Managing Traffic in WarehouseSATS Cargo ServicesKevinder Singh

� 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

� Signage and line markings

� Other initiatives

� Safe work procedures

� Training

� PPE

� Q & A

Agenda/Contents

Target

partially

achieved

Asia’s Largest Food and Gateway Services Network

1 Based on FY15 aviation statistics for Singapore and overseas operations

84 million

Meals1

83 millionPassengers1

4 millionTonnes of cargo1

45 Airports 12 Countries

6

638,000

Flights1

Indonesia

Singapore

ManilaHo Chi Minh City

Macau

Hong Kong

Taipei

BeijingTianjin

ShenyangJilin

Tokyo

Brisbane

Male

India

Gateway Services

Food Solutions

Gateway Services and Food Solutions

Rockhampton

Trivandrum

Mangalore

BangaloreChennai

Goa

Mumbai

Hyderabad

Delhi

Amritsar

Kolkata

(Narita & Haneda)

Kaohsiung

TaichungMedan

Pekanbaru

Padang Palembang

SemarangTimika

Manado

MakassarSurabaya

YogyakartaSolo

Halim

Batam

Lombok

Sesayap, Tarakan

BontangMuara Teweh BalikpapanBatu Kajang

Asam-Asam

Jakarta

Abu Dhabi

Denpasar

BandungKuala LumpurPenang

Changi Airfreight Centre (CAC)

• SATS Coolport

AFTs 1 - 4

SATS’ AFTs

AFT 6AFT 5

Free Trade Zone

6

Terminal 1

B C D

Terminal 3

G

Terminal 4 Terminal 6Terminal 2 Terminal 5

All Airlines Import

F NE

SATS

eCommerceAirHub(2016)

Coolport & Mail Handling

Customer Airlines Export Handling & Express

Courier Centre

SQ/MI/TZExport Handling

H I J K L M

SATS Cargo Transshipment Centre

61 Airline Customers

6 Airfreight Terminals

Capacity

2.1M tons

Under

Construction

SATS Airfreight Terminals (AFTs)

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

Our Key Facilities

Analysis

Types of Accident Classification and Contributory Factors

Target

partially

achieved

Top 3 contributory

factors

� ‘Inattention’

� ‘Misjudgment’

� ‘Non-conformance

to SOP’

� Process flow� Habits and

behaviour� Time factor –

Rushing during peak hours

� Congestion

Challenges:

Risk Control

Risk controls selected to control hazards and reduce risks.

Control measures selected based on hazard identification and risk evaluation.

� Automation

� Vehicle pedestrian

segregation

� Safety devices and

technology

� Traffic calming devices

� Signage/line marking

� Safe Work Procedures

� Training

� PPE

Current Solutions and Solutions Under

Trial

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 SegregationA-safe barriers

(Awaiting trial at AFT

5) Barriers provide

resistance to vehicle

impact on barrier and

offers better protection

for pedestrians along

designated walkways

Barriers installed in front of

the office doors which lead to

the warehouse in order to

protect staff from forklift

movement.

• 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

Automation

Manual and semi-automaticFully automatic – eliminating

the need for operators.

ETV (Elevating Transfer Vehicles)

Safety Devices & Technology

Enhancements for Motorised Equipment

Tractors are commonly used

for towing non-motorised

equipment

Factors affecting traffic safety in the warehouse – Vehicles/Motorised Equipment

Safety Devices & Technology

Tractor

Sensors beside the driver’s seat

to detect the presence of

operators. Tractors will

automatically cut off if neutral

gear is not engaged when

operator disembarks without

switching off the engine. This

prevents accidental runaways.

Operators are given personal

ibuttons which store their

training records through a

fleet management software

(iFleet).

Ibutton prevents authorised

usage of tractors. Operator

needs to tap the ibutton to the

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 non-motorised equipment

Proper Connection Improper Connection

� 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

� When the engine is cut-off, operator will not

be able to restart until pin is fully inserted

Tractor Tow hitch sensor to cut engine off

when tow pin is not fully inserted

WSH Innovation Award for Logistic and Transport Sector – Gold Award*Patent (10201407738P) was awarded for this innovation

Safety Devices & Technology

Forklift

Speed limited to <12km/h

Reverse backing alarm

volume increased to

warn pedestrians and

other vehicles

Sensors installed below the operator

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

seated

Safety Devices & Technology

Reverse Cameras, Sensors & Warning Lights

Provides operators with real time

guidance and information in

ensuring safe reversing to prevent

contact with other vehicles and

pedestrians.

LED Lights mounted on reach truck

• Visibility improved to alert personnel of an

approaching reach truck

• Projects a blue spot light, effective for areas

with curtains

• Connection is direct to the ignition

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

� Visual and audible warning devices

� Signage

� Demarcation – Stop Lines

A traffic light system is currently being installed to enhance the traffic 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.

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

Signage & Line Markings

Current

� Location Monitoring

� Operational status monitoring

� Engine status monitoring

� Equipment map / map reports

� KPI manager

� Speed monitoring

� Condition monitoring

� Impact monitoring

Other initiatives

Fleet Management Software

Enhancements under consideration

� Total Engine Control

� Remotely shutdown engine

� Automatic engine shutdown

� Prevent users from using equipment that requires maintenance

� Tracking of Equipment

� Vehicle health

� Vehicle usage analysis, running time, idling, fuel consumption

� Driver inputs

Use of software to design layout for traffic management

• AutoCad

Other initiatives

Software

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