From Efficiency to Safety: A Simulation-Based Framework for Evaluating Empty-Container Terminal Layouts

Empty container depot (ECD) design significantly impacts maritime terminal efficiency, yet traditional evaluation approaches assess limited operational factors, constraining comprehensive performance optimization. This study develops an integrated discrete event simulation (DES) framework that simultaneously evaluates lifting equipment utilization, truck turnaround times, and potential collisions to support terminal decision-making. This study combines operational efficiency metrics with safety analytics for non-automated ECDs using Top Lifters and Reach Stackers. Additionally, a regression analysis examines efficiency metrics’ effect on safety risk. A case study at a Chilean multipurpose terminal reveals performance trade-offs between indicators under different operational scenarios, identifying substantial efficiency disparities between dry and refrigerated container operations. An analysis of four distinct collision zones with varying historical risk profiles showed the gate area had the highest potential collisions and a strong regression correlation with efficiency metrics. Similar models showed a poor fit in other conflict zones, evidencing the necessity for dedicated safety indicators complementing traditional measures. This integrated approach quantifies interdependencies between safety and efficiency metrics, helping terminal managers optimize layouts, expose traditional metric limitations, and reduce safety risks in space-constrained maritime terminals.