MTAC Workgroup 115Flat Mail Prep & Entry
in FSS Environment
MTAC Workgroup 115Flat Mail Prep & Entry
in FSS Environment
November 18, 2009
MTAC 115 – November 18
, 2009
2
FSS Update
USPS / IDEAlliance Think Tank II
MTAC 115 in Review
FSS Mail Prep - Next Steps
Agenda
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FSS UpdateFSS Update
Rosa Fulton
Executive Director, FSS
MTAC 115 – November 18
, 2009
4
Flat Volume by Class FY 2009RPW
First Class Periodicals Standard Total Flats
2008 3,347,726 8,466,043 34,107,226 45,920,995
2009 2,834,331 7,838,032 28,888,753 39,561,116
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
50,000,000
Vo
lum
e / P
iece
s (0
00)
Class & Total Volume
FY 2009 Flat Volume Comparison by ClassOctober 1, 2009 - September 30, 2009
-15.3%
-15.3%
-7.4%
Flat volume decline FY 2009 -13.8%6.3 bil pieces
Flat volume decline FY 2009 -13.8%6.3 bil pieces
MTAC 115 – November 18
, 2009
5
20
25
30
35
40
45
50
55
60
2001 2002 2003 2004 2005 2006 2007 2008 2009Vol (Bil) 58.2 57.8 51.7 52.4 53.9 53.8 52.4 45.9 39.6
Flat Volume TrendRPW
Flat volume decline FY 2009 -13.8%Flat volume decline FY 2009 -13.8%
FY 2005 – FY 2009Flat volume decline 26%
14.3 billion fewer flats annually
FY 2005 – FY 2009Flat volume decline 26%
14.3 billion fewer flats annually
MTAC 115 – November 18
, 2009
6
Sequencing Operations
● Dulles – 4 FSS
● Columbus – 2 FSS
● Kansas City – 2 FSS
● Phoenix – 3 FSS
Operations & Installations
Installation of 14 FSS in progress
MTAC 115 – November 18
, 2009
7
FSS Operations – Ramp-up Status
FSS Site# FSSOn-line
# Delivery Units
On-line
# ZonesOn-line
Dulles P&DC 4 39 52
Columbus FSS Annex 2 24 36
Kansas City P&DC 2 18 44
Phoenix (West Valley) L&DC 3 8 27
Totals 11 89 159
MTAC 115 – November 18
, 2009
8
Installations – 14 FSS, 9 Sites
Area FSS Location Install Start% Complete
Install
CM CURSEEN-MORRIS DC P&DC 12-Sep-09 90%
NE NEW JERSEY NDC 12-Sep-09 95%
NE MID-ISLAND NY P&DC 26-Sep-09 65%
NE NEW JERSEY NDC 26-Sep-09 55%
NE NW BOSTON MA P&DC 10-Oct-09 45%
SE ORLANDO FL L&DC 10-Oct-09 20%
PA VAN NUYS CA FSS ANNEX 24-Oct-09 10%
SE SOUTH FLORIDA L&DC 24-Oct-09 10%
EA TRENTON NJ P&DC 7-Nov-09 5%
SE SOUTH FLORIDA L&DC 7-Nov-09 5%
GL INDIANAPOLIS IN MPA 21-Nov-09
NE MID-ISLAND NY P&DC 21-Nov-09
NE NW BOSTON MA P&DC 5-Dec-09
SEORLANDO FL L&DC 5-Dec-09
Install schedule of next 25 FSS in
progress
MTAC 115 – November 18
, 2009
9
FSS Redirection – New Deployment Plan
19 FSS planned for redirection
● Deploy fewer FSS in 10 sites
Two sites removed from original plan
12 new FSS sites
42 FSS sites versus 32
MTAC 115 – November 18
, 2009
10
Phase 1A (Redirect Sites) Space Planning
FSS Site # FSS
Linthicum MD IMF 1
Charlotte NC L&DC 1
Rochester NYL&DC 2
Philadelphia PA NDC 1
Philadelphia PA P&DC 2
Mid Island NY P&DC 1*
Westchester NY P&DC 1
Stamford CT P&DC 1
North Metro GA P&DC 2
Atlanta GA L&DC 2
North Houston TX P&DC 1
Minneapolis / Eagan P&DC 2
San Diego P&DC 2
* Mid-Island receiving 4th FSS
®
USPS / IDEAllianceThink-Tank II
USPS / IDEAllianceThink-Tank II
Susan Hawes
Operational Requirements
MTAC 115 – November 18
, 2009
12
WG 115 collaborated with IDEAlliance, again!
● Met September 2, 2009
● Focus: Presort software programs and data files
● Participants this time included production and systems/software representatives
Provided context for Think-Tank II Participants
● Reviewed workgroup recommendations
Auto-ready pallet
Non-compensated bundles
Bundle heights 3”, 4”, or 6”
Think-Tank II Meeting
MTAC 115 – November 18
, 2009
13
Modeling Exercise
What would FSS pallets look like today?
