Case Study
Freightliner Mendip schedule optimisation
Railwhere SEEsim supports Freightliner to overhaul and transform Mendip Quarry Timetable.
Overview
Freightliner, a leading UK rail freight operator, secured a landmark contract in 2018 for the Mendip rail services from Whatley and Merehead quarries in Somerset. This contract was considered the largest single freight contract in the UK at the time. However, Freightliner inherited a legacy rail timetable that had grown inefficient and complex as new services were added over time. To address operational inefficiencies, Freightliner sought to optimise operations from the ground up.
They used the Railfreight Energy and Emissions Calculator (REEC, now know as Railwhere SEEsim) developed in partnership with the University of Hull Logistics Institute to test and validate many alternatives, considering train consists, feasible running times, energy and emissions efficiency. This was a groundbreaking and award-winning project.
Business Challenge
Freightliner faced a range of challenges, including outdated running times, future regulatory requirements, and the need to modernise operations to handle growing demand. The scale of the challenge is exemplified by the fact that 6,000 loaded trains annually transport 8.5 million tonnes of stone from the Mendip quarries.
Key issues included:
Legacy Timetable:
The existing timetable had been added to over time, with new services added in rather than optimising existing schedules as per standard practice. This led to inefficiencies and complexity in operations.
Operational Complexity:
The Mendip Rail network, along with the maintenance at Whately and Merehead, required a significant overhaul to accommodate booming demand while improving efficiency.
Network Congestion:
The dense nature of the rail network, especially between the southwest and east country, posed further operational challenges and opportunities for improvements to support demand.
Solution
To tackle these issues to overhaul the Mendip Quarry operation from the ground up Freightliner reached out to us to provide them with the ability to model running times using different consists from single heading to double heading trains. This allowed Freightliner to explore different operational options and identify the most efficient strategies.
Development of the REEC (now Railwhere SEEsim):
We partnered with Aether, Carrickarory, and the University of Derby to create the Railfreight Energy and Emissions Calculator (REEC). The platform integrates key rail data, including:
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Track geometry and gaging constraints
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Locomotive and wagon performance data
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Network electrification and historic rail schedules
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Expected driver behaviour based on history OTMR data analysis
Railwhere SEEsim utilises physics modelling, specifically force-balance calculations and the Davis equation methodology, to model the energy required for trains to achieve specific speeds, considering factors such as acceleration, gradient, locomotive power settings and average driver behaviour. This builds on work carried out during several RSSB projects (including T1186 and T1187), along with extensive analysis of on-train telematics data, to ensure the values and methodology used are representative of real-world UK conditions
Railwhere SEEsim calculates the speed profiles, energy usage and emissions (CO2, NOx, and particulates) for a specific train consist travelling a specified route and schedule.
Simulating and Optimising Timetables:
Using Railwhere SEEsim, Freightliner was able to run simulations to identify the most efficient combinations of train length, weight, and locomotive configuration (single vs. double heading). This analysis helped Freightliner make significant changes to their timetable, including the introduction of double-headed trains, which offered the following benefits:
Increased Efficiency: Double-heading trains allowed for faster running times and reduced energy consumption by avoiding excessive stop-start running and allowing locomotives to operate more efficiently.
Emissions Reduction: By optimising the configuration of trains and reducing unnecessary fuel consumption, SEEsim helped Freightliner reduce CO2 and NOx emissions.
Operational Flexibility: The tool helped determine the optimal schedules, improving both fuel usage and emissions performance, while also giving Freightliner the flexibility to meet customer demand.
Results
The new timetable and operational processes, supported by SEEsim, resulted in significant improvements in operational performance:
Increased Punctuality
Right-time departures increased by 20% in the first week of the new schedule, with overall punctuality approaching 80%.
Reduced Delays
Delays decreased by 45% year-on-year, leading to more reliable services.
Improved Journey Times
The new timetable and optimised train configurations reduced journey times by up to one hour.
Increased Train Lengths
The introduction of longer trains, made possible by optimised scheduling and double-heading, increased network capacity and improved cost-effectiveness.
Emissions Reduction
SEEsim insights allowed Freightliner to reduce emissions through improved scheduling and better locomotive use.
Additional Benefits
What-If Scenarios: The SEEsim tool enabled Freightliner to simulate various "what-if" scenarios, supporting data-driven decision-making and future operational planning.
Reliability of Outputs: The accuracy of SEEsim's sectional running times was validated through real-world operations, providing Freightliner with confidence in the tool’s results
Conclusion
Using the tools developed by the University of Hull Logistics Institute and our partners, Freightliner successfully addressed significant operational challenges. The development and implementation of the Railwhere SEEsim enhanced operational efficiency, improved punctuality, and reduced delays, helping Freightliner achieve a transformational improvement on one of the largest freight contracts in the UK. The same team that helped Freightliner to achieve this is now part of the Railwhere team.
Collaborators:
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University of Hull (Logistics Institute)
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Aether Limited
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Carrickarory
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University of Derby
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Rail Safety and Standards Board (RSSB)
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Innovate UK
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Department of Transport (DfT)
Conclusion
"The Lampada REEC (Railwhere SEEsim) tool has allowed Freightliner to quickly and accurately analyse new and existing operations and routes. This has been a key enabler in allowing the company to test new routes and services, including the Mendip timetable recast and and new intermodal routes. REEC (Railwhere SEEsim) has also been an effective tool in allowing us to model and understand the environmental implications of different route and traction options to support our delivery of our Net Zero targets."
Paul Long
Head of Traction and Rolling Stock Engineering
Freightliner Group Ltd