Ports of Auckland is one of New Zealand’s largest container ports and primary port by import volume. At present POAL handles ten trains per day with the capacity of loading/ unloading 492 TEUS in a 24 hour period. To enhance operational efficiency at rail side, POAL decided to implement Camco’s Rail OCR Solution. The system is fully operational since November 2018, and allows for automated identification and inventory of containers and railcars.

DROPPING MANUAL DATA ENTRY WITH 95%

Ports of Auckland Rail planner Jackie Dickinson elaborates: “The Rail OCR system is very user friendly and effective. It has reduced manual data entry to the bare minimum (data entry dropped with 95%) and it eliminates human error. In our expe­rience, the system is very thorough when reading container numbers and ISO codes. Errors in pre-advised lists relating to container size or type are noticed and can be followed up on easily. For example, we’ve had containers pre-advised as 20’ when they were 40’, and containers pre-advised as GENL when they’re covered in hazardous placards.”

TRAIN GATE OPERATOR FOR DATA VALIDATION AND CONDITION CHECK

The system comes with a Train Gate Operator application, where operators perform post-processing tasks. This application allows operators to visually inspect the condition of each container and railcar, and verify, correct and validate the OCR processed data. When the collected information is complete and correct, the processed data is sent to the TOS for further processing.

The Ports of Auckland Train Gate Operator is a comprehensive application capturing all Rail OCR data including an exception handling tool and crisp pictures for condition recording.

Aera scans (above) and line-scans (below) providing sharp pictures for exception handling and condition recording

Located directly at the open sea, CSP Zeebrugge (+1M TEU) is very close to the main shipping routes in North Western Europe and can cater for the largest container vessels in the world. It is a coastal port with excellent hub capabilities to the UK, Ireland, Scandinavia and the Baltic region. Camco installed and supports CSP Zeebrugge Truck OCR portal, Gate and LSTP kiosks as well as the GOS system. With the migration to the new Navis N4 TOS, Camco upgraded and integrated the GOS into the TOS. In a later stage the existing VBS system was replaced by Camco’s new Vehicle Booking System.

UPGRADING EXISTING VBS SYSTEM

Since Camco had already implemented the automated gate system and GOS, Camco was asked for its upgrading. CSP Zee-brugge took more time to check other VBS providers before finally awarding this contract to Camco. Since the Camco team was working already on the GOS upgrade, the same team could speed up VBS integration allowing VBS to be ready before the planned Go Live.

VBS SOFTWARE DEVELOPMENT AND TESTING

After signing the agreement, the CSP project team and Camco’s business analysts started mapping the existing process flows, defining GOS/TOS and VBS/TOS requirements, and mapping the new process flows. Subsequently Camco software developers designed the new VBS application which was tested thoroughly before implementation. Process flows were reviewed and more tests were performed and test results double checked. After training the operators and informing all stakeholders of the VBS benefits, the VBS solutions went live.

A CUSTOMER-ORIENTED SOLUTION

Freighters and trucking companies were initially reluctant to the change. Based on their feedback additional adjustments were made to make the tool even more user-friendly. Once the community adopted the new technology, the complaints disappeared. Soon users started to experience the benefits: a big improvement in creating appointments and faster truck turnaround times.
For CSP Zeebrugge, the new VBS solution is a success as well: with the VBS, most of the pick up or drop off information is prefilled in the TOS, reducing the number of mistakes at the gate, limiting the need and time of solving issues by gate controllers and reducing customer service resources.

OFFERING MORE FLEXIBILITY TO TRUCK DRIVERS

To allow maximum flexibility to the drivers and to further reduce the gate processing time, CSP will integrate the Camco VBS mobile app in a next automation step. The free mobile app (Android and iOS) must be activated using a token, to be obtained at the CSP registration desk. The token will be linked to the driver’s Mifare ID card, allowing him to swipe his card at the gate to link his pre-announcement with the visit at the gate. The VBS mobile app will allow truck drivers to check alerts, modify tasks and complete missing information from the cabin as well as better organize tasks, offering more flexibility and efficiency.

