Northern New Jersey FSS Optimization Lean Six Sigma

®

Northern New Jersey FSS Optimization

Lean Six SigmaLean Six Sigma

May 15, 2009

®

NNJ FSS Optimization Lean Six Sigma

Flat Distribution Plan

Define Phase

NNJ LSS FSS OptimizationDefine Phase – Action Items

Goal Statement (SMART – SSpecific MMeasurable AAchievable RRelevant TTimely):

Align DVD, NNJ Metro, Kilmer, West Jersey, and Newark Flat distribution to maximize the flow of machineable flats to FSS and thus achieving the highest FSS % (85% initially). Goal also includes eliminating APPS rejects at both NJI-BMC and at DVD.

Baseline 0% FSS. Goal is 80 % FSS or higher.

Eliminate DVD APPS Rejects.

Eliminate NJ-BMC APPS Rejects.

Project Goal Measured by:

1. FSS %

2. 146 volume %

3. Carrier Cased volume

Project Scope:

All NNJ plants (DVD, NNJ Metro, Kilmer, West Jersey, and Newark)

USPS Flats Guiding Principles

1. Always run the committed mail first, then balance the planned run time volume with uncommitted mail

a. Deliver on-time, every time

b. Keep classes segregated until carrier route or DPS

2. FSS schedule drives preceding schedules (align & synchronize using pull system methodology)

3. Maximize automation of Flat Operations End-to-End (Arrival at acceptance unit to delivery at DU)

4. Mail is always sorted to the finest depth of sort

a. Only ship 100% finalized product to downstream operations

5. 100% adherence to dispatch of value (DOV) and clearance times (CTs)

6. Adhere to labeling, placarding, & color coding procedures

7. Transportation

a. Adhere to flats operating plan schedules

NNJ LSS FSS Optimization




Aligning APPS/SPBS/AFSM & FSS Processes

What Needs to be Done to Align the Processes ?

1. Eliminate rejects– all bundles flowing from APPS must be finalized to the finest depth of sort.

2. Minimize the flow of loose pieces from APPS due to broken bundles

3. Align Flats Distribution

Alignment across all NNJ facilities Improve flow, transport, and processing time Eliminate missing FSS processing times

®

NNJ FSS Optimization Lean Six Sigma

Flat Distribution Plan

Measure Phase


DVD STD Flats Current Process Flow Chart

3 & 5 digit Pallets

3 digit sacks

5 digit sacks machineable

5 digit sacks non-

machineable

3 digit sacks

5 digit sacks

HSUS

APPS STD

SPBS STD

AFSM 145 Prime

AFSM 146 STD

Delivery

3 digit bundles

5 Digit Sacks

Mailers

NJ BMC

HSTS

SUPPLIER PROCESS

Dispatch

3 di

git s

acks

sh

akeo

ut 5 di

git n

on- C

R

bund

les

5 digit CR bundles

Dispatch

Newark AFSM100 146 STD

5 digit bundles

Dispatch

Dispatch

UFSM1000 & Manual

OUTPUT

5 digit sacks DVD zones

5 digit sacks NWK zones

5 digit non-machineable bundles

5 digit CR bundles


DVD 2C Flats Current Process Flow Chart

3 & 5 digit Pallets

3 digit sacks

5 digit sacks machineable

5 digit sacks non-

machineable

HSUS

APPS 2C AFSM MMP

AFSM 146 FCM

Delivery

Mailers

SUPPLIER PROCESS

Dispatch

Dispatch

UFSM1000 MMP

OUTPUT

5 Digit Sacks

Dispatch5 digit CR bundles

3 digit bundles

Dispatch5 digit non CR

bundles

5 D

igit

sack

s C

R

& n

on C

R

3 D

igit

bund

les

Dispatch

Broken bunles Machineable

Bro

ken

bund

les

Non

M

achi

neab

le

L009 Sites

Manual Cases 2C

(desitnating)

07099 working tubs (machineable flats)


Other NNJ Plants Current Process Flow Chart

NNJ Metro SPBS

NNJ Metro AFSM 146

Delivery

Mailers

DVD

SUPPLIER PROCESS OUTPUT

West Jersey SPBS

Kilmer SPBSKilmer

AFSM 146

West Jersey AFSM 146

UFSM1000 & Manual

UFSM1000 & Manual

UFSM1000 & Manual


NNJ Current Distribution Profile (APPS, SPBS, AFSM, UFSM)


NNJ Current Flat Distribution Profile (STD Runs)

Standard Bundle Runs


NJI BMC Current Flat Distribution Profile


Data Collection Goals:

Data Collection Goals:

•Identify a drop shipment arrival profile at all NNJ Plants and at the NJ-BMC(STD and PER)

•Pieces at risk at the APPS at DVD and NJ-BMC

Northern New Jersey FSS Optimization Lean Six Sigma

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