Optimization of Shipping Operations in Steel Yards via Digital Twin: A Yard Allocation Heuristic for Throughput Improvement

This paper presents a Digital Twin developed to optimize shipping operations in a steel logistics yard. The current operational policy relies on reactive allocation, leading to a high in cidence of unproductive reshuffling. To address this issue, an intelligent heuristic guided by a multivariable cost function is proposed to reduce yard disorder by grouping steel plates according to shipping route and chronological order.

The model incorporates strict operational constraints, including mechanical stability, stack height limits, 18-hour operational shifts, and a minimum vehicle loading threshold of 90% for dispatch authorization. Simulation results show that proactive inventory management reduces the overhead crane’s workload, identified as the system bottleneck.

The proposed approach achieved throughput improvements of up to 6.27% in dispatched tonnage, improving logistical throughput and operational efficiency without requiring additional capital expenditures (CapEx).