VBS REQUIREMENTS

• Reduce input from transport companies
• Minimize the risk of mistakes
• Optimize user friendliness in creation
• Facilitate working with ERO, EDO, open refs

CSP Zeebrugge

• Capacity: 1 Million+ TEU/year
• 7 Super post-panamax  ZPMC gantry cranes
• 2.340 m of rail tracks

COMPLETE MAKE-OVER OF THE GATE PROCESS

Camco has been MPET’s technology partner since its relocation of the Delwaidedock to the Deurganckdock in 2016. The relocation strategy responded to increasing vessel size and offered more opportunities for process improvement and for further growth. The gate process at the previous location was less automated. Gate-Out had OCR, but Gate-In was still in full manual operation, with all manual lanes, problem & admin desks and an important overall administration. The relocation was the perfect occasion to completely rethink and automate the Gate process: A Truck Appointment System (TAS), visual OCR Gate-In and Pre-Gate-In with automated Gate process were implemented. Gert Bulté, MPET Terminal Manager: “The new process design also allows more container ground-slots which reduces need for truck parking at the admin complex and safer tallying and physical checks at the In-Gate. Today, only the exceptions are processed manually.”

A TRUCK APPOINTMENT SYSTEM FOR MANAGING THE TRUCK-FLOW

One of the process changes for speeding up the gate process, was the implementation of an in-house developed Truck Appointment System (TAS). The terminal, trucking companies and truck drivers benefit from the TAS: For MPET, the TAS is a great tool for managing transparent time-slots for the terminal’s 24/5 schedule. The tool contributes significantly to managing peaks but also facilitates yard housekeeping. Getting trucking companies and drivers on board required communication and training, but with upfront truck, driver and cargo registration, the terminal’s users were able to reduce the hassle at the gate and significantly improve their truck-turnaround.

SIMPLIFIED PROCESS AT THE INTERCHANGE ZONE

Prior to the relocation, also the processes at the Interchange Zones required extensive input from truckers, delaying turnaround. With the Truck Appointment System and the Camco interchange kiosks put in place, the admin hassle for the driver is replaced with a simple badge swipe. With reduced paperwork, now only one admin point is needed for each two container transfer lanes. Apart from faster turnaround, the Camco Interchange Kiosks contribute to increased safety since its process design requires drivers to stay in a safety zone during container pick-up and drop-off: drivers need to hold down the safety button during the complete container transfer process.

Increased safety: the truck drivers needs to push a safety button in the interchange zone during the complete transfer process.

With 12 Pre-Gate kiosks, 20 Self-Service Desk kiosks, 5 OCR Gate In portals and 15 Gate-In kioks lanes, bottlenecks and queuing are a thing of  the past.

ALL 41 CRANES EQUIPPED WITH DISRUPTIVE CAMCO BOXCATCHER STS CRANE OCR

Another cornerstone of the terminal automation strategy implied STS crane automation. Prior to the terminal relocation, each of the 41 STS crane had a tallyman in the gang operating a handheld terminal manually completing container ID & ISO code, IMDG, seal presence and max gross weight. In search of a robust OCR crane solution, different routes had been assessed. A PTZ camera system soon seemed not a viable solution, fixed CCTV cameras were considered for a moment, but this solution would require a substantial set of cameras per crane to avoid blind spots, a complex system integration and possible significant downtime during camera maintenance. Moreover, lack of proven solutions in the container handling industry was an additional drawback. The risk assessment for both alternatives soon turned negative.

With only two dynamic cameras per crane, Camco BoxCatcher system came out as the best STS crane automation solution. The Camco BoxCatcher disruptive design composed of a flying camera system hoovering over vertical rails fixed onto the crane frontal legs, enabling the capturing of every container, whatever the spreader flight path. With the Camco solution, only two BoxCatchers per crane are required for container identification providing 360° images of each box, be it 20, 40 or 45ft containers.

With the BoxCatcher linked to the crane PLC, and taken into account the container flightpath, the BoxCatcher system travels along the vertical rails to the exact location for container identification and condition recording. On each of the 41 cranes, 2 BoxCatcher identify each container and take 360° pictures for condition recording.

ACCURACY OF INFORMATION

The sooner information is available, the sooner real-time planning processes can start. It goes without saying that the information needs to be accurate and reliable. For any terminal, it should be a target to put every box in the right position and not touch it again until it leaves the terminal. Accuracy of information is a key parameter to reduce planning errors, avoid re-handles, housekeeping or shifting moves and idle moves. Fewer moves mean less fuel consumption, less wear and tear of the handling equipment and a higher productivity rate on the yard.

