1. Out of Sequence Case Study

2. OOS Case Study Equipment Performance Focus • Machine Indicators • MPEWatch • WebEOR • DCS • Test Deck Results • Quality of Product Process Improvement Recommendations

3. MPE Watch Daily Reports Archive

4. MPE Watch DPS Summary

5. MPE Watch Sunday night / Monday Morning

6. MPE Watch – DPS Summary – DBCS #5 5 more pages of out of sequence info for this machine OOS shut the machine down. Mail processor restarted 24 seconds later. Too many OOS mail pieces – Sequence Error: 1st Pass 18, 14 (28 lines similar to this one, over the next 5 pages)

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

8. 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.

9. 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?

10. webEOR

11. webEOR EOR Viewer

12. webEOR NHO PDC DBCS #5 First Pass (2) Second Pass (3)

13. webEOR –DPS 2nd Pass Total Fed: 7788 Stops: 30 Stacker Full: 1 OOS: 259 OOS %: 3.3% (12 times the target!)

14. 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

15. Data from the DCS – DPS 2nd Pass Sequence Tray # Should be 1,2,3,4,5, etc. Stacker #

16. Data from the DCS – DPS 2nd Pass

17. 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

18. 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

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

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

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

22. 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.

23. 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

24. 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)

25. 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

26. 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