| Written by Constance Stickler
What Role Does the Type of Port Development Play in Automation?
Before focusing on automation's benefits, it is essential to understand how port development affects the implementation process. Port development can generally be divided into two categories: greenfield developments and brownfield developments, both of which present unique opportunities and challenges.
Greenfield Developments
They provide a blank canvas for innovation as they are built from scratch on undeveloped land, offering a very high degree of flexibility in the choice of design and technology. In this scenario, automation is incorporated right into the basic planning stages without considering the needs and capabilities of what already exists.
One of the constraints to be considered when building new facilities is sustainability in all its forms. However, the significant advantage of greenfield port development is that it can be included from the beginning of the planning process, and many automation measures directly or indirectly benefit sustainability. For example, energy-efficient and low-emission processes avoid unnecessary electricity consumption and excessive greenhouse gas emissions right from the start.
However, the scope and cost of these projects are considerable, as everything has to be newly designed, created, or procured. Building a new port requires high investments, but the reward speaks for itself: a future-proof facility designed for maximum efficiency from day one.
Brownfield Developments
In these port developments, existing facilities are expanded and modernised during operation. Operators face a double challenge: maintaining container terminal operations as smoothly as possible while implementing automation modules. Meticulous planning, flexibility and continuous communication are therefore essential to minimise disruption.
In addition, it is a prerequisite to determine the current status of employees' technologies, equipment, and skills in order to develop appropriate measures for navigating legacy systems and outdated infrastructure and adapting the workforce.
Depending on the situation, a phased introduction of the solutions is recommended to provide enough time and buffer for the transformation. Crucial is the extensive testing of the individual modules to avoid problems on day zero when the switch is made from analogue to digital.
This modular approach offers quick wins that can be activated individually, such as the automation of gate operations. These offer the advantage of congestion prevention outside and inside the container terminal as soon as they run.
Whether a port is greenfield or brownfield, ((((container port automation)))) requires a strategic approach. Both require a robust IT infrastructure, clear planning, and the commitment of employees to be successful. Ultimately, the role of automation in port development is to address current challenges while creating the conditions for future growth. Whether redesigning or improving an existing facility, automation provides the tools to make ports smarter and more efficient and prepare them for the demands of a rapidly evolving industry.
Why Should Ports Care About Instant Gains from Automation?
Every year, billions of tonnes of cargo move from terminal to terminal across the world's oceans, and the number is increasing. Ports are facing unprecedented challenges: congestion hampers their operations, labour shortages slow their pace, and inefficiencies hurt their bottom line.
In addition, they have to work with limited resources: the workforce, equipment, and land available are limited and not easily expandable. Yet, sometimes, even that is out of the question.
So whatever is there must be used as efficiently as possible. How can this be ensured? Through targeted automation tailored to the terminal's circumstances and needs.
Implementing container port automation projects can take quite some time. However, phased implementation of different modules helps to address important and urgent challenges in the medium term, if not in the short term.
And here's the good news: Once in effective operation, the automated solutions deliver immediate, tangible results from day one. Let's take the traffic jam problem, for example. There are various approaches to solving this problem using automation: automated gate processes, optimised yard planning and routing, and job prioritising.
Depending on what exactly is causing traffic jams at a specific port, individual measures can significantly improve the situation, even before all planned solutions are in operation and working together.
One thing must be clear: Automation isn't about preparing for some time in the future; it's about solving today's problems. Without it, we can no longer do if we want to remain competitive despite adversities such as increasing demand, climatic events and geopolitical changes.
What Preparations Are Necessary to Benefit Instantly from Port Automation?
In order to be able to take advantage of the many benefits of automation from day one, ports must first lay the foundations for a seamless transition. The most relevant requirements and preconditions are:
Assessing the Current Infrastructure
Are the equipment and facilities compatible with modern automated systems? Outdated container handling equipment (CHE) or software may need to be updated or replaced to integrate with the new systems. A thorough review of physical and digital assets is the first step in identifying gaps and opportunities.
Building a Robust IT Framework
Automation thrives on data. To exploit its full potential, a reliable IT infrastructure is needed that is able to process large amounts of information in real-time. This includes, for example, high-speed networks, cloud-based platforms and secure systems for data storage and processing. If these are unavailable, they must be included in the requirements for the new solutions.
