Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators...
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Transcript of Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators...
![Page 1: Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators MPEWatch WebEOR DCS –Test Deck Results –Quality of Product.](https://reader035.fdocuments.in/reader035/viewer/2022062314/56649cf05503460f949bf166/html5/thumbnails/1.jpg)
Out of Sequence
Case Study
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OOS Case StudyEquipment Performance Focus
– Machine Indicators• MPEWatch• WebEOR• DCS
– Test Deck Results– Quality of Product
Process Improvement Recommendations
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MPE Watch
Daily Reports Archive
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MPE Watch
DPS Summary
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MPE Watch
Sunday night / Monday Morning
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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.
![Page 7: Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators MPEWatch WebEOR DCS –Test Deck Results –Quality of Product.](https://reader035.fdocuments.in/reader035/viewer/2022062314/56649cf05503460f949bf166/html5/thumbnails/7.jpg)
MPE Watch – DPS Summary – DBCS #5More out of sequence
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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.
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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?
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webEOR
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webEOR
EOR Viewer
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webEOR
NHO PDC DBCS #5
First Pass (2)
Second Pass (3)
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webEOR –DPS 2nd Pass
Total Fed: 7788
Stops: 30
Stacker Full: 1
OOS: 259
OOS %: 3.3%
(12 times the target!)
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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
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Data from the DCS – DPS 2nd PassSequence Tray #
Should be 1,2,3,4,5, etc. Stacker #
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Data from the DCS – DPS 2nd Pass
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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
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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
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OOS – DPS 2nd Pass Tray 9 followed by Tray 16
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OOS – DPS 2nd Pass Tray 18 followed by Tray 14
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OOS – DPS 2nd Pass Tray 16 followed by Tray 12
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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.
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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
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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)
![Page 25: Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators MPEWatch WebEOR DCS –Test Deck Results –Quality of Product.](https://reader035.fdocuments.in/reader035/viewer/2022062314/56649cf05503460f949bf166/html5/thumbnails/25.jpg)
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
![Page 26: Out of Sequence Case Study. OOS Case Study Equipment Performance Focus –Machine Indicators MPEWatch WebEOR DCS –Test Deck Results –Quality of Product.](https://reader035.fdocuments.in/reader035/viewer/2022062314/56649cf05503460f949bf166/html5/thumbnails/26.jpg)
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