each tub costs euro So the calculator uses attributes that indicate the number of bag positions in the EBS and whether it concerns an EBS with or without tubs 199 Appendices 200 Appendices Appendix M Adjustments of the BAX Suite objects In this appendix the objects in ED called atoms in the BAX Suite Version 01 b part of the Airport Suite see appendix G are described which had to be adjusted in order to use the cost calculator filename VI_LCC_Calculator atm in the Enterprise Dynamics simulation software The total set of atoms including the adjusted atoms are saved in the file VI LCC_BAX atm The adjusted atoms have new names to make distinction with their originals possible Original New Adjustments Reason for adjustment atomname atomname A006 VI Carousel 1 Added attribute Identification and Carousel LCC_Code component price calculation Tilted which depends on whether 2 On userevent added the carousel is tilted or not menu option Tilted or not A007 VI CheckIn 1 Added attribute Identification and Check in Isle LCC_Code component price calculation Block NrDesks which depends on the Collectorlength number of desks and the 2 On userevent added length of the collecting menu options Number of conv
268. sorting equipment etc So the developed calculator is based on the objects concept of Enterprise Dynamics and can be loaded in the ED objects library the left column in the screen dump of figure 6 5 The calculator is based on a base class empty object integrated in the ED software The attributes that were added are described in appendix J After or during the building of the simulation model of a certain BHS the engineer can drag the cost calculator into the model layout window The appearance of the cost calculator after dragging it into the window is shown in the screen dump in figure 6 7 In the blue left column the initial input parameters are displayed the right column displays the output fields _ 84 Chapter 6 W Taylor ED 2000 untithed Eo Model Smide Bonde Tool Qupiap Window Mei OSES ABSA AHA Dog Se Ha O ad 3 BEAT am 0425 REE FeG tinea aeGeen QC 2A OR Sew loj xj BUSS anch Supporting tools CHAS 1666 atomivi Lot Calcultori at 200041000 size 2000 2000 Figure 6 7 Result after dragging the LCC calculator atom in the model layout window After the cost calculator is placed in the model layout window the input parameters have to be entered By double clicking on the LCC icon between the columns a menu opens with the following options Capex Organisation amp Management set up Operation and Maintenance When clicking on one of these options a submenu appears in which the engin
269. stries fit the characteristics related to the development approach But to get the development started a combination of both approaches is suggested The developed design methodology including supporting tools forms the starting point from which the organisation can develop into the desired direction The one time change in process activities must lead to continuous improvement The new process plays a directive role in further development 8 2 Pilot project Because most of the process activities and the tools are not applied in a real sales phase situation yet the benefits as stated in this thesis are not ensured in practise Therefor before implementing the new process and tools they should be applied and evaluated in a pilot project Measurement of the actual results regarding the number of sold BHS projects is hard to perform because most improvements are qualitative and their impact is even in the future hard to measure due to complex influences of all kind of unpredictable factors Therefor feedback on the proposed changes of the employees is very important in order to judge whether the process of change is on the right course It is hard to 111 Chapter 8 Suggested implementation plan quantify this judgement but the answers to the following questions can lead in qualitative judgement e Did the involved employees work in conformity with the way of working as introduced in this report By interviewing the involved employees a
270. t description are given Nr Name Initial Description value 1 CapexTotal 0 Total purchase price in euro of the BHS components and the system controls integer 2 MaintenanceTotal 0 Total of maintenance expenditures including maintenance personnel spare parts and consumables during the life cycle in euro integer 3 O amp Mtotal 0 Total of organisation and management setup expenditures including documentation training O amp M equipment and initial spares in euro integer 4 OperationTotal 0 Total of operational expenditures including control room and handling personnel and energy in euro integer 5 LCCTotal 0 Total expenditures on system from the customers point of view during the life cycle in euro integer 6 EnergyValue 0 If true the energy expenditures will be included in the calculations if false they will be omitted boolean 7 CycleTime 15 Number of years the system will perform its function real range 0 30 8 CapexValue 1 If true the capital expenditures will be included in the calculations if false they will be omitted boolean 9 Documentation 1 If true the documentation expenditures will be included in the Value calculations if false they will be omitted boolean 10 InitialSpares Value 1 If true the expenditures on initial spares will be included in the calculations if false they will be omitted boolean 11