Training and Upskilling the Workforce
Automation takes over dangerous and repetitive tasks, but it requires skilled employees; hence, further training can lead to a change in the roles of the existing team. Practical training and a transparent roadmap ensure that the workforce recognises the benefits of the new way of working and is ready to work with automation rather than compete against it.
Ensuring Data Accuracy and Integration
Automated systems rely on accurate data and efficient processes to function optimally. If the current data entry is inconsistent or fragmented but is still required in parts, data cleansing, standardisation, and integration across all systems must be done before automation is introduced.
Digitising a nonsensical or inefficient analogue process achieves nothing - it remains nonsensical and inefficient. Therefore, all processes must be examined closely and possibly redesigned - based on future digital possibilities.
Prioritising Quick-Win Areas
As mentioned above, not all areas of the automation project have to start at the same time, by identifying the most pressing problems that threaten to hold up everything else or smaller sub-areas that can be implemented quickly, "quick wins" can be achieved that can, for example, free up the workforce for other tasks. Besides that, starting small and then scaling up can mean a smoother transition and a faster ROI.
Collaborating with Trusted Technology Partners
Choosing the right solution providers can make or break your automation efforts. Work with providers who understand the unique challenges of port operations and can customise solutions to your needs. Their expertise and ongoing support will be invaluable for troubleshooting and optimising your systems.
Planning for Change Management
Introducing automation is as much about managing change as it is about adopting new technology. Transparent communication with all stakeholders, from employees to customers and partners to local communities, builds trust and reduces resistance. Clearly outlining the benefits and addressing concerns honestly and promptly paves the way for a smoother transition.
If these requirements are met, an environment is created in which automation can be successful from day one. This means that the change is not a leap into partial uncertainty but a conscious strategic step for everyone.
What Problems Can Automation Solve From Day One?
Many of the improvements achieved through automation are effective from day one. By targeting specific pain points, workflows can be redesigned to deliver immediate value. Here are some of the problems automation can solve immediately after implementation:
Reducing Delays
One of the most impactful problems at ports is delays, which is why improvements to critical congestion factors become immediately visible. A case study of the "Automation of the Road Gate Operations Process at the Container Terminal" at DCT Gdansk SA says, "Even if peak hours do not occur, container terminal gates are the source of congestion due to in-gate processing delays. A typical in-gate process includes the manual verification of the truck driver and container and equipment inspection. These delays vary according to the transaction type and the degree of manual inspection experience at the terminal gate. A typical delay at a terminal entrance gate is four to five minutes." (1)
The same document states the possible gate processing times after the implementation of automation as:
"Self-service lanes: Minimum: 30 s, maximum 90 s, average 60 s
Security IN gates: Minimum: 20 s, maximum 60 s, average 40 s
Security OUT gates: Minimum: 15 s, maximum 35 s, average 25 s"
Let's assume that 2000 trucks arrive at our port every day and have to go through the gate. Using the conventional manual procedure (five minutes per truck), this would take around 167 hours in total. If we compare this to the self-service lanes, which have an average duration of 1 minute, this results in a saving of around 133 hours, which leaves a duration of around 34 hours. So, we can see that considerable time savings can be achieved here instantly.
Minimising Human Error
Human error is a significant source of inefficiency and costs in many operations. If we stick with our example above, errors can occur when entering container IDs or licence plates for trucks due to transposed numbers, forgotten characters or similar errors. There can also be misunderstandings between the gate operators and the truck drivers or procedural lapses, especially when fatigue or distractions come into play.
A game-changing support for our gate process is optical character recognition (OCR). This enables information such as container IDs, licence plates and other information, such as hazardous goods notices, to be automatically recognised, making manual entry obsolete. The accuracy is 98-99.5%, even when the trucks pass the gate at up to 50 km/h. (2)
Improving Workflow Consistency
Automation provides a level of consistency that manual processes often lack. Tasks are performed with predictable precision each time they occur, even if they are performed by several different units, for example. Updates only need to be implemented centrally once - they are performed immediately and simultaneously by all units in the future. This consistency increases overall productivity and reduces bottlenecks and delays.
Enhancing Equipment Utilisation
Equipment usage can be monitored in real-time, allowing underutilised equipment and vehicles to be identified and their use optimised. Resources can be used more efficiently and the terminal's operational capacity can be maximised without additional equipment.
Perfect Accuracy Through Yard Management Systems
These systems aim to track containers and optimise space. From day one, they use real-time data to optimise capacity and reduce bottlenecks. Equipment idle times are minimised, and terminal operators gain unprecedented transparency in monitoring movements and promptly resolving disruptions.
