Flats Container Development Work Group

Flats Container Development Work Group Meeting Notes: March 28, 2003 – Fort Myers, FL

The MTAC Flats Container Development Work Group met at the USPS Processing & Distribution Center in Fort Myers, FL on March 28. The meeting was scheduled to coincide with a live mail test using postal supplied trays (black and/or blue tray concept developed by USPS).

The test had been delayed because it was being based on the utilization of a newly implemented 5-digit automated scheme for flats. We had hoped to be able to perform the test in February, but delays in the updating of software pushed it back more than a month. Assumptions had been made that by utilizing the schemes more mail volume would be created to the sort and would facilitate the creation of full (or more full) trays. That did not happen.

The assumptions proved to be incorrect, and the volumes needed to fill the trays (a goal of our group in any new design) did not materialize. As a result, the only mail that was submitted for the test came from Quebecor World who supplemented the 5-digit scheme mail in trays with carrier route presort.

Observations made: difficult to generate enough mail to fill the trays; saddle stitch books create problems related to uniform thickness of piece; filling tray (manually or automated) will either create labor-related issues or cost associated with development of automated process; and depending on the number of trays created for a pallet, problems with associated with leveling of pallets need to be resolved.

We also questioned the Postal Service on general issues related to the 5-digit schemes: Are the lists correct? (correct zips, more added, some deleted, etc.) With the list being comprised six months earlier, how many changes would have taken place and how will the updates and changes be managed? And as mentioned earlier, will there be enough mail created within a scheme to ever fill the trays?

The answer to the last question in our opinion would only be if and when the Postal Service ever moves to FSS (Flats Sequencing System) or DPP (Delivery point Packaging).

It was decided that we would not pursue another test until we could determine a facility that would produce enough mail volume in a 5-digit scheme to fill the trays. Analysis would have to be conducted by the USPS and mailers.

Roger Bilodeau, Muller Martini, gave a presentation and showed a video of a new stacker that had been developed. The interesting aspect, which the Postal Service was very interested in, is that the stacker has the ability to create much larger packages than current stackers on binding lines. That’s the good news. The bad news is that like we have Page 2 – Meeting Notes

encountered before, the key to being able to utilize the ability to created larger packages is having enough mail volume for that zip or zips. That would entail changing the presort parameters and requirements…not part of our group’s focus. This observation has been communicated to another MTAC work group (Flat Mail Preparation Optimization), whose focus is presort and/or preparation changes related to