SAFETY FIRST – REMOTE EXCEPTION HANDLING

Apart from increased performance, Camco‘s STS crane solution contributes to more safety under the crane. Tallymen now let the crane OCR do the work and only focus on exceptions from a remote and safe office. “The BoxCatcher crane software application integrates seamlessly with the terminal TOS via the PSA middleware ConEqTer that serves as the tallyman exception portal. The primary OCR process with connection to the crane PLC is run by Camco”.

ORGANIZING BOXCATCHER INTALLATION

Implementing 41 cranes with two BoxCatcher systems each was quite a challenge. The joint project team was well prepared and had learned from an earlier BoxCatcher implementation project at PSA Antwerp. Each party focused on its expertise. Camco organized to have the 42-meter rails assembled beforehand on a dedicated warehouse on-site. Hoisting the rails took place in scheduled windows of 2 by 2 cranes. This way, Camco and MPET managed to install and commission two cranes in just a 2-3-day time window. Aware of the many challenges, the MPET team succeeded well in taking into account all aspects of the operation without disrupting operations:

• Maximum preparation of the cranes during normal maintenance windows: cabling, electrical cabinets, industrial PCs, IT network testing etc.
• Detailed planning of installation weeks: hoisting, fiber cable pulling
• Relying on the in-house partner for STS welding works for greater efficiency
• Avoiding aerial/boom lifts and relying on specialized STS crane climbing team.
• Getting stakeholders on-board with an extensive training and communication roll-out.

A temporary on-site Camco workshop and specialized MPET STS crane welding and climbing team contributed to speed and agility during installation.

KEY-DRIVERS FOR CHOOSING CAMCO

When selecting the appropriate solution, system performance remained the key driver. Accuracy is paramount as it determines the exception rate of the automated process. In the end, the exception rate determines the business-case for implementing the solution. Camco has a proven track record of integrated terminal automation solutions including complete gate automation systems and Crane OCR. Working with a single experienced integrator, who carries end-to-end responsibility and provides support, definitely limits the number of different systems interfacing with each other.
The complete automation project includes a substantial quantity of hardand software. Good upfront SLA contract clauses and a daily/weekly liaising between the MPET Service Management Department and Camco Maintenance & Support team is key for maximum uptime and performance.

ON-BOARDING OF STAKE-HOLDERS

All internal and external stakeholders were involved in the change process: customers, unions, tallymen and the terminal management. Tallymen received training for their new exception handling role. Today, they can handle exceptions safely from a desk instead of doing the same tasks in dangerous conditions right under the crane. Customers such as trucking companies and independent truck drivers have also been informed about the changes well before, and now embrace the automation process since it significantly reduces the paper hassle and endless waiting at the gate and Interchange Zones.

MPET ANTWERP, BELGIUM

• Capacity: 9 Million TEU/year
• Quay lenght: 3,700m
• Max draft: 17m
• Quay cranes: 41
• Straddle carriers: 234
• Rail handling cranes: 2
• Reefer connections: 2,564
• TOS: Cosmos/TOS

All 41 cranes equipped with Camco BoxCatcher Crane OCR system

MPET, Europe’s largest container terminal located in Antwerp, equipped its 41 STS crane with Camco BoxCatcher OCR camera system for container identification and condition recording. The flying camera, hoovering on crane mounted rails, is linked with the crane PLC and captures every box, regardless the container flight path. Seamless TOS integration ensures that the captured data is instantly sent to the TOS, ultimately improving vessel turnaround time.

MPET: SINGLE LARGEST CONTAINER TERMINAL IN EUROPE

MPET operates Europe single largest container terminal located in the port of Antwerp. In 2015/2016, the MSC PSA European Terminal (MPET), a 50/50 joint venture between TIL and PSA, moved its operations from the Delwaidedock on the right bank of the river Scheldt to the Deurganckdock on the left bank. The terminal’s annual throughput capacity thus expanded to 9 million TEU. MPET now features a total of 41 quay cranes across 9 berths, 234 straddle carriers and a quay length of 3,700 meters, making it the single largest container handling facility in Europe.

