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Managing Traffic in Warehouse

SATS Cargo Services


Kevinder Singh
Agenda/Contents
 Introduction to SATS Cargo
 Challenges & Analysis
 Current solutions
 Solutions under trial
 Risk Control
 Current solutions & Solutions under trial
 Vehicle Pedestrian Segregation
 Automation
 Safety devices and technology Target
partially
 Signage and line markings
achieved
 Other initiatives
 Safe work procedures
 Training
 PPE
 Q&A
Asia’s Largest Food and Gateway Services Network
45 Airports 12 Countries
638,000
Flights1 Jilin
Shenyang
Beijing
Tianjin
Tokyo (Narita & Haneda)
Medan
83 million Abu Dhabi
Taichung Taipei
Hong Kong
Macau Kaohsiung
Pekanbaru
Batam
Sesayap, Tarakan
Manado
India Muara Teweh Bontang
Manila Padang Palembang Balikpapan
Passengers1 Ho Chi Minh City Batu Kajang
Asam-Asam Timika
Halim
Male Penang Jakarta Semarang Makassar
Kuala Lumpur Bandung Surabaya
Singapore Solo Lombok
Yogyakarta Denpasar

84 million Amritsar
Indonesia

Delhi
Meals1 Rockhampton
Brisbane
Mumbai Kolkata
Hyderabad
4 million Goa
Mangalore
Bangalore
Chennai
Gateway Services
Tonnes of cargo1 Food Solutions
Trivandrum Gateway Services and Food Solutions

1 Based on FY15 aviation statistics for Singapore and overseas operations 6


Changi Airfreight Centre (CAC)

Free Trade Zone

AFTs 1 - 4 AFT 5 AFT 6

• SATS Coolport
SATS’ AFTs
SATS Airfreight Terminals (AFTs)
SATS Cargo
Transshipment Centre

Terminal 1 Terminal 2 Terminal 3 Terminal 4 Terminal 5 Terminal 6


SATS
Customer Airlines SQ/MI/TZ All Airlines Import
eCommerce Coolport &
AirHub Mail Handling Export Handling & Express Export Handling
(2016) Courier Centre
B C D E F G H I J K L M N

Under
Construction

61 Airline 6 Airfreight Capacity


Customers Terminals 2.1M tons

6
Our Key Facilities

Automated Material Handling


Systems
• 159 Truckdocks
• 3660 ULD storage positions
• 15 Elevating Transfer Vehicles (ETV)
• 14 Transfer Vehicles
• 44 workstations
• 5 bridge vehicles
• 6 bypass vehicles
• 5 stacker machines

Special Handling

• 2 Dangerous Goods (DG) Room


• 1 Strong Room
• 8 Vulnerable (VUN) Cages
• 1 Livestock Room
• 5 Coldrooms
Our Key Facilities

Manpower

• 1300 operations staff working on shift


in the terminals

Motorised Equipment/Vehicles

• 144 three ton forklifts


• 5 five ton forklifts
• 1 ten ton forklifts
• 65 tractors
• 24 vans
Analysis
Types of Accident Classification and Contributory Factors

Challenges:

 Process flow Top 3 contributory


 Habits and factors
behaviour  Target
‘Inattention’
 Time factor –  ‘Misjudgment’
partially
Rushing during  ‘Non-conformance
achieved
to SOP’
peak hours
 Congestion
Risk Control
Current Solutions and Solutions Under
Trial

 Automation
 Vehicle pedestrian
segregation
 Safety devices and
technology
 Traffic calming devices
 Signage/line marking
 Safe Work Procedures
 Training
 PPE

Risk controls selected to control hazards and reduce risks.


Control measures selected based on hazard identification and risk evaluation.
Vehicle – Pedestrian Segregation
Key factor in warehouse traffic management-
The most effective way to protect pedestrians is to eliminate traffic hazards. This can be
done by designing the layout of the workplace to eliminate interactions between
pedestrians and vehicles.

Where this is not possible, the risks must be minimised so far as is reasonably practicable.
This can be done by careful planning and controlling vehicle operations and pedestrian
movements at the workplace.
Vehicle – Pedestrian Segregation
A-safe barriers

Barriers installed in front of (Awaiting trial at AFT


the office doors which lead to 5) Barriers provide
the warehouse in order to resistance to vehicle
protect staff from forklift impact on barrier and
movement. offers better protection
for pedestrians along
designated walkways
Automation
ETV (Elevating Transfer Vehicles)

• Able to travel horizontally and vertically


• Can carry load of up to 6.8 tons
• Used to store ULDs and to drop and pick up at queue lanes

Fully automatic – eliminating


Manual and semi-automatic
the need for operators.
Safety Devices & Technology
Factors affecting traffic safety in the warehouse – Vehicles/Motorised Equipment
Enhancements for Motorised Equipment

Tractors are commonly used


for towing non-motorised
equipment
Safety Devices & Technology
Tractor

Operators are given personal


Sensors beside the driver’s seat ibuttons which store their
to detect the presence of training records through a
operators. Tractors will fleet management software
automatically cut off if neutral (iFleet).
gear is not engaged when Ibutton prevents authorised
operator disembarks without usage of tractors. Operator
switching off the engine. This needs to tap the ibutton to the
prevents accidental runaways. receiver on the tractor before
being able to start the engine.

