Out of Sequence

Case Study

OOS Case StudyEquipment Performance Focus

– Machine Indicators• MPEWatch• WebEOR• DCS

– Test Deck Results– Quality of Product

Process Improvement Recommendations

MPE Watch

Daily Reports Archive

MPE Watch

DPS Summary

MPE Watch

Sunday night / Monday Morning

MPE Watch – DPS Summary – DBCS #55 more pages of out of sequence info for this machine

Too many OOS mail pieces – Sequence Error: 1st Pass 18, 14

(28 lines similar to this one, over the next 5 pages)

OOS shut the machine down.

Mail processor restarted 24 seconds later.

MPE Watch – DPS Summary – DBCS #5More out of sequence

MPE Watch – DPS Summary – DBCS #5More out of sequence

5 pages of out of sequence 28 occurrences that shut the machine down.

-How many OOS pieces?

-What’s it take to shut the machine down? 10 OOS pieces in a row?

-28 occurrences x 10 pieces = 280 pieces out of sequence?

-The real number is thousands of pieces(!) sent to the carriers in their DPS mail for this sort plan this morning.

NHO DBCS #5 - OOS• Discussion

– So, what happened Sunday night / Monday morning on this machine?

– Machine problem?– Jogging, Edging, Sweeping?– What actions can we take to identify the

problem and correct?– What other data is available to isolate the

problem?

webEOR

webEOR

EOR Viewer

webEOR

NHO PDC DBCS #5

First Pass (2)

Second Pass (3)

webEOR –DPS 2nd Pass

Total Fed: 7788

Stops: 30

Stacker Full: 1

OOS: 259

OOS %: 3.3%

(12 times the target!)

Data Collection Server Data• Files available on the DCS that shows

data for each mail piece

• Lots of data, don’t need to look at daily, but useful for problem identification and solving

Data from the DCS – DPS 2nd PassSequence Tray #

Should be 1,2,3,4,5, etc. Stacker #

Data from the DCS – DPS 2nd Pass

Data from the DCS – DPS 2nd Pass

DPS 2nd Pass

Fed Tray #1

Fed Tray #2

? Fed more Tray #1 – OOS

First 20 pieces of Mail went to Last Stacker

Data from the DCS – DPS 2nd Pass

First 20 pieces of Mail went to Last Stacker

Machine Shut Down

On restart, Sequence # resets, and we sort the OOS mail to the Carrier

OOS – DPS 2nd Pass Tray 9 followed by Tray 16

OOS – DPS 2nd Pass Tray 18 followed by Tray 14

OOS – DPS 2nd Pass Tray 16 followed by Tray 12

What’s this?

Most likely a triple feed on the first pass. Jog and edge every piece, every day, on the first pass

Could also be a diverter problem, gate could have stuck open for 3 pieces.

What Happened?• In this preceding example, OOS was

caused by – Combining first pass trays (in error)– Sweep errors (putting stacker #16 mail in tray

#12)– Didn’t use GPCs with trays to stage the first

pass mail

Action• First Pass Checklist

– Jog and edge all mail fed– Sweeper must sweep stackers continuously, don’t

wait for stackers to get full (No blinking red lights).– Sweep into numbered tray racks (Stacker #15 should

be swept to Tray #15, on a labeled tray rack.)– Don’t combine partial trays– Pull down First Pass trays into GPCs with shelves, in

numerical order (Don’t use u-carts or nutting trucks)

Action• Second Pass Checklist

– Jog and edge all mail fed– Feed trays in numerical order– Sweeper must sweep stackers continuously,

don’t wait for stackers to get full (No blinking red lights).

– Sweep into numbered tray racks (Stacker #15 should be swept to Tray #15, on a labeled tray rack.)

– Don’t combine partial trays

Action• Maintenance and Operations

– Use MPEwatch and EOR Viewer to identify problems

• Full Stackers• OOS Volume• Stops

– Post Prior night’s data on each DBCS– Acknowledge good OOS performance – Use DCS data when needed to identify a

problem