Using transponders and readers, incorrect container placement is avoided and rapid container collection is ensured. Automatic display and updates of tasks avoid communication misunderstandings that would otherwise lead to delays.
Integration of External Trucks
We'll stick with our example of gate operations, where it is possible to include trucks from outside the terminal in the internal processes and monitoring. Using permanently installed devices or transponders fitted during each visit, some of the advantages enjoyed and offered by internal trucks can also be passed on to external trucks. This ranges from automatic recognition to optimal routes to job promotion, which can significantly reduce waiting times on both sides and increase container throughput (see also: Container chassis operations)
So, there are plenty of automation solutions that prove their value from day one and help deliver ROI. These successes not only address the most pressing operational challenges but also create motivation for broader, long-term automation strategies.
FAQ
What Are Quick Wins, and How Can Automation Deliver Them?
Quick wins are smaller, more achievable improvements that have a significant impact without a huge investment of time or resources. These low-hanging fruits boost morale by bringing positive change and can provide momentum for larger, more ambitious projects that require more effort.
Across industries, quick wins can take many forms, including:
- Streamlining a cumbersome process to save time and reduce frustration.
- Improving communication channels to encourage better collaboration.
- Implementing simple cost-cutting measures that free up resources.
Automation measures are predestined to deliver quick wins because they take on tedious or high-volume work and provide consistency:
- Reducing repetitive tasks and freeing up employees for more strategic tasks.
- Improving data accuracy through automated reporting and analysis.
- Minimising errors and delays in workflows, resulting in faster turnaround times.
Improvements like these primarily increase efficiency, but they also build confidence in automation as a worthwhile investment.
Takeaway
Today's port development goes hand in hand with automation. It offers a robust answer to the diverse challenges facing modern terminals. Whether it is the flexibility of greenfield projects or the particular rapids of brownfield projects, automation meets both by enabling immediate and measurable successes. Prioritising quick wins - such as streamlined gate operations, optimised yard planning and consistent processes - leads to immediate efficiency and cost savings improvements.
The key to such improvements lies in preparation. The existing infrastructure, from container handling equipment to IT systems, must be assessed and integrated, replaced or expanded according to their validation.
It is not just about keeping up with the basic requirements. Rather, due to the medium—and long-term nature of the entire automation project's execution, it is necessary to look ahead to the needs of a rapidly evolving maritime industry and trends in global trade.
Delve deeper into one of our core topics: Port Automation
Glossary
External Trucks, also known as over-the-road trucks (OTR, USA), container lorries, or haulage trucks, are vehicles that transport containers to and from container terminals. In contrast to terminal trucks, they comply with road traffic regulations and are designed for long-distance travel. Their efficient management is crucial in avoiding congestion at the gates and in the container yard. (3)
Optical Character Recognition (OCR) is a technology that converts images of text into a machine-readable format. It uses a combination of hardware and software to scan physical objects and process the captured images. OCR systems analyse light and dark areas in the scanned image to identify characters, then use algorithms to recognise individual letters and words. OCR has applications in various fields, including document management, data entry automation, and accessibility for visually impaired individuals. (4)
Sources
(1) Automation of the Road Gate Operations Process at the Container Terminal—A Case Study of DCT Gdańsk SA https://www.mdpi.com/2071-1050/13/11/6291#B14-sustainability-13-06291
(2) Visy OCR Portal. Automatic recognition and imaging of vehicles and containers https://www.visy.fi/wp-content/uploads/2022/02/Visy-OCR-Portal.pdf
(3) A simulation-based optimisation approach for external trucks appointment scheduling in container terminals https://www.academia.edu/89477391/A_simulation_based_optimization_approach_for_external_trucks_appointment_scheduling_in_container_terminals
(4) Optical Character Recognition: An Illustrated Guide to the Frontier" by Stephen V. Rice, George Nagy, and Thomas A. Nartker (2019, 2nd Edition)
Illustration source: https://resources.experfy.com/bigdata-cloud/four-intelligent-automation-methodologies-one-objective/
Author
Conny Stickler, Marketing Manager Logistics
Constance Stickler holds a master's degree in political science, German language and history. She spent most of her professional career as a project and marketing manager in different industries. Her passion is usability, and she's captivated by the potential of today's digital tools. They seem to unlock endless possibilities, each one more intriguing than the last. Constance writes about automation, sustainability and safety in maritime logistics.
