6. Automate Flats Sequencing
Delivery point sequencing (DPS) of letter mail started in 1993. Prior to DPS, carriers were required to manually “case”, or sort letters and flat mail in delivery order. Today 86 percent of letters are sequenced using automation equipment. The two major components impacting delivery costs involve in-office operations and street delivery. Sequencing both letters and flats provides a platform for maximizing efficiencies in both of these functions and sets the stage for the elimination of other fixed costs such as delivery unit space and the number of delivery vehicles. The next step is to replicate the letter automation program by automating the sequencing of flat mail with deployment of the Flats Sequencing System (FSS). Flat mail volume exceeded 52 billion pieces in 2007 and represents about one-quarter of the total volume.
Pre-production Flats Sequencing System (FSS)
The FSS will sort flats into delivery sequence at high speeds and at a much higher productivity than today‘s manual process. Prior to roll-out of the production systems, a pre-production FSS has been installed. This integrated end-to-end system consists of several major components. Combined, these various components can sequence flat mail at 16,500 pieces per hour. The FSS is equipped with a self-contained staging and material handling system. At the end of pass-one sorting an automatic sweep occurs and all trays are returned to the feed area in correct order for immediate pass-two sequencing. At the end of the run, mail is automatically swept, placed into street trays, and discharged onto mail transport equipment that will be dispatched to the dock, and ultimately loaded onto trucks destined for delivery units.
This one-year pre-production operation provides time to work through the technology changes, processes, and human impacts associated with this new system. Working with this machine will allow testing of the technology, further development of processes and methods, and valuable operating experience. The knowledge gained will go into the production phase. The production phase of 100 FSS machines will begin October of 2008 and deployment is expected to take about two years.
Changes to Flat Mail Design, Preparation, and Entry
The Postal Service provides customers incentives to integrate mailer production techniques with postal processing to improve overall operating efficiency. Affordability and quality service are key to fostering growth in the mailing industry. The Postal Service is committed to continue to work closely with the mailing industry on initiatives regarding flat mail to reduce handlings.
As the Postal Service works with commercial mailers to reduce the total cost of flat mail, several collaborative strategies will be pursued. New standards will require optimal addressing and the use of an IM barcode or 11-digit POSTNET barcode on automation-rate flats. Bundling and containerization requirements for flats will be developed to align with the new flats sequencing environment. Technology solutions and mail make-up modifications will continue to be explored and feasible concepts will be tested during the pre-production and early phases of the production operation. Matching mail preparation requirements to processing needs and structuring rates to support sortation and handling will benefit the Postal Service and the mailing industry toward achieving lowest combined costs.
Plan Future FSS Phases
Planning for future phases of FSS is underway. Full implementation could require up to 400 systems. Space planning activities, primarily examining existing space, are in progress and considerations for flats sequencing technology with lessened capacity requirements and a smaller footprint needs to be considered to enable a full-up flats environment. In addition to the savings expected with FSS, the program is helping to shape a path to other related benefits. Delivery vehicle stowage and retrieval systems are under consideration for vehicles servicing FSS sites. These new units are designed to provide ergonomic solutions and tools for loading, organizing, conveyance, and presentation of mail to the carrier. Testing is in progress and final design for deployment is expected in 2008.