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®
Northern New Jersey
FSS Optimization
Lean Six Sigma
May 15, 2009
®
NNJ FSS Optimization
Lean Six Sigma
Flat Distribution Plan
Define Phase
NNJ LSS FSS Optimization
Define Phase – Action Items
Goal Statement (SMART – Specific Measurable Achievable Relevant Timely):
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)
NNJ LSS FSS Optimization
USPS Flats Guiding Principles
1. Always run the committed mail first, then balance the planned run time
volume with uncommitted mail
USPS Flats Guiding Principles
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 ?
USPS Flats Guiding Principles
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
NNJ LSS FSS Optimization
DVD STD Flats Current Process Flow Chart
SUPPLIER PROCESS OUTPUT
5 Digit Sacks
Dispatch
5 digit CR
bundles
Dispatch
3 & 5 digit
Pallets
3 digit sacks
3 digit bundles
Mailers UFSM1000
AFSM 145
APPS STD HSTS & Manual
Prime
5 digit sacks
machineable
5 digit sacks HSUS
5 digit non- CR
non-
bundles
machineable
Delivery
3 digit sacks
shakeout
3 digit sacks
NJ BMC
5 digit sacks Newark
AFSM 146 AFSM100
STD 146 STD
SPBS STD
5 digit bundles
5 digit sacks
DVD zones
5 digit sacks
NWK zones
5 digit non-
machineable bundles Dispatch
5 digit CR
Dispatch
bundles
NNJ LSS FSS Optimization
DVD 2C Flats Current Process Flow Chart
SUPPLIER PROCESS OUTPUT
5 Digit Sacks Dispatch
5 digit non CR
bundles Dispatch
5 digit CR Dispatch
bundles
3 & 5 digit
Pallets
3 digit sacks
Mailers UFSM1000
APPS 2C 3 digit bundles AFSM MMP MMP
5 digit sacks
5 Digit sacks CR
machineable
& non CR
5 digit sacks
non-
machineable
Broken bunles Delivery
HSUS
Machineable
Broken bundles Non
3 Digit bundles
Machineable
AFSM 146
FCM
Manual
Cases 2C
(desitnating)
07099 working tubs
L009 Sites
(machineable flats)
Dispatch
Dispatch
NNJ LSS FSS Optimization
Other NNJ Plants Current Process Flow Chart
SUPPLIER PROCESS OUTPUT
UFSM1000
& Manual
NNJ Metro NNJ Metro
SPBS AFSM 146
UFSM1000
& Manual
Mailers
Kilmer
Kilmer SPBS
AFSM 146
Delivery
DVD
UFSM1000
& Manual
West Jersey West Jersey
SPBS AFSM 146
NNJ LSS FSS Optimization
NNJ Current Distribution Profile (APPS, SPBS, AFSM, UFSM)
NNJ LSS FSS Optimization
NNJ Current Flat Distribution Profile (STD Runs)
Standard Bundle Runs
NNJ LSS FSS Optimization
NJI BMC Current Flat Distribution Profile
NNJ LSS FSS Optimization
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
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