| Written by Constance Stickler
Balancing Man and Machine: The Next Step Towards More Safety in Ports
The history of container terminals has seen technological advances and efficiency improvements and a growing awareness and development of health, safety and environmental standards. From the dangerous, manually controlled operations of the mid-20th century to today's automated systems, the industry has continually adapted to reduce risks and protect its workforce and environment. With the further integration of terminal automation, balancing the roles of humans and machines will define the next chapter of HSE progress in ports.
In the early years of container shipping, working at the port was risky with minimal regulations. The focus was clearly on speed and operational efficiency, often at the expense of worker safety and environmental concerns. The hard physical work, supported only by basic tools such as simple cranes, frequently resulted in injuries, and even deaths were not uncommon. Interaction with heavy machinery was dangerous, the manual processes were unergonomic, and people often came into unprotected contact with toxic substances.
The environment was treated with equal negligence. Diesel-powered cranes and vehicles emitted tons of emissions, and waste management was rudimentary at best. Spills and accidents involving hazardous substances endangered workers and the local ecosystem alike.
With the advent of mechanisation in the 1980s, the industry began to address some of the most significant health and safety risks associated with manual labour. Cranes, forklifts and conveyor systems were introduced to increase efficiency but also reduce the physical strain on dock workers. This marked the beginning of an era in which technology began to play a critical role in protecting dock workers.
Formal HSE regulations and frameworks were also put in place. Governments and international organisations recognised the need for tighter oversight. The port was required to follow stricter safety protocols, conduct environmental impact assessments and develop risk reduction strategies. Employee training, personal protective equipment, and accident response plans significantly reduced injury rates.
Then, as global trade surged in the 2000s, ports faced the dual challenge of increasing their operations while maintaining higher HSE standards. Automation has become increasingly central to solutions to remove workers from hazardous environments and create safer workplaces.
In parallel, awareness of environmental protection also increased. Regulations on emissions from ships, port equipment and vehicles became stricter, forcing terminals to adopt more sustainable practices. The introduction of environmentally friendly technologies such as electric cranes and fuel-efficient vehicles was driven by both government regulations and a broader shift in the industry towards greater sustainability.
Last but not least, improved ergonomics is also an important argument for automation. Remote control of machines from indoors and ergonomically adjusted chairs and monitors help to avoid the effects of poor posture and constant machine vibration.
The Middle Ground: Where Humans and Machines Work in Tandem
The trend towards semi-automation is the next step in the evolution of HSE at container terminals and depots. It offers a middle ground between full automation and traditional human-operated systems. Here, machines perform repetitive or dangerous tasks while human workers continue to monitor operations and make complex, high-risk decisions. This hybrid approach is designed to increase efficiency and create safer, healthier and more environmentally friendly working environments.
The interaction between man and machine reduces the physical demands of the job and, thus, injuries caused by manual handling and heavy machinery. Workers can avoid the dangerous proximity of containers, cranes and other equipment, which significantly reduces the risk of accidents. Remote control and digital monitoring allow workers to carry out many tasks from the safety of a control room.
Significant improvements can also be made in terms of safety. Machines are simply better suited to completing repetitive tasks with consistent precision. This significantly reduces the scope for human error due to fatigue or distractions, for example. The semi-automatic systems can also quickly identify hazards such as equipment malfunctions or operational inefficiencies, thus achieving faster response times and reducing risks.
From an environmental perspective, energy consumption is optimised, emissions are reduced, and waste is minimised. Semi-automation reduces idle time and improves fuel efficiency, contributing to optimised resource management. This not only supports environmental regulations but also helps to save unnecessary costs.
Healthy Ports, Happy People: How Semi-Automation Keeps Workers Well
Semi-automation of container terminals has proven to be an essential factor in improving workers' overall health and well-being and reducing physical strain. Terminal workers can focus on monitoring, supervisory and decision-making functions.
One of the most immediate impacts of semi-automation is the reduction in heavy lifting and dangerous manual tasks. This has significantly reduced repetitive strain injuries, back problems and musculoskeletal disorders.
In addition, workers can now often stay away from the most dangerous environments. By monitoring and controlling equipment from a safe, enclosed control room, workers avoid exposure to noise, vibration and pollutants.