● Volume and thickness of flats has changed since earlier modeling of bundles and pallets in 2007
● Pallet prep the same as 5-D/5-D schemes today
Test Plan included real “address lists” for destinating Dulles FSS site
● Using specific ZIP Codes processed on FSS
● Using real mailpiece characteristics and volumes
MTAC 115 – November 18
, 2009
14
Test plan included:
● Bundle and pallet counts● Current presort rules for comparison● ‘Artificial’ Labeling List data to use when identifying FSS schemes● Presort software that used LL to make up bundles and pallets● Specified bundle heights for each presort processing
Testing process was to:● Run presort for all 3-digits (201, 220-223, 226 and 227) ● Roll up data for non-FSS 5-digits using today’s rules● Prepare individual FSS sort plan pallets (1-4 5D ZIPs per sort plan)● Prepare multi FSS pallets based on each site
Presort FSS Test Plan
MTAC 115 – November 18
, 2009
15
FSS schemes:
● FSS sort plans mirror 5-digit and 5-digit scheme sort plans● Dulles currently has 49 FSS sort plans
19 sort plans with 1 5-digit ZIP Code 20 sort plans with 2 5-digit ZIP Codes 8 sort plans with 3 5-digit ZIP Codes 2 sort plans with 4 5-digit ZIP Codes
Test results:● Periodicals had few FSS sort plan pallets● Pallet counts remained same for PER and STD mailings● FSS scheme pallet (all sort plans at a site) has potential
Test Plan Results
MTAC 115 – November 18
, 2009
16
Test Plan Results
Test # Bundle height # Bundles Pallet Presort # Pallets Weight
Standard Mail
1 209,694 1,607 1,331
2 207,543 1,602 1,329
3 3 1,217 FSS 19 675
4 3 870 FSS Scheme 5 1,819
3 4 916 FSS 19 675
4 4 656 FSS Scheme 5 1,819
3 6 614 FSS 19 675
4 6 441 FSS Scheme 5 1,819
Periodicals Mail
1 105,460 443 1,310
2 105,375 442 1,311
3 3 - FSS 0
4 3 142 FSS Scheme 1 781
3 4 - FSS 0
4 4 70 FSS Scheme 1 797
3 6 - FSS 0
4 6 68 FSS Scheme 1 666
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MTAC 115 in ReviewMTAC 115 in Review
Krista Finazzo
Postal Co-ChairJoe Schick
Industry Co-Chair
MTAC 115 – November 18
, 2009
18
Workgroup Focus – Issue Statement
Deployment Phase1 FSS● FSS program will impact:
Flats preparation How mail is presented and scheduled for entry
Continuous process - mail owner to USPS● Interdependencies of inputs and outputs through
entire process, concept to delivery Will drive standards/requirements for prep & entry Will play a major role in determining efficiency of
processing on FSS
MTAC 115 – November 18
, 2009
19
Desired Results
“Identify areas of impact to the USPS and customers associated with preparation and entry of flats in an FSS environment including the lowest combined cost model.”
MTAC 115 – November 18
, 2009
20
Workgroup Action Items
Workgroup 96 handed off four items to MTAC WG 115:● Bundle preparation● Containerization● Presort Parameters● Destination entry
MTAC 115 – November 18
, 2009
21
Workgroup Activities
Developed a prototype system “Automated Flats Processor” (AFP) to improve:
● Productivity of bundle processing
● Equipment space required to process daily volume
● Capability to accept multi-zone pallets
● Flats auto processing – induction to piece sorting
MTAC 115 – November 18
, 2009
22
Workgroup Activities
AFP key functions are:● Auto Depalletize Bundles – automatically unloads
bundles from pallets
● Distribute Bundles based on sort plans with OEL
readability – convey & prep bundles for processing
● Process Bundles – cut and remove bundle strapping
and load bundles into ACTs
● Make Dollies – produce sort plan based dollies
● Dispatch Dollies – full ACTs, produced for specific sort
plans, released for induct into flats sorting equipment
MTAC 115 – November 18
, 2009
23
Workgroup Activities
Bundle / Container testing:● Built on auto-ready pallet concept
● Evaluated – uniform bundle heights, compensation of bundles, containerization, and bundle securing methods
● Determined counter-stacked bundles of uniform height travel well through transportation / distribution system
Bundle securing methods tested:● Two cross-straps around length and girth● Shrinkwrap “bellyband” with a single-strap as alternative
to strap only
MTAC 115 – November 18
, 2009
24
Workgroup Activities
Discovered auto-ready pallet prep will allow bundles to flow directly to the bundle prep operation and bypass APPS processing
Evaluated potential pallet levels:● Pure FSS (single scheme)
● Pure FSS (multiple schemes)
● Combined FSS and non-FSS
MTAC 115 – November 18
, 2009
25
Workgroup Activities
Assessed impact of volume reduction● Volume reduction has required more ZIP Codes and
FSS sites than original plan● Some original sites receiving fewer machines● Volume reduction makes preparation of FSS single-
scheme pallets more difficult
Considered single preparation solution● Lowest end-to-end cost achieved with one bundle
preparation method Prep compatible with FSS and AFSM process
MTAC 115 – November 18
, 2009
26
Status of Action Items
Bundle● Optimal bundle height of 3”, 4”, 6”● Secured using two cross-straps
Container● Non-compensated bundles on compensated pallet● Content determined by FSS scheme & destination
Presort● Driven by FSS Label List and sort plan contents
Entry● Destination entry, at minimum, should not change
and may contract with optimized network
MTAC 115 – November 18
, 2009
27
®
FSS Mail Preparation
Next Steps
FSS Mail Preparation
Next Steps
Krista Finazzo
Manager, Operational Requirements
Rosa Fulton
Executive Director, FSS
MTAC 115 – November 18
, 2009
29
FSS Flat Mail Prep – Next Steps
Propose new MTAC workgroup● Workgroup: “Implementing FSS Presort Parameters”● Align under the “Optimization of Mail Preparation
& Entry” focus area
Charter of new workgroup:● Develop and implement presort parameters to
support defined (optional) FSS prep ● Identify timing of software updates related to FSS
deployment● Communicate timing & FSS Label List
MTAC 115 – November 18
, 2009
30
In closing