# Presentation: 946586

## FSS System Overview

**FSS System Overview**

**PCC Workshop-in-a-Box**
**Module 2**

**Notes:**
Presenter notes:  This module describes the FSS functionality and operating strategy and can be easily removed if not geared toward the target audience or if time does not allow. 
Now I’ll describe the FSS machine process and how the mail flows through the system.
What’s important to understand is the FSS machine is equipped with a self-contained staging and material handling system; at the end of pass-one sorting an automatic sweep occurs and all trays are returned to the feed area in correct order for immediate pass-two sequencing.  At the end of the run, mail is automatically swept, placed into street trays, and discharged onto mail transport equipment that will be dispatched to the dock, and ultimately loaded onto trucks destined for the delivery units. 
Let’s take a look at the flow...

## Stand-Alone Mail Prep Overview

**Stand-Alone Mail Prep Overview**

**Dolly**

**ACTs**

**Notes:**
Stand-alone Mail Prep is the point of entry for FSS mail.
Flat mail bundles in containers are loaded into the Mail Prep Subsystem, the Bundle Distribution Conveyor transports the singulated bundles to the mail prep stations, where, the operator prepares the mail by removing the polywrapping and strapping materials from the bundles and orients the flats and places them into Automation Compatible Trays, or ACTs, (Spine down, address up) 
Once filled, each ACT is conveyed to a Dolly Maker which automatically stacks full ACTs on dollies which are staged for later processing
This is the last time the mail is touched until received by the Carrier.

## Dolly Induct Process

**ACTs**

**Dolly**

**Dolly Induct**

**Dolly Induct Process**

**In-Feed Line**

**Notes:**
Dollies of prepped mail from the Stand-alone Mail Prep system are inducted into the FSS system by loading them into the Dolly Induct docking station. 
At the Dolly Induct, the full ACTs are removed from the dolly, then inducted into the system for the first pass of the sortation process. 
Automated material handling equipment consisting of conveyors and lifts transport ACTs to the automatic induction (ai) feeders at each of four input lines. 

## Infeed Line: Automated Feeder

**Infeed Line: Automated Feeder**

**Automated Feeder**

_**Infeed Line Facts:**_
-  2 Infeed Lines per machine
-  2 Feeders per Infeed Line
-  3 Flats per Second per Feeder
-  6 Flats per Second per Infeed
-  12 Flats per second total

**Notes:**
The feeders on the input lines incorporate automatic induction and automatic stack correction.
Two operators are assigned to the four infeed lines and can control both of their feed stations from either location.

## Infeed Line Functionality

**Infeed Line Functionality**

**Image Acquisition Module**

**Labeler**
**Printer**
**Verifier**

**6 piece per second processing rate**
**OCR / VCS System**

**Notes:**
The input line transports the singulated flat mailpieces past the Image Acquisition Module at a rate of 6 pieces per second. Here, each flat mailpiece is scanned and read to determine its appropriate sort destination. 
The Optical Character Recognition system incorporates the latest Siemens OCR/VCS technology to resolve address and barcode information on each mailpiece. This system also sorts the flat mail to the correct walk sequence delivery point.
The Flats Labeling Module, based on technology developed for the AFSM100 Flats Identification Code Sort, applies a label to the mailpiece and sprays the appropriate ID tag on only those flat mailpieces that do not contain a valid 11-digit barcode. 

## TOP 2000 Sorter

-  2 levels, 2 sides
-  360 bins
-  Automated empty tray supply
-  Automated tray exchange
-  Automated full tray takeaway

**TOP 2000 Sorter**

_**Rigid Captive Tray (RCT)**_
-  Improves stack quality
-  Maintains mail sequence
-  Used within FSS only
** **

**Notes:**
Once past the Flats Labeling Module, the input line injects the mail into a mini-carousel, which is part of the Flats Sorting Machine subsystem, from the subsystem the mail is transferred to a moving bucket attached to a carousel motorized chain within the flats sorting machine which then discharges the mail pieces from the motorized chain buckets into the designated output trays.