Mental wellbeing is also improved. Working at the port can be very stressful, with strict time constraints and disruptions to the planned schedule due to delayed vessels or cargo. Often, over long shifts, the team must maintain a high level of concentration. The pressure to maintain productivity can lead to fatigue and stress-related problems.
Of course, tiredness is not only a challenge for the mind. Long working hours also tire the body, a significant cause of accidents. Avoidable errors and injuries occur again and again, especially during peak times and at night. This risk can be reduced by handing over tiring, repetitive work to machines.
Ports are harsh working environments that place a lot of demands on people and equipment. In addition to gruelling conditions such as rough weather, salt air from the sea and dust, port work generates a lot of pollutants, including carbon monoxide, nitrogen oxide and particulate matter. By keeping people out of the hustle and bustle and taking other measures such as electrifying vehicles, respiratory and other health problems can be avoided.
Out of Harm's Way: Safety Boosts from Semi-Automated Terminals
Integrating advanced technology with human supervision significantly improves safety outcomes for dock workers and the environment.
One key safety benefit of semi-automation is the increased precision with which tasks are performed. Automation uses sensors, cameras, and artificial intelligence to monitor operations and movements, which are performed with a level of accuracy that human operators alone cannot achieve.
The systems can detect hazards such as equipment malfunctions up to insufficient tire pressure or unauthorised behaviour such as incorrect container placement in real-time and alert to potential risks before they lead to accidents.
Container terminals are usually busy, with various vehicles, container handling equipment (CHE) and even people having to navigate through tight spaces. Semi-automated traffic management systems have proven to be critical in optimising operations while ensuring safety.
Human error remains the main cause of accidents in port operations. Removing this source of error from the equation by automating high-risk and repetitive tasks reduces incidents significantly. In a semi-automated terminal, technology integration can also greatly improve emergency protocols. In critical situations, functions can be activated automatically and responses streamlined.
Another benefit of automation is simulations. They can significantly improve training programs and allow more realistic scenarios to be played out. This means that the correct actions and reactions can be practised repeatedly without taking risks associated with live operations.
Automation typically generates a flood of data, such as operational performance, vehicle telematics and safety incidents. This data can be analysed to identify trends, assess risks, and develop targeted initiatives to improve safety in ports.
Green Ports, Clean Future: How Semi-Automation Reduces Our Environmental Footprint
Green ports for a cleaner future are also a goal of automation. It is a crucial strategy for reducing the ecological footprint of port activities. In times when the consequences of climate change and environmental degradation have reached almost all of us, ports are also recognised as critical areas for sustainable development.
An essential task that automation is given is optimising energy consumption. Real-time data is used to improve the efficiency of machines and processes. Semi-automation ensures that adjustments can be made relatively flexibly should conditions change. Less idle time, energy-efficient equipment, and the port's own generation and renewable energy enable container terminals to significantly reduce their carbon emissions.
Efforts to electrify vehicles and equipment are moving in the same direction. Semi-automated terminals are increasingly using electric and hybrid machines to reduce pollutant emissions. Together with the shore power approach, which allows vessels to use electricity from the berth and switch off their diesel engines, this mitigates the impact on local air quality.
Improving logistics planning and traffic management also helps to reduce unnecessary emissions. It also reduces fuel consumption, a significant advantage over traditional processes in times of high prices.
When automation is introduced at the port, inefficiencies are often uncovered during planning that can be mitigated through structural measures, such as optimising traffic routes. So when terminals upgrade their facilities for this reason, they are more likely to adopt environmentally friendly building practices and materials, such as green roofs or energy-efficient lighting.
The data obtained through automation can also be used to assess ports' environmental performance regularly and identify areas where further improvements can be made.
Safe and Smart: The Economic Edge of Semi-Automation
Of course, semi-automation is not just about increased safety and environmental sustainability; the main driver definitely comes from the significant economic benefit. By streamlining operations, reducing human error and optimising resource use, cost efficiencies are created that directly impact profitability.
One of the most immediate economic improvements is operational efficiency. Automated systems perform repetitive tasks quickly and consistently, resulting in faster turnaround times and higher throughput. By processing more containers in less time, higher trade volumes become manageable and revenue potential increases. The speed and precision of these systems also reduce bottlenecks, minimising costly delays.
