Reference FIEGE

Handling Air Cargo Using AI

Optimizing Aircraft Load with Intelligent Technology

In order to make optimal use of the available loading space on aircraft, the handling company FIEGE Air Cargo Logistics must take the contour limits of the aircraft pallets into account with centimeter precision. This is the only way to ensure the fine balance between optimal volume utilization and contour violation. Until now, skilled workers had to perform precision work with great effort. Using their eyes and contour sheets, they planned the loading individually for the respective cargo holds of the different aircraft types.

Together with Deutsche Telekom, FIEGE Air Cargo Logistics has developed a digital assistance system to make the time-consuming and labor-intensive contour check more efficient with the help of IoT and AI support.

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Reference at a Glance

Task

Optimization of the contour inspection process and reduction of workload for employees through digitalization

Solution

Assistance system automates freight measurement using LiDAR laser technology and AI

Result

Greater efficiency and speed in air freight handling

With the Build Up Eye, we have jointly developed a digital assistance system with great added value for air cargo logistics. Jannis Kumbrink, Teamlead Strategic Development FIEGE

Benefits for our Customers

Time, cost, and resource savings through digital support
Avoidance of revenue losses by reducing offloads
Optimal utilization of cargo aircraft through more accurate measurements

Requirements

SOlution

Benefit

Requirements

Optimizing Air Cargo Capacity Utilization

To make the most of the cargo space in passenger and transport aircraft, airports load piece goods onto what are called unit load devices (ULDs). They have to place the different-sized cargo on a pallet so that no space is wasted and all loading limits are followed. A contour is specified for this process, which is derived from the planned position in the cargo hold.

If the specified contour is not adhered to during loading, the special pallet cannot be secured in the aircraft due to the protrusion, which poses a risk of damage to the cargo hold. In such an offload case, the transport or passenger aircraft flies without or with only a reduced load, which means a loss of revenue for FIEGE. In order to reduce the number of offloads and relieve the burden on employees, FIEGE was looking for a solution that would allow the contour check of the ULDs to be carried out digitally in the future. What was needed was an assistance system that could record the air freight pallets with the piece goods and check the load according to the assigned contour. In addition, the check-up had to be carried out with minimal interference in the packing process – a complex challenge from both a technical and organizational point of view.

SOlution

Digital Measurement of Freight Goods Using LiDAR Laser Technology and AI Image Analysis

The digital assistance system called Build Up Eye monitors pallets as they are loaded at the packing station directly on the chassis. The software performs a three-dimensional measurement and contour check of the pallets using LiDAR cameras. These are mounted around the pallet packing station and capture measurements such as depth data and distance of the ULDs in real time. Employees can then place a virtual template over the image of the pallet at their digital workstation and simulate the specified contour. AI Vision – a Telekom AI-supported image and video analysis platform – then evaluates the data on edge in real time, displays contour violations of the current load, and offers the option of calculating the unused area of the pallet for optimal utilization.

The digital inspection system is used at Frankfurt Airport, but administrators can access the solution remotely via the mobile network at any time, regardless of local infrastructure, to perform maintenance work or integrate new functions. This makes it possible to roll out Build Up Eye quickly and easily to other locations in the future.

Benefit

Assemble Air Cargo Safely and Efficiently

Thanks to the AI-based assistance system, measurement errors when packing pallets are detected before they are transported to the aircraft. This allows specialist staff to react in good time, load aircraft more quickly, use transport space highly efficiently, and avoid revenue losses due to empty spaces. In the future, Build Up Eye could even make an important contribution to sustainability. By scaling the application, the volume could be optimized to such an extent that the CO2 balance per aircraft would improve significantly. The higher precision combined with minimal intervention in the loading process is a unique selling point that strengthens FIEGE's position as a reliable partner in air freight logistics. The digital assistance system also reduces the workload for FIEGE staff, as it minimizes and, in some cases, completely replaces the time-consuming manual contour check. The digital documentation of all packing processes helps to identify potential for improvement and become even more efficient in the long term.

About FIEGE

The FIEGE Group, headquartered in Greven, Westphalia, is one of the most innovative logistics providers in Europe. With 22,000 employees at 139 locations in 14 countries, FIEGE operates internationally – from its core markets in Europe to Asia. FIEGE is a fifth-generation family business and is considered a pioneer in contract logistics.

FIEGE Air Cargo Logistics handles around one million tons of freight per year with its 800 employees. The FIEGE subsidiary has 70,000 m² of logistics space and has been a partner of Lufthansa Cargo since 2020.

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