The output trays are called Rigid Captive Trays (RCTs), and are located on two levels and two sides of the FSM. 

## Tray Staging

_**Tray Staging used between passes**_
-  Pass 1 to Pass 2
-  Pass 2 to Dispatch

**Tray Staging**

_**Staging Capacity**_
-  768 Staging locations
-  360 Full Tray Accumulation Line

**Notes:**
Tray Staging is used between passes
 Pass 1 to Pass 2
 Pass 2 to Dispatch
Staging Capacity is: 768 Staging locations and 360 locations on the Full Tray Accumulation Line for a total capacity of 1128.
When Pass 1 is complete, the trays are swept from the machine to the Tray Staging Subsystem.
The Tray Staging Subsystem stages the full trays until the beginning of Pass 2.
The Tray Handling Subsystem manages the tray transport and sequencing between the two passes and also processes the mail for dispatch.
When mail that has completed Pass 1 sorting is ready to begin Pass 2 sorting, the RCTs move from the Automated Tray Management System to the Integrated Tray Converter.
During Pass 2, as trays fill up with sequenced mail, they are ejected from the machine and transported to the staging area once more. 

## Integrated Tray Converter

- Integrated Tray
- Converter (ITC)

- 1st Pass Mail
- In RCTs

**Automating Second Pass Feeding**

**Integrated Tray Converter**

**Notes:**
Automated 2nd pass is accomplished by 1st pass RCTs conveyed from Tray Staging to ITC and converted to ACTs. 

ACTs are then conveyed back to Auto Induction for 2nd Pass.

At the same time, empty RCTs are conveyed back to the Sorter Carousel.

## Integrated Tray Convert

- Integrated Tray
- Converter (ITC)

- Sequenced Mail
- In Rigid Trays

**Verticalizing Flats for Dispatch**

**Integrated Tray Convert**

**Notes:**
Dispatch is accomplished by conveying 2nd Pass RCTs, of sequenced mail, from Tray Staging to ITC where the carrier mail is removed from the RCTs, and placed  vertically into street trays with the bindings to the right.

A labeler prints and applies a human readable dispatch label to the Street Tray. Street Trays are then conveyed and automatically loaded onto CASTR carts.

At the same time, empty RCTs are again conveyed back to the Sorter Carousel

## Tray Labeling and Container Loading

**Street Trays are loaded automatically into rolling carts**

**Carrier Automated Street Tray Rack (CASTR)**

**Tray Labeling and Container Loading**

**Notes:**
Labeled Street Trays are automatically loaded on to CASTR carts.

CASTR carts are then removed from the system.

When removed , a CASTR manifest is printed and inserted on the CASTR cart...the final product!

## 17 Hour Run Day (Operating Window)
280,500 Sequenced Pieces Per Day Per Machine
1st and 2nd Pass are Run Consecutively
Each Zone Will be Run Once a Day
One Dispatch Per Day Per Zone (other than FCM)
FCM May Not be in DPS based on FSS Operating Window and Mail Availability

**280,500 Sequenced Pieces Per Day Per Machine**
**1st and 2nd Pass are Run Consecutively**
**Each Zone Will be Run Once a Day**
**One Dispatch Per Day Per Zone (other than FCM)**
- FCM May Not be in DPS based on FSS Operating Window and Mail Availability

**FSS Processing Strategy**

**Notes:**
FSS sequencing operations will begin early in the operating day – each FSS machine will sequence mail for approximately 17 hours on an average day.  This translate to about 280,500 sequenced flats per day, per machine. 
The FSS two-pass process is different from our DBCS letter two-pass process.  With FSS, the first and second pass are run consecutively and each zone will only be run once per day, and the expectation is one dispatch per zone per day, other than FCM.
Each machine can serve 40 to 50 carrier-routes per run.
FSS is principally targeting Standard and Periodical mail.
Depending on the window and mail availability, FCM may not be in DPS.

## Questions

**Notes:**
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