41 QUAY CRANES FEAUTURING INTELLIGENT OCR/OFR CAMERAS

In 2018, Camco Technologies was awarded the contract for the supply, implementation and maintenance of BoxCatcher Crane OCR systems for 41 cranes. In only two years, all of the BoxCatcher equipped quay cranes were fully operational.

A DISRUPTIVE SOLUTION FOR STS CRANE AUTOMATION

In search of a robust OCR crane solution, MPET had been assessing different routes. A PTZ camera system seemed not a viable solution, fixed CCTV cameras were considered for a moment, but this solution would require a substantial set of cameras per crane to avoid blind spots, a complex system integration and possible significant downtime during camera maintenance. Moreover, lack of proven solutions in the container handling industry was an additional drawback. The risk assessment for both alternatives soon turned negative. With only two dynamic cameras per crane, Camco BoxCatcher system came out as the best STS crane automation solution. The Camco BoxCatcher disruptive design composed of a flying camera system hoovering over vertical rails fixed onto the crane frontal legs, enabling the capturing of every container, whatever the spreader flight path. With the Camco solution, only two BoxCatchers per crane are required for container identification providing 360° images of each box, be it 20, 40 or 45ft containers. Apart from increased performance, Camco STS crane solution contributes to more safety under the crane. Tallymen now let the crane OCR do the work and only focus on exceptions from a remote and safe office.

The BoxCatcher crane software application integrates seamlessly with the terminal TOS via the PSA middleware ConEqTer which serves as the tallyman exception portal. The primary OCR process with connection to the crane PLC is run by Camco.

With the BoxCatcher linked to the crane PLC, the system predicts the precise location where the container will cross the frontal crane legs, avoiding unnessary moves for identification.

STREAMLINING THE TALLY PROCESS DURING LOADING AND DISCHARGE

The intelligent BoxCatcher cameras are equipped with OCR/OFR engines and partially take over the tallyman’s tasks. They capture images and data of each container while it’s loaded or discharged from the ship, without interrupting normal crane operations. The system reads the container number, ISO code, dangerous goods labels and checks for seal presence. At the same time, it takes high-resolution pictures for later damage claims management. Captured container data is then verified against the load lists. Waterside container handling is thus fully automated – human intervention is only needed in case of exceptions. To swiftly handle these exceptions, MPET uses Camco’s Crane Operator application.

ACCURACY OF INFORMATION

The sooner information is available, the sooner real-time planning processes can start. It goes without saying that the information needs to be accurate and reliable. For any terminal, it should be a target to put every box in the right position and not touch it again until it leaves the terminal. Accuracy of information is a key parameter to reduce planning errors, avoid rehandles, housekeeping or shifting moves and idle moves. Fewer moves mean less fuel consumption, less wear and tear of the handling equipment and a higher productivity rate on the yard.

Per STS crane, 2 BoxCatchers hoover along the crane legs, capturing data as well as pictures of the container long and short sides.

COMMUNICATION AND CLOSE COLLABORATION

Implementing 41 cranes with two BoxCatcher systems per crane was quite a challenge. The joint project team was well prepared and had learned from an earlier Box-Catcher implementation project at PSA Antwerp. Each party focused on its expertise. Camco organized to have the 42-meter rails assembled beforehand on a dedicated warehouse on-site. Hoisting the rails took place in scheduled windows of 2 by 2 cranes. This way, Camco and MPET managed to install and commission two cranes in just a 2-3-day time window.

Aware of the many challenges, the MPET team succeeded well in taking into account all aspects of the operation without disrupting operations:

• maximum preparation of the cranes during normal maintenance windows: cabling, electrical cabinets, industrial PCs, IT network testing etc.
• detailed planning of installation weeks: hoisting, fiber cable pulling
• relying on the in-house partner for STS welding works for greater efficiency
• avoiding aerial/boom lifts and relying on specialized STS crane climbing team
• getting stakeholders on-board with an extensive training and communication roll-out

Hoisting the rails onto the cranes. Every 2 to 3 days, 2 cranes were equipped with 2 BoxCatcher per crane.

A temporary on-site Camco workshop and specialized MPET STS crane welding and climbing team contributed to speed and agility during installation.

PROTECTING OUR PEOPLE

Safety is built into MPET’s company culture: a lot of effort is put into prevention and supervision of processes. Automation of the tally process enables MPET to have a clearer separation between the man/machine layer. This separation is an important step to prevent accidents from happening.

