John S. Usher G. Don Taylor Jamie Little University of Louisville

1. Improving Flat Mail Preparation at USPS John S. Usher G. Don Taylor Jamie Little University of Louisville

2. Poster Overview • Overview of AFSM 100 Problem • Internal and External Mail Flow Patterns • Handling and Presentation Options • Options Based on Procedural Change • Options Based on AFSM 100 Enhancements • Options Based on Material Handling Methods • Summary

3. Overview of AFSM 100 Problem • The postal service has done an excellent job of automating letter mail, but flat mail lags behind. • The AFSM 100 flats sorter has automated sortation, but preparation is still manual and difficult. • The preparation task is partially out of USPS control. • The task is highly constrained. • Current rates better support the ‘old way’ of doing business.

4. AFSM 100 Input Area

5. AFSM 100 Input Station

6. ERGO-Cart

7. AFSM 100 Output Area

8. External Flow Patterns Printers Mailers Consolidators Other USPS Facilities USPS Facilities (P&DC, BMC, and Sectional)

9. Internal Flow Patterns Very Complicated Flows

10. Options Based on Procedural Change • Increased use of banding • Avoidance of loading managed mail in ergo-carts • Avoidance of mixing mail with different sort depth levels • Handle local mail in trays • Utilize larger 3-digit bundles • Review flats rate structures • Review definition of machinable flats • Eliminate Sacks • Avoid overcompensation in ergo-carts and bundles • Increase AFSM 200 capacity…..

11. Options Based on AFSM 100 Enhancements • Increase output bin locations • Read both sides of flat mail pieces • Increase the number of input stations • Print addresses at the AFSM 100 • Automatically label and sweep trays

12. Options Based on Material Handling Methods • Use ergo-cart inserts • Use a pallet-sized ergo-cart insert • Use larger bundles • Use ‘logs’ of flat mail • Use extended input buffers • Develop automatic bundle openers • Increase the use of flats trays • Use an ergo-pallet fixture • Use a mechanical lifting assist device

13. Summary • Parts presentation & packaging are important parts of the automation process. • When automating processes, it is important to audit existing practices, pricing strategies, etc. • Procedural changes offer low-cost improvement opportunity. • Equipment or material handling changes may offer the most ‘bang for the buck’. • USPS prefers a focus on inserts and extended buffers.