271. t tray sorter a carousel a security screening machine etc are grouped in a repository named the ED BAXSIM library In appendix I the possibilities of the simulation package ED are described in more detail The description of the objects integrated in the BAXSIM library can be found in section I 10 of the appendix I When a model layout is determined by dragging all required equipment into the model with the right physical dimensions the engineer can connect the equipment in the baggage flow sequence for details is referred to the Enterprise Dynamics User Manual Via menus the input parameters can be set without actual programming Figure 6 5 shows the screen layout of ED while running a simple model At the left side the library tree window in which the building blocks are listed In the model layout some simplified BHS equipment is shown check in conveyors and a carousel including their connections E Taylor ED 2000 G Tjipke TaylorED3_01 work rapportmodel mod a loj x File Model Simulate Results Tools Display Window Hep Dems ang RRR Bor s oo w o Pao tT PECTS E ZOMM ARES BUS S RO f RSS 8 Oh 2H Go 8 4H AB Peay xa Library Tree lo x Run Control xl view Tree M al uf Slide Control 14 STORAGE 1 75 2 fa 3 15 SYSTEM D 6 H 16 TOOLS ID 81 7 8 17 TRANSPORT 1 93 Mere Layout CER 6 18 VIRTUAL REALITY 10 10 SESAN E19 VISUALIZATION 1D 113 20 AUTOLOADED
272. tems engineers Besides this text there are IDEF 0 models included in appendix D2 for further explanation These models divide the activities in sub activities to zoom in for more detail These IDEF 0 models include some new supporting tools that are further explained in chapter 6 59 Chapter 5 A new design methodology Gather and document information The actual concepting activity starts with gathering information IDEF 0 level N_A2 1 The first information about relevant stakeholders and their requirements is obtained from the analysis results documented by the Sales man In conversations with the Sales man lacks of clarity can be filled and a mental model of the problem is formed Then in an iterative process the Sales engineer collects information from the Internet e g characteristics and missions of the airport the Vanderlande Industries Network potential sub contractors the call for tender document colleagues and of course the customer The way the voice of the customer input is obtained during the design effort must be defined and documented The engineers must complete the constraints and requirements with priority attributes and ID codes to trace them through the design effort In consultation with colleagues the analysis is evaluated When a satisfying level of completeness and correctness has been reached the results can be base lined and the development of potential BHS concepts starts Design possible BHS conc
273. tened or omitted General worksheet Man Den ianve OND U STORI ES Supporting the design of VI Baggage Handling Systems Project name CT Customers organisation name s ____ Project number SS in accordance with the VI guideline sales document numbering 8 2137 0139 G Author Date Reason for revision initials dd mm yyyy Document objective The objective of the tool is to support the VI employees in 1 Performing and documenting a stakeholders network analysis 2 Eliciting prioritising and documenting the total set of requirements on the future BHS 3 Objectively founding the designed BHS concepts by documenting each part of the concepts in relations to the requirements that apply to that specific part determine evaluate assigned to satisfies needs based on justify 149 Appendices Stakeholders worksheet Dan Den PTT A E Be BST Ras Stakeholder analysis the customer and his environment Document objective Enable all involved VI persons to consistently exchange knowledge about the customer s environment the customer s characteristics the project approach and project status in order to determine and communicate the best strategy to be followed Content 1 Initial problem description 2 Organisation chart customer 3 Stakeholders 4 Stakeholders characteristics 5 Stakeholders objectives and perspectives 6 Stakeholders means 7 Stakeholders interdependencies
274. the interdependencies between the stakeholders organisations or different layers within one organisation offers Vanderlande Industries the opportunity to influence the actions of stakeholders via other stakeholders e Strategic behaviour If Vanderlande Industries knows all real interests of the stakeholders it is possible to anticipate on strategic behaviour of the stakeholders It helps coping with aspects like dual agendas e Different perceptions When the Vanderlande Industries engineers are able to project themselves in the position of the stakeholders who are involved they can recognise the different ways of looking at a problem and its possible solutions e Closeness Every individual and every organisation communicates in a different way with the outside world Some are extrovert communicating and sharing information with their environment Others are introverted keeping all information as much as possible for themselves Understanding how the stakeholders communicate with external stakeholders but also within the organisation it self helps 44 Chapter 5 A new design methodology Vanderlande Industries to break through the closeness by approaching the stakeholders in the right way e Dynamics The world is changing each day Therefor the way certain stakeholders were approached in earlier projects might no longer be the right way for the same stakeholder in a new project An stakeholder analysis performed for each proje
