flats sequencing system (fss) overview · flats sequencing system (fss) overview barbara trower ......
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FLATS SEQUENCING SYSTEM (FSS)
OVERVIEW
FLATS SEQUENCING SYSTEM (FSS)
OVERVIEW
Barbara TrowerManager, Flat Mail Technology
Rosa FultonExecutive Director, FSS
May 17, 2007
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AGENDAAGENDA
Program Timeline
Prototype FSS Test
Pre-Production – Dulles VA
Production System / Deployment
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MULTI-PHASE DEVELOPMENT / DEPLOYMENTMULTI-PHASE DEVELOPMENT / DEPLOYMENT
Prototype – Indianapolis IN Apr 2006
BOG Approval 100 Production FSS Machines Dec 2006
Pre-production Install – Dulles P & DC Jun 2007
Pre-production – Live Operations Oct 2007
Production First Article Jul 2008
Phase 1 Deployment Begin Oct 2008
Phase 1 Deployment End Oct 2010
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FSS PROTOTYPE MACHINEFSS PROTOTYPE MACHINE
Test System - 192 bins and 2 feeders21,600 Pieces per hour16,200 Delivery pointsCarrier Routes – 20 - 25Flat volume 30,000
Mail prep work stationsai equipped flat feedersOCR / VCS / ICS2nd pass feeder assist
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INDIANAPOLIS PROTOTYPE TESTINDIANAPOLIS PROTOTYPE TEST
Test performed from April 17th to June 10th 2006
FSS Machine LocationMail Processing Annex (MPA)Indianapolis, IN
FSS Delivery UnitCarmel INZip Code – 46032, 46033, & 46082City Carriers – 35Rural Carriers - 31
Processed mail for
Zone: 46032
City Carriers – 24Rural Carriers - 16
Processed mail for
Zone: 46032
City Carriers – 24Rural Carriers - 16
Carmel Indiana Delivery Unit
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FSS PROTOTYPE TEST PLANFSS PROTOTYPE TEST PLAN
Four Major Areas Tested1. Machine Performance
2. Function 1 Operational Impacts
3. Function 2 (City & Rural) Impacts & Concepts• In-office
• Street
4. Function 4 Impacts
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PROTOTYPE MACHINE PERFORMANCEPROTOTYPE MACHINE PERFORMANCE
Attribute Test Goal Actual
Sort Accuracy 98% 98.8%
Accept Rate 93% 92.2%
2nd Pass Throughput 17,500 pph 16,000 – 18,000 pph
16,000 – 17,000 pph
7,700 – 8,000 pph
17,500 pph
8,250 pph
1st Pass Throughput
Combined Throughput** Starts with first letter on first pass until first letter on first pass of subsequent run
Impacts to Acceptance RatesAddress Hygiene11-Digit BarcodePolywrap Standard
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FSS RESULTS - CARMEL DELIVERY UNITFSS RESULTS - CARMEL DELIVERY UNIT
Non-DPS Flat RouteNon-DPS Flat Route
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FSS RESULTS - CARMEL DELIVERY UNITFSS RESULTS - CARMEL DELIVERY UNIT
DPS Flat RouteDPS Flat Route
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FSS RESULTS - CARMEL DELIVERY UNITFSS RESULTS - CARMEL DELIVERY UNIT
DPS Flat RouteDPS Flat Route
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FSS RESULTS - CARMEL DELIVERY UNITFSS RESULTS - CARMEL DELIVERY UNIT
DPS Flat RouteDPS Flat Route
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DPS FLATS DIRECTLY TO THE STREETDPS FLATS DIRECTLY TO THE STREET
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OVERALL % FLATS SORTED to DPSOVERALL % FLATS SORTED to DPS
Standard Residential Central Business
Zone 46032 Routes Receiving DPS Flats
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
CA CB CF CH CK CM CN CO CP CQ CT CV CW CD CE CG CJ CS CX CC CI CL CR CU
Perc
ent o
f Fla
t Mai
l DPS
d
Best Day All Days - Cased Sat. Not Included
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FSS PRE-PRODUCTION – DULLES VAFSS PRE-PRODUCTION – DULLES VA
Dulles VA – 201, 226 & 227
Install: June 2007Field Acceptance Test: Sep 2007Live Operations: Sep/ Oct 2007
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FSS PRODUCTION MACHINEFSS PRODUCTION MACHINE
Automatic High Speed Feeders
Dolly Induction Subsystem
Carousel-styleSorter
Tray Staging
Integrated Tray Converters
Mail Prep Subsystem
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FSS PRODUCTION MACHINEFSS PRODUCTION MACHINE
Prep
Image Processing
Auto-Induct
StreetTrays
Tray Transfer
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PRODUCTION FSSPRODUCTION FSS
Attribute Production FSS
Outputs (Bins) 360
Inductions / Feeders 2 / 4
Feeder Throughput (4 Feeders - Maximum Theoretical) 43,200 pcs/hr
Approximate Delivery Points Sequenced / 2 Pass Run 30,000
Typical Carrier Routes / 2 Pass Run 40 - 50
Average Day Run – TimeActual Run Time Varies by Season 17 hours
Typical Number of Daily Runs 6 - 8
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FSS NEW EQUIPMENT – FLAT TRAYSFSS NEW EQUIPMENT – FLAT TRAYS
Tray Type Contents Where used
Mail to be sequenced12” mail
1st pass & 2nd
pass in process mailSequenced mail9” mail
Verticalized mail for carrier15” mail
Automation Compatible Tray (ACT)16”x16.25”x10.4”
Mail preparationAutomated Induction (ai)ITC output
Rigid Tray19” x 13.75”x 12”
Sorter outputsIn process tray stagingITC Input
Street Tray17.83”x12.125”x6”
ITC output dispatchDispatchMail Carrier
Prototype Trays – Under Development
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FSS NEW EQUIPMENT – STREET TRAYSFSS NEW EQUIPMENT – STREET TRAYS
Prototype Trays – Under Development
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FSS NEW EQUIPMENT – STREET TRAYSFSS NEW EQUIPMENT – STREET TRAYS
Prototype Trays – Under Development
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NEW EQUIPMENT – TRANSPORTNEW EQUIPMENT – TRANSPORT
Carrier Automation Street Tray Rack (CASTR)Prototype – Under Development
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PHASE 1 DEPLOYMENT – 100 SYSTEMSPHASE 1 DEPLOYMENT – 100 SYSTEMS
29 Districts
32 Processing Facilities (FSS Locations)
27 Existing Processing Centers
5 New Facilities
2 - 5 Systems per Facility
1,500 Zones
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PHASE 1 FSS VOLUME / ZONESPHASE 1 FSS VOLUME / ZONES
Phase 1 FSS Volume – 28 million28%
Full-up FSS Volume100 million
Average Daily Volume
Phase 1 FSS Zones – 1,50021%
Full-up FSS Candidate Zones7,000
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FSS PROCESSING STRATEGYFSS PROCESSING STRATEGY
17 Hour Run Day (Operating Window)
280,500 Sequenced Pieces Per Day Per Machine
1st and 2nd Pass are Run Consecutively
Each Zone Will be Run Once a Day
One Dispatch Per Day Per Zone (other than FCM)
FCM May Not be in DPS based on FSS Operating Window and Mail Availability
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