Partial automation does not eliminate the need for human workers, but it does change the areas of responsibility and skill requirements. When exhausting, dangerous tasks are handed over to the machines, the workforce can be redistributed to more strategic and value-adding roles.
Crane drivers, for example, no longer sit at dizzying heights but at desks with control levers and multiple monitors that offer them different perspectives of their work and the environment.
Partial automation does not eliminate the need for human labour, but it does change the areas of responsibility and skill requirements. When strenuous, dangerous tasks are handed over to the machines, the workforce can be redistributed to more strategic and value-adding roles.
Crane drivers, for example, no longer sit at dizzying heights but at desks with control levers and several monitors that offer them different perspectives of their work and the environment.
There are also changes in the gate process. Through optical character recognition (OCR) and tags permanently attached to the external trucks, the vehicle and load are automatically recognised without manual registration. OCR can also be used to carry out damage control on the container, which previously had to be carried out by a port employee.
The tags mentioned can also be flexibly mounted when passing the tag, allowing the non-port truck to be integrated into the port system. This means that efficiency optimisations are also available for external trucks, such as job promotion, which assigns a CHE the time-optimised task of the closest truck, regardless of whether it is internal or external.
Semi-automation usually means using predictive maintenance features that allow for better monitoring and maintenance of machines. Potential problems are identified before they lead to costly breakdowns and repairs. This also leads to a longer equipment lifespan and reduces capital expenditure on frequent replacements or major repairs.
With their precision and reliability, semi-automatic systems help minimise human error, which can lead to injuries and damage to containers or equipment. Fewer sources of accidents protect not only employees but also the company itself from lengthy investigations and repairs.
Full automation is often complex and challenging to adapt to. By maintaining human-machine interaction, operations can more easily scale to respond to fluctuating demand. This allows for faster adjustments without requiring significant changes to labour or infrastructure. This provides a competitive advantage in responding to market changes, seasonal peaks, or sudden surges in demand. It also makes handling a more comprehensive range of business opportunities easier, attracting more customers and increasing revenue growth.
While the initial investment in semi-automation can be significant, the long-term financial benefits outweigh these costs. Term terminals become more financially resilient by reducing labour and maintenance costs, minimising errors, and increasing operational efficiency. Over time, these savings add up, allowing ports to reinvest in further innovations, infrastructure improvements, or expansion projects, strengthening their competitive advantage in the global market.
FAQ
Can semi-automation help with safety in ports during emergencies, such as fires?
Yes, semi-automation can help in emergencies or natural disasters by enabling faster and more efficient responses. For example, real-time monitoring and detection capabilities can detect fire outbreaks and chemical leaks and immediately alert both human operators and automated systems to initiate emergency protocols.
Automated fire suppression systems are activated within seconds, and vehicles and CHE are diverted to prevent further damage. Based on data from thermal sensors and surveillance cameras with pattern recognition, people can be evacuated using the fastest and safest route possible.
Is semi-automation feasible for smaller ports, or is it only suited to large, high-traffic terminals?
Semi-automation is also feasible for smaller ports and is not limited to large, high-traffic terminals. While the initial investment can be significant, the long-term benefits outweigh the costs, and the ROI is often achieved quickly.
For smaller terminals, in particular, it is crucial to optimise the limited workforce and free up staff to focus on higher-value activities. Reducing human error is also an advantage in environments with low staff to correct these errors.
Automation for smaller ports is not necessarily less complex, but the advantage of scaled-down, modular solutions is that they can be tailored precisely to the specific needs. For example, automating container handling and gate operations often brings immense improvements without automating all other processes. The modular approach also enables tackling individual automation areas one at a time.
Takeaway
Semi-automation in ports offers a balanced approach that combines human expertise with machine precision and transforms health, safety and environmental (HSE) standards. By automating high-risk tasks, dock workers are protected from hazards and the risk of injury is reduced as heavy lifting and other heavy manual tasks are a thing of the past. This impacts both the physical and mental health of employees as certain stress components are eliminated.
In addition to personnel, the environment also benefits from moving to a semi-automated system. Optimisations on many levels help ports achieve their sustainability goals and a smaller environmental footprint.
Finally, there are also obvious economic benefits, such as reducing operating costs, increasing throughput, and overall productivity. Ports of all sizes can benefit from this modular and scalable technology, making it a viable solution for small terminals as well as large, high-traffic ports.
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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.
