Sorting without rejects: Strategies that eliminate costly manual handling
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Transcript of Sorting without rejects: Strategies that eliminate costly manual handling
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Mark A. RyderDirector: Marketing & Key Accounts
100% SORTING: REMOVING BARRIERSSorting without rejects: Strategies that eliminate costly manual handling
Post-Expo 2014Stockholm
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Who are Prime Vision?
• Part of a postal operator ourselves;• Core technology developer in reading and coding systems;• Middleware developer between sorting systems, decision
systems and IT;
Partners with posts to develop automation solutions or reutilize existing investments in automation and software in new ways;
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Postal / parcel automation has come a long way
Sorting becomes as easy as loading and unloading
Fewer operators required Higher throughput in less time Lower processing costs Higher quality
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The main challenge with an automation strategy becomes the mail that fails automation
You need processes You need people You need time Higher error potential Higher processing costs
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Common causes of automation rejects
Damaged, scuffed, poor quality addressing / bar code;
Identification failure; Input errors, such as double-feeding or
incorrectly faced; Machine errors, such as blockage Operational errors, such as chutes full
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Rejects: Structural or dynamic?
Structural: predictable, for example barcode based systems will never be 100%. Expect a 2-5% reject rate;
Dynamic: unpredictable, for example operational events such as loss of critical data links, eDi information, batches of poorly printed labels
You need to develop strategies for both categories!
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Increased sophistication of sorting / automation
Ever increasing scope means higher potential and impact of rejects
Multi-format sorters (wide range of mail) Growth of cross-border e-commerce Data-rich identification, deeper level reading,
indicia, volume, weight….capturing every aspect of a mailpiece
Revenue recovery & protection measures Sequencing and more complex sorting schemes Increasing involvement of sender and recipient,
i.e. track and trace, delay or divert in-transit and more
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The cost perspective
Impacts of automation rejects vary considerably depending on complexity and volume; For one major client, handling 4% rejects costs them 7 times
more overall than handling the 96% with automation Can you put a price on all the cost drivers?
Potential for errors; Calling in emergency or agency staff; Late or missed deliveries / SLA
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Video-coding can be a quick win strategyVideo-coding can be a quick win strategy
A surprising number of parcel / packet sorters have no video-A surprising number of parcel / packet sorters have no video-coding capability, compared to letters / flats etc;coding capability, compared to letters / flats etc;
Video-coding provides a low-cost means of keeping the item on Video-coding provides a low-cost means of keeping the item on the sorter and reducing extra physical handling;the sorter and reducing extra physical handling;
Value on barcode based sorters as well as more complex OCR Value on barcode based sorters as well as more complex OCR systems systems
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Impacts are much more than cost alone
Missed delivery windows Do you have the people available? Drafting in extra people is one thing, but do they have the
process knowledge?
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100% sorting efficiency: some strategies at design stage
Identification at the earliest opportunity; Build in delay lines to enable additional process time if required, or
recirculation for loop sorters for example; Enables second pass opportunity or video-coding;
Consider multi-side imaging systems on sorters rather than single side; A hybrid identification system, for example operators can voice the
destination city as they load parcels onto the sorter which can be combined with label identification on the sorter to reduce rejects;
Prioritise what you need to sort the mailpiece as opposed to what is necessary for secondary processes;
Build-in tools that enable easy analysis of rejects
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100% sorting efficiency: strategies on existing automation
Reject mode analysis is critical to prioritise; Significant percentage of rejects can be read simply by a second pass; After conducting an analysis of your reject items, consider what can be
done prior to sorting for those difficult categories, i.e. fix it before you put it on the sorter (maybe re-labelling);
Consider an upgrade to older identification / reading systems; Review the original specifications of existing automation…maybe your
mail mix or operation of the machine differs from original design parameters
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Final thoughts
100% sorting efficiency is achievable, in ways that minimise re-work and costs;
Identifying dependencies for your sorting/automation process enables you to mitigate risks;
Ensure mission-critical elements are duplicated (servers, data lines)
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Mark A. RyderDirector: Marketing & Key Accounts
100% SORTING: REMOVING BARRIERS
Thanks for your attention!