275. the commitment to the design effort The following employees should join the team a Salesman a Sales or Systems engineer a CAD engineer a Simulation engineer a Controls engineer a Calculation engineer and a Project manager if applicable The first thing to do is the documentation of the responsibilities for the different tasks during the design process Besides the primary tasks such as drawing the system writing the tender document and building a simulation model managerial tasks have to be accomplished by the team members For example planning and preparation of meetings adjusting the contents and delivery times of intermediary products checking the design process progress information spreading etc Team based evaluation The moment the team is formed the actual team based evaluation starts with discussing the initial stakeholders and requirements analysis results Guided by checklists the completeness and the correctness of the analysis are discussed This evaluation must also reveal different interpretations of information in order to get all team members on one line The evaluation of the completeness and the correctness of the information on which the BHS concept designs are based must be repeated during the sales phase The number of evaluation moments depends on the dynamics of the environment such as new stakeholders entering the decision process new events happening etc The meetings are scheduled ahead e g every two w
276. time necessary for the Yes The documentation of the results of the stakeholder and sales phase should not increase requirements analysis takes time But most of this time can be spend in the period before the call for tender is published Besides the tool prevents that more than one employee spends time on gathering the same information and meetings are more efficient everybody is updated and the documentation structure guides the evaluations 98 Chapter 7 Evaluation of methodology and tools Requirement Com Tool characteristic pliant Identifying prioritising and Yes The tool offers the edit fields to document the requirements group hierarchically grouping all wise including priority and ID code the requirements Keeping up the history of Yes Old requirements remain in the tool The new requirements are the changes of the added including an ID code that is derived from the original code requirements Seeking certain sets of Yes The standard find feature of MS Excel can be used to trace ID requirements bi directional codes in the concept template to trace the consequences if a from the requirements requirement changes In the concept template the ID s of relevant towards the systems concept requirements are mentioned for that particular part of the concept and v v description to trace the consequences if a concept changes Viewing the relations Partly Only in textual way
277. tion between a BHS and its environment Appendix C Involved employees of Vanderlande Industries Appendix D1 IDEF 0 model of the current design functions Appendix D2 IDEF 0 model of the new design functions Appendix E The design choices justification tool layout Appendix F Cost Breakdown Structure Appendix G Components of a BHS and their functionality Appendix H Object model of a BHS Appendix I Enterprise Dynamics and the BAX Suite evaluation Appendix J Attributes of the cost calculator Appendix K Calculation steps of the cost calculator Appendix L Internal table of the cost calculator External reports contain a censored version of appendix L Appendix M Adjustments of the BAX Suite objects Appendix N Cost estimation guidelines External reports contain a censored version of appendix N 123 Appendices 124 Appendices Appendix A Vanderlande Industries the company In this appendix Vanderlande Industries VI will be introduced by describing the company s profile and giving a brief overview of the company s history After that the organisational structure will be explained Profile Vanderlande Industries is an international company that provides automated material handling systems The company designs and implements tailor made solutions and strives an integrated system approach see figure A 1 The company s head office is based in Veghel The Netherlands It incorporates design enginee