Automation systems assist the labor force. On the terminals in Antwerp, it is nowadays a challenge to recruit terminal workers. Automation systems at the gates and on the cranes allow motivated, skilled and trained staff to handle the exceptions requiring human interventions. The gang composition can be optimized to handle the work volume. Working smarter, not harder, certainly applies!

MPET ANTWERP, BELGIUM

• Capacity: 9 Million TEU/year
• Quay lenght: 3,700m
• Max draft: 17m
• Quay cranes: 41
• Straddle carriers: 234
• Rail handling cranes: 2
• Reefer connections: 2,564
• TOS: Cosmos/TOS

All 41 cranes equipped with Camco BoxCatcher Crane OCR system

HOW CAMCO VBS DRIVES GATE EFFICIENCY AT PD PORTS

PD Ports implemented the CAMCO gate automation and Vehicle Booking System (VBS) in July 2019 at Teesport. In just 12 months over 370,000 appointments were created amongst 1,300 individual users and over 6,000 license plates registrations. VBS has become a strategic tool in gathering truck visit info upfront, and a key driver for gate efficiency and optimum customer experience.

TEESPORT, THE UK NORTHERN GATEWAY FOR GLOBAL SHIPPERS

With a capacity of 575,000 TEU, Teesport is the UK’s northern gateway for global shippers. Serving worldwide markets including Scandinavia, the Baltics, Russia, Belgium and the Netherlands, Teesport supports the movement of international imports and exports throughout the North of the UK. An onsite intermodal rail terminal enables direct access to the national rail network.

VBS AND GATE AUTOMATION: ELIMINATING THE GATE BOTTLE NECK

In 2018, Camco Technologies was awarded the gate automation of the Teesport terminal. The automation project included the design, engineering, construction and software integration of the terminal’s in and outbound Truck OCR, gate kiosks as well as the Gate Operating System (GOS).

For Melanie Hannaway, Change & Delivery Manager, the original intention was to go live with the Automated Gate without a truck appointment system, but including a pre-gate. Early in the journey, it became apparent that in order to have the most efficient gate process, a Vehicle Booking System was to be considered too since this would improve the data quality of bookings before drivers even arrived at the gate.

Without VBS, certain problems surfaced only when trucks physically arrived at the gate (incorrect PIN numbers etc). Rectifying exceptions would continue to require manual work of handling exceptions, slowing down the process for other hauliers. As the VBS was implemented in conjunction with the GOS, the combined solution allowed to remove a pre-gate and filter out problematic traffic before it arrived.

TEESPORT (UK)

• Capacity: 575,000 TEU/year

Camco Gate Solution:

• 5 x Truck OCR
• 8 x in and outbound gates
• Gate Operating System with Service Desk application

VBS:

• 370,000 appointments/year
• 1,300 individual users
• 6,000 registered license plates
• VBS Mobile App

ONBOARDING THE CUSTOMER IS KEY TO SUCCESS

Initially, there was some resistance from customers and hauliers. Especially as short sea customers had complete flexibility to turn up to the terminal at any time. They felt that this would introduce a burden they did not want.
Customer Service worked closely with them and gathered feedback or concerns and fed them into the Project Team. This allowed defining a solution that customers would be comfortable using and not too onerous. Even today, customer feedback continues to be reviewed in order to continually improve the system and subsequent service delivery.

CUSTOMER TRAINING AND PHASED IMPLEMENTATION

PD Ports Customer Service team spent a lot of time speaking to customers directly, organized site visits, forums and email communications. A dedicated section was developed on the PD Ports website to provide customers with all the information they needed in preparation for the go live including video tutorials and FAQs. The top 20% of the customer base generating 80% of the traffic was specially targeted in order to get them registered and adopting the VBS before the main launch, which reduced the risk on go live significantly. The phased implementation allowed identifying issues and fixing them before opening up the VBS to a wider customer base. Some early adopters provided valuable feedback. VBS was tested gradually with more volume but still in a controlled manner, which proved very successful as some infrastructure concerns with load were uncovered.
Early adopters were switched back to the manual process while problems were fixed and then moved back to VBS to ensure it worked as anticipated. At the VBS go live, the project team was confident that it would work as expected.