How to pilot automation – the right way

For terminal operators, starting the journey to automation can feel very intimidating. To test things out, the standard approach is to conduct some kind of small-scale automation pilot – ideally at minimum cost and with no long-term commitment – to see if the system works first.  

The problem is that this kind of micro-scale piloting seldom produces any meaningful learnings about the operation of an actual terminal-wide automation deployment. Any competent industrial automation provider will be able to handle the systems integration required to get a single machine moving a container from point A to point B within a designated test area. But that proves very little about how the system would function at full scale.

How would the tested solution work with 10, 100 or 200 machines? How does it integrate into the processes of the terminal as a whole? How does it serve your landside trucks and quay cranes? At best, the pilot project has successfully demonstrated a technical solution that has no actual application. At worst, it can handicap the development of the terminal if, based on the pilot, the conclusion is that terminal automation is not worth pursuing since it's too complicated to scale – when in fact there already exist field-proven automation solutions (namely Kalmar One) with years or even decades of solid operational history at some of the world's largest terminals.

No need to wait for the future

It is interesting to note that companies developing autonomous public transportation have been grappling with similar questions for years. It's one thing to build a driverless bus that shuttles between a few stops on a quiet university campus. It's wholly another to try to build a fleet of them that can navigate rush hour traffic in a major city centre.

However, the difference between autonomous public transportation and container terminal automation is that the latter is not a futuristic vision that may become a reality at some later date. It's a well-established industrial concept that is delivering value and competitive advantage to terminal operators right now, every day of the year.  

So what, then, is the right way to get started with piloting automation? At the very least, if you do feel the need for a pilot project, be sure to pick a solution that is guaranteed to scale to the level you think you will need, and beyond. Pick a solution provider with a track record. If you need to reinvent the wheel for a one-off bespoke demo, you will waste months or even years in getting started on your automation journey.

Pay attention to your choice of automation system. Our own Kalmar One offers the most comprehensive, field-proven set of functionalities including full OEM-agnostic compatibility with any type of equipment, IEC 62443-4-1 certified cybersecure development, extensive open APIs as well as seamless integration with Terminal Operating Systems and third-party applications.

Also, be sure to make full use of simulation and emulation when evaluating your automation options. Simulation involves exploring a range of "what if" scenarios with a carefully built model of the entire solution, while terminal wide emulation (Digital twin) validates the integration of the chosen automation concept with actual production systems and software. Both are crucial tools to ensure that your solution is technically feasible, and help you understand the operational possibilities of an automated fleet.

And – as a further thing to think about – do consider whether a pilot is even necessary. The Kalmar One automation system has amassed a track record of tens of millions of container moves at major terminals around the globe. How much more proof and piloting do you need?

Tomi Tuulkari

Tomi Tuulkari works as Senior Manager, Product Management in Kalmar. Tomi’s expertise comes from delivering multiple Automatic Stacking Crane projects, extensive customer collaboration as well as from Product Management, i.e. ensuring that the developed yard cranes fulfill the needs of the industry and that they can be maintained easily during the product's lifetime. Today Tomi focuses on the product management tasks dedicated to Kalmar One. He spends his time communicating with Kalmar's customers and partners, steering product development, as well as designing and scouting new technologies that can help customers operate automated sites even more smoothly while increasing productivity.