278. tomer to reject the proposed concept decreases Another advantage of discussing more than one concept of a BHS is that the engineer is able to determine the different requirements of the customer together with their relevance Note that there is a difference between involving your customer in the choices you have to make and asking your customer everything Otherwise the customer can start questioning the professionalism of Vanderlande Industries Feedback as instrument Another way of showing your customer you care about their business is arranging feedback moments during the different phases of a systems life e g development installation and usage This is also a good way of gathering and documenting the customers meaning which enables the Vanderlande Industries engineers to learn from the past and monitor changes in the customer expectations 43 Chapter 5 A new design methodology Coping with the complexity of the stakeholders network An important aspect of the analysis of complex environments as mentioned in the literature Enserink e a 1999 is the insight in the range of involved stakeholders including their interests and perceptions of the situation Based on that information the stakeholders network can be analysed regarding the interdependencies balances of power and relationship dynamics Such an exploration of the customer s environment is called a stakeholder analysis note that stakeholders can be individual people
279. tquest has to be purchased separately 1 8 4 Database Possibility to store and evaluate the data in a database 185 Appendices Possibilities Remarks The tables created automatically or defined with the Incontrol ED Database link via ODBC Writing Data recorder atom can be copied in e g Excel by the data to a database is very fast The Database Windows copy amp paste functions The Export table atom can be used to connect to a database view atom only writes tables in text txt files The Data the database and perform queries on it recorder atom makes it possible to write data into Excel or Word files during the run 1 8 5 Business graphics Graphs plotters histograms etc during the run and after the run Possibilities Remarks The monitor atom also includes an elementary graph that is updated during the run After the run several graphs can be produced with the option graphs in the results menu By using the graph option a histogram and other graph types can be made of several performance indicators such as the waiting times in a queue or on a conveyor 1 8 6 Statistical Calculations such as means variances half width t test etc Possibilities Remarks Only means of staying times integrated in reports 1 9 User 1 9 1 Hardware Desired hardware to run the simulation package Possibilities Remarks Workstation including
280. ts analysis Regarding the thought of integral design all requirements and wishes of the stakeholders have to be mapped and documented in a structured way to support all different team members in performing their activities The definition of a requirement used in this report is stated as follows INCOSE 1993 If it mandates that something must be accomplished transformed produced or provided it is a requirement The requirements analysis starts a long time before the first line of a BHS concept is set on paper by the Salesman in some cases supported by information from a local Agent At first the requirements will be rough such as requiring certain functionality or requiring certain tender procedures The further the process unfolds the more detailed the requirements can be After a team is formed and a Sales or Systems engineer starts working for a certain project the requirements documented by the Salesman form the basis From that moment on the engineer must expand and prioritise the requirements by gathering information guided by checklists see section 5 4 and 6 2 and considering the business process of the customer When the call for tender document is received from the potential customer the written requirements are added to the analysis results During the design process requirements can change expire or expand These changes can be detected by all team members and should be reported to the responsible person e g the S
281. ts are given as a percentage of the capex the calculation of these capex formed the centre of attention An internal table of the cost calculator is used as the base of the capex calculation Appendix L describes this table including the way the calculations are made Advantage of using one table in the cost calculator instead of storing the capex data in each BHS component separately is the easy finding and entry of the data if for instance for inflation correction several values have to be modified As mentioned the calculator finds all BHS components in a loop It must identify the component and in some cases obtain some additional attribute values in order to calculate the capex of the concerning component Therefor the components objects of the BAXSIM Suite are adjusted to make them suitable for the cost calculator Appendix M describes these adjustments per object The moment the capital expenditures are calculated the other cost elements can be estimated The labour costs are simply calculated by multiplying the number of operational hours with the hourly cost per employee The other elements are estimations based on a percentage of the total capital expenditures on the system During talking to engineers about the life cycle cost of a BHS some remarks and estimations were made concerning the percentages These estimations can be guiding but should be verified before applying in a certain situation These estimations are given in appendi
