New AI Tool Achieves Up to 98% Accuracy in Predicting Daily Tonnage Across Global Warehouse Network
Worldwide Flight Services (WFS), a member of the SATS Group, has launched a sophisticated digital tool that utilizes machine learning to deliver high-precision forecasts of air cargo volumes. By analyzing a decade of operational data, the system provides warehouses with daily, flight-specific projections, allowing managers to align their workforce and resources with unprecedented accuracy.
The Performance Management Platform – Machine Learning Forecast (PMP MLF) was trained on more than 3 million air waybills and historical movement records. By factoring in seasonality, holidays, and specific cargo types, the tool addresses the air cargo industry’s long-standing struggle with volume volatility, which traditionally causes a 10–15% gap between manual staffing estimates and actual workloads.
Global Scale and Predictive Precision
The PMP MLF is currently deployed across 75 warehouses in 13 countries, generating weekly forecasts for 9,842 flights and 6,216 truck movements. The system produces daily data on tonnage, unit load devices (ULDs), and piece counts, broken down by transport mode and customer.
Key operational benefits of the tool include:
- Proactive Resource Adjustment: Detects volume surges early, allowing teams to shift labor between sites with greater agility.
- Service Consistency: Reduces Service Level Agreement (SLA) breaches caused by understaffing or overloading.
- Operational Efficiency: Minimizes unnecessary overtime and idle time by replacing “guesswork” with data-driven clarity.
Data collected during the rollout shows the tool outperforms traditional models, maintaining an accuracy range of 92–98% even during irregular demand periods.
Future-Ready Digital Innovation
Following a successful phase one, Summer 2025 saw the rollout of phase two, which introduced enhanced visual analytics, tighter integration with rostering systems, and customer-level forecasting for joint peak-period planning.
Jimi Daniel Hansen, SVP Operational Excellence at WFS, stated that the goal was to replace reactive management with predictive precision. He noted that the transformation has moved the company away from manual spreadsheets and rolling averages, leading to fewer delays and improved service consistency—digital innovations that are increasingly demanded by global customers.
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