This study enhances safety and efficiency in air cargo handling by comparing manual and automated processes and optimizing the use of unit load devices (ULDs). Air cargo is vital to global trade, yet ensuring safe and efficient handling remains challenging. This research uses Arena simulation software to evaluate the effects of safety measures and handling methods, and an Excel-based Cargo Loading Problem (CLP) solver to optimize container packing for maximum space utilization and weight balance. Results indicate that automated handling is faster and safer than manual operations, reducing accidents and delays. By integrating simulation and optimization, this study offers a comprehensive approach to improving safety and efficiency in air cargo operations.