282. uality control Material inventory e Packing and shipping Operations and maintenance Operations e Operating personnel e Operator training Operational facilities e Support and handling equipment Equipment development and test Engineering models Test and evaluation Construction of e Manufacturing acilities e Test facilities Operational cilities e Maintenance acilities Engineering data Figure F 1 Cost Breakdown Structure Blanchard 1991 p322 Initial logistic support e Program management e Provisioning Inital spare repair parts Initial inventory management e Technical data preparation x Initial training and training equipment e Test and support equipment acquisition e First destination transportation Maintenance Maintenance personnel and support e Spare repair parts e Test and support equipment maintenance Transportation and handling Maintenance training Maintenance facilities e Technical data System equipment modification System phase out and disposal 163 Appendices 164 Appendices Appendix G Components of a BHS and their functionality 165 General name VI name Functionality Object class C
283. ultiple perceptions of what is good by filling predefined templates and evaluating the information Direct benefits of using the justification tool e Guidance of the analysis and documentation of the stakeholders network and requirements e Guidance of the documentation of the BHS concept design choices e Guidance of the foundation of the design decisions e Preparation tool for the team kickoff meeting everybody well informed e Guidance of the structured team evaluation of design choices and the information they are based on Indirect benefits of using the justification tool e Possibility for inexperienced engineers to learn from earlier projects e Possibility to reuse work in other projects because all conditions are known 100 Chapter 7 Evaluation of methodology and tools 7 4 Evaluation of the simulation tool In sub section 7 4 1 the simulation software evaluation framework of Nikoukaran is used to determine the suitability of the chosen simulation package for the support of the BHS concept design In sub section 7 4 2 the test against the requirements on the simulation tool is described which includes the making of three simulation models In the final sub section 7 4 3 the evaluation results are summarised 7 4 1 Test against evaluation criteria The criteria of the framework of Nikoukaran based on which the evaluation of the ED simulation package is executed are described in table 7 2 Nikoukaran et al 1999 Belo
284. ure legitimacy of the Yes Every involved Vanderlande Industries employee understands the tool the user must used terminology in the tool Comments considering content understand and appreciate handling and application are integrated in the development of the the tool content application tool participation during development and handling Logical and transparent Yes The general worksheet of the tool explains the relation between the structure three other worksheet templates Each template starts with a table of content and the template objective Clear user interface easy to Yes All involved employees often work with MS Excel so use also by inexperienced extending modifying of the templates is easy All edit fields are engineers recognisable by the colour white in contrary to the rest in the colour blue Extendable adjustment to Yes It is easy to add edit fields hint text or concept templates dynamic environment must be possible Ensure security of the data The justification tool is meant to be an internal tool only that can be of use to the Accessibility constraints and portability restrictions must prevent competitor s abuse of stored data The tool must be kept up to Yes Because the users of the tool have to tailor the tool to each specific date consistent and project new relevant aspects are added The maintenance maintained procedure makes sure these aspects are added to the centrally stored tool templates The
285. verage utility are shown A023 Similar to Check in block Transfer Unloading Quay A024 Container for the curves scan Wish A pull down menu in the Define Tray Sorter discharge and induction points Structure table in order to choose the atoms The Structure Table is the most important part of the atom present in the container instead of typing the names would be faster and prevents mistakes Wish automatically set of the type of the atoms in the structure table e g based on the 190 Appendices Characteristics Remarks When scrolling through model layout the trays including contents of the tray sorter disappear when the atom block of the sorter is of the screen Statistics about the occupancy rate of the inducts and discharges can be shown in a table by clicking on the concerning induct or discharge mother type of the atoms faster and prevents mistakes Wish Always display the atom contents also when the atom itself is out of sight The physical distances of the tray sorter components discharge induction scanning are not used to set the structure table so great differences between what you see and what really happens can occur Wish automatic filling of the structure table based on the physical distances in the model layout view Wish statistics about the occupancy rates of the discharge and induction points grouped in one view