Speed limiter limits


speed to <30km/h
Safety Devices & Technology
Tractor

Root cause analysis on runaway Tractor Tow hitch sensor to cut engine off
non-motorised equipment when tow pin is not fully inserted

 Tractor engine to cut off within 7 seconds


when tow hitch is not fully inserted
 Engine cut off only when in drive gear to
prevent engine cut-off when reversing to
connect tow pin
Proper Connection Improper Connection
 When the engine is cut-off, operator will not
be able to restart until pin is fully inserted
WSH Innovation Award for Logistic and Transport Sector – Gold Award
*Patent (10201407738P) was awarded for this innovation
Safety Devices & Technology
Forklift

Sensors installed below the operator Speed limited to <12km/h


seat
Audible alarm will sound when
operator leaves seat without
switching off the engine
Forklift will not be able to more or
be operated
Alarm will continue even when
operator returns to the seat
Forklift gear will need to be reset
to neutral gear while operator is Reverse backing alarm
seated volume increased to
warn pedestrians and
other vehicles
Safety Devices & Technology
Reverse Cameras, Sensors & Warning Lights

LED Lights mounted on reach truck


• Visibility improved to alert personnel of an
approaching reach truck
• Projects a blue spot light, effective for areas
Provides operators with real time with curtains
guidance and information in • Connection is direct to the ignition
ensuring safe reversing to prevent
contact with other vehicles and
pedestrians.
Safety Devices & Technology
ETV and vehicle crossings

ETV has to travel across the warehouse where there is an


intersection for motorised equipment to pass through.
Control measures:
 Boom barriers on both sides of the lane
 PIR sensors installed on the front and back of the ETV
 Proximity sensors linked to the ETV to automatically stop the
ETV and barriers to detect equipment that are passing
through midway A traffic light system is
 Visual and audible warning devices currently being installed
 Signage to enhance the traffic
 Demarcation – Stop Lines management at the
intersection.
Safety Devices & Technology
Convex Mirrors

Convex mirrors are placed at locations where there are


 blind spots
 Obscure intersections
 Complex crossings with plenty of forklift movement
 Cargo lifts
Traffic Calming Devices
Boom Barriers & Speed humps

Boom barriers and speed humps are used to bring traffic movement to
a momentary halt or reduce the speed of vehicles. For example, they
are placed at warehouse entrances/exits, pedestrian and vehicle
crossings, and intersections.
Signage & Line Markings

Clear road markings and signage used to alert vehicle operators on:
 Exclusion zones (No-go areas)
 Parking and no parking zones
 Speed limits
 Pedestrian crossings
 Vehicle crossings
 Blind corners
 Low height
 Other known hazards
Other initiatives
Fleet Management Software

Current Enhancements under consideration


 Location Monitoring  Total Engine Control
 Operational status monitoring  Remotely shutdown engine
 Engine status monitoring  Automatic engine shutdown
 Equipment map / map reports  Prevent users from using equipment that requires
maintenance
 KPI manager
 Tracking of Equipment
 Speed monitoring
 Vehicle health
 Condition monitoring
 Vehicle usage analysis, running time, idling, fuel
 Impact monitoring
consumption
 Driver inputs
Other initiatives
Software

Use of software to design layout for traffic management


• AutoCad
Safe Work Procedures

 Safe work procedures to indicate the


requirements for safe operation of vehicles
and equipment including ‘Do’s and Don’ts of
equipment operation’
 They also include staging of equipment in the
warehouse and PPE requirements
Training

Training is important to equip staff with the


required knowledge and skills to work in a safe
manner. Drivers and operators are trained with
the model of vehicles they will operate.

 Workforce Skills Qualifications (WSQ)


Operate Forklift Course for new hires and
refresher training every three years
 Tractor Driving Course for designated drivers
and refresher training
 Business Unit specific safety training
 Cargo Safety Awareness training for
new hires and refresher training
includes topics such as safety for
pedestrians in the warehouse and
equipment operation.
PPE
The mandatory personal protective
equipment for staff shall include company issued
1.Safety shoes
2.Reflective vests (Strap or full vest)
3.Gloves
*Gloves must be worn when carrying out any
manual handling
Safety shoes must be worn at all times when
carrying out work
Safety shoes and reflective vest must be worn
before entering and at all times in the
warehouse terminals
Reflective vests must be worn in the night
when working at the landside
*Note: This includes forklift and tractor
operators
Available Resources

For more information, please visit WSH Council website


Thank You