Zero error principle

The concept of “Zero Error” is based on quality and control and is realized by deploying a mix of technology that  cooperates in a way that the “what” and “where” question for people, equipment and containers can always be answered when moving boxes through the terminal facility. Zero error implies for terminal operators that:

  • The planning (TOS) is 100% followed
  • All moves are tracked without operator input
  • Exceptions are pre-defined and handled centralized
  • Only authorised users can use equipment
  • Only authorised users can access data

More and more terminals embrace the total traceability concept resulting in reliable performance, increased productivity and safer operations.

How it works

Job Orders are created in the TOS as a result of planning activities. During operations, technology like RTLS and GPS constantly identifies the real time position for any equipment. The container is identified by means of OCR at the terminal borders. During every following movement, the box is traced and every job step is verified by matching it against the job order details. 

The technology mix of OCR, RTLS and GPS will make sure:

  • All container details are automatically identified
  • All container moves are automatically identified
  • All equipment positions are continuously reported
  • Operators are presented with the appropriate “job step”
  • Any move that is not correct is physically stopped

The net result is total control over container movements within the terminal facility, enabling central control over any exceptions that may occur.

Solution benefits

The zero error concept is intended to provide far-reaching benefits to terminal operators that require optimal traceability and are specifically focussed on error reduction and increased productivity.

Primary benefits include:

  • Prevent stack inventory errors based on accurate matching of containers to blocks, lanes and slots. Without this double check, the system is relying on the operator to place or pick up a container from the correct position. Without the real time position of carriers, the TOS may select a less optimal piece of equipment to whom to assign a task resulting in lost productivity.
  • Improve productivity through the elimination of data input and/or task confirmations thereby increasing the accuracy and velocity of the transactions resulting in higher throughput and improved container inventory accuracy. 
  • Improve container security by preventing misplaced containers which can include disabling the twist locks on a move that is inconsistent with the job order.

Second level benefits include:

  • Improved turn times on lifts/drops. The operator is no longer entering data or searching an RDT task queue so the task can be executed faster. 
  • Safer operations. No inventory clerks are required on the ground to check transactions, because all data capture of transactions is automatic.

Please also refer to our references section for a better impression on earlier deployed Zero Error automation solutions.

Products part of this solution

The solution compromises of the following. More information on the products part of this integrated solution can be found in the products section.

  • Crane OCR, Gate OCR, Rail OCR
  • Position Detection
  • Access Control
  • CCTV
  • Global Control System