286. w the table the summary of this evaluation is given For the complete overview of the evaluation is referred to appendix I This appendix also includes the description of the BHS objects that exist in the BAXSIM library section I 10 of appendix I Criteria Explanation Vendor Criteria related to the credibility of the vendor and to some extend his her software Model and input Issues related to a model its developments and data input Execution Issues related to experimentation Animation Issues related to creation running and quality of animation Testing and efficiency Issues for evaluation of testability debugging power and efficiency of a package Output Kinds of output and included analysis instruments User Needs and circumstances to be able to use the simulation language Table 7 2 The criteria for the simulation tool evaluation Vendor The vendor of ED Incontrol Simulation Software B V gained experience in modelling BHS in projects for Amsterdam Schiphol Airport They give training courses in how to use ED on several levels of experience Besides their helpdesk the thorough user manuals help the in experienced simulator in getting started easy Model and input Building a model in ED is a combination of configuration dragging objects in the model and connect them and parameter setting via menus This offers a quick way of building high level BHS models by inexperienced engine
287. wed by a more detailed description of the design activities of the Sales and Systems engineers Macro Meso Micro Cooperation of Coordination of processes Primary tasks at organisations between VI departments workplace level Getting grip on the Teamwork regarding Integral justification Way of decision process of the evaluation and information including documentation of thinking customer processing design choices Lobby BHS design choices justification Way of Stakeholders analysis Team formation amp documentation workin Requirements analysis Team based evaluation BHS dynamic behaviour analysis g cee i Feedback elicitation BHS cost analysis Table 5 2 The relation between the way of thinking and working 5 2 1 Way of working a macro perspective Summarising the way of thinking from the macro perspective the employees of Vanderlande Industries should get a better grip on the decision process of the customer The following activities should contribute to that objective Lobby To keep on communicating with the customer and his environment all possible relevant stakeholders the lobby must continue during the design process next to the official meetings and visits Obviously the lobby must be performed by the Agent the Salesman and or his Area manager The lobby activity should be included when documenting the team responsibilities But also other team members and the higher management could lobby and c
288. wijzen bij het ontwerpen van informatiesystemen In H G Sol TB311 Introductie reader 2000 Delft Faculteit Techniek Bestuur en Management opleiding Technische Bestuurskunde 2000b Sulzmaier S Consumer oriented business design The case of Airport management New York Physica Verlag Heidelberg 2001 Twist M J W van Edelenbos J Organisatieverandering ontwerpen en ontwikkelen In I S Mayer H G van der Voort 7B32 Management van verandering Fourth edition Delft Faculteit Techniek Bestuur en Management opleiding Technische Bestuurskunde 1999 1 33 Verbraeck A Ontwerpen van producten In H G Sol TB311 Introductie reader 2000 Delft Faculteit Techniek Bestuur en Management opleiding Technische Bestuurskunde 2000 Young R R Effective Requirements Practices New York Addison Wesley 2001 Electronic data The Internet Arsham H University of Baltimore Professor www ubmail ubalt edu harsham simulation sim htm INCOSE International Council on Systems Engineering www incose org Wiegers K E Doctor of Philosophy www processimpact com Other www airport information com www airport technology com www idef com The Vanderlande Industries network Public library Sales Reference Database Internal documentation of sold BHS projects of Vanderlande Industries 2000 122 Appendices Appendices Appendix A Vanderlande Industries the company Appendix B Interac
289. wing services to the organisation 1 Advice on technical conceptual issues go no go decisions pricing cost performance of systems or strategic matters 2 Concepting of large complex special high risk projects in the industry groups Baggage Handling Express Services In plant Handling and Assembly based on experience innovation and alternative solutions 3 Cost estimating and verification of system sub prices as well as development of price calculation tools and databases 4 Simulation studies and support 5 Education and training of concepting and pricing activities to Customer Centres through centralisation and actualisation of system knowledge and spreading this knowledge among Customer Centres 6 Analysing market demands within industry groups and providing product solutions for these demands together with R amp D 7 Knowledge Management specifically the facilitation of transfer of system related know how within the Sales phase between the Customer Centres 126 Board of Managing Directors Other Support General Support Operations VI NL Logistics Manufacturing Research amp Development 4 Controls Project Engineering H Mechanical Project Engineering Personnel amp Organisation Group Finance amp Control Secretary to the Board Group activities Systems Group Warehousing amp Distribution Group Contracting Quality amp Service International Figur
290. x N 6 5 Maintenance of supporting tools The tools as mentioned in the previous sections have to be stored at one central accessible place such as VI_Projects on the internal network to ensure the users to work with the latest versions The responsibility for the maintenance of the design choices justification tool completeness and correctness of the templates can be allocated at the 90 Chapter 6 Supporting tools Knowledge Management team part of the Systems Group This requires feedback on the usefulness of the templates in real practise and ongoing improvement Maintenance of the tools to support the simulation and cost analysis also is the responsibility of the Systems Group Knowledge Management Simulation and Proposal Verification amp Pricing Regarding the simulation tool and the user interface of the cost calculator two simulation engineers should integrated updates and gather feedback about the usefulness The content of the cost calculator should be guarded by a pricing engineer in consultation with a Knowledge Management team member 6 6 Summary During the development of the new design methodology development and or evaluation of supporting tools were integrated Three tools based on in participation stated requirements are introduced to support the employees of Vanderlande Industries in the BHS sales phase the design choices justification tool developed the simulation tool existing and the cost calculator
291. y of resources redundancy tests Besides the quantitative system performance the engineers also require insight in the system behaviour to identify bottlenecks The engineer must be able to compare different BHS concepts based on the performance output as mentioned above The concepts can differ in e Locations of the BHS processes processes described in section 1 2 e Connections and therefor the sequence between these BHS processes e Technology used for these BHS processes and connections technology described in section 1 2 In order to represent the BHSs in the right way it must be possible to simulate the BHS objects BHS components of appendix H 6 3 2 Description simulation tool The engineers of the Simulation Group of Vanderlande Industries had put their mind on a simulation software package next to AutoMod to enable the simulation engineers to quickly build simulation models with less detail than the AutoMod models Therefor a license for special purpose material handling discrete simulation software is purchased named Enterprise Dynamics ED Within this ED simulation environment a simulation 81 Chapter 6 Supporting tools model can be build by placing predefined building blocks objects in a layout To decrease the time necessary for simulating a BHS several building blocks specially tailored for baggage handling are added to the standard logistic objects integrated in ED These BHS building blocks e g a til
292. ystems characteristics with the requirements as stated by the stakeholders Figure 5 4 shows the relations between these elements 69 Chapter 5 A new design methodology evaluate determine assigned to satisfies needs Figure 5 4 Relations between the stakeholders the BHS concept and the requirements These relations are modelled in the earlier mentioned templates for the requirements analysis and the BHS concept documentation For each documented requirement the stakeholder who determined that requirement is included with the priority that stakeholder assigns to the requirements and the priority in the eyes of Vanderlande Industries 5 4 5 Simulation model The combination of different processes such as scanning screening transport storage and sorting see section 1 2 in a BHS that influence each other make the systems to complex to analyse the behaviour by analytical techniques only Therefor the dynamic behaviour analysis is supported by the making of a simulation model of the BHS concept Because of the characteristics of baggage handling bags entering the sub systems one after the other a discrete event simulation model is chosen Animation is used to visualise the operation and results of the simulation effort It offers insight in the BHS behaviour In order to represent the BHSs in the right way the engineers have to be enabled to simulate the BHS components as applied in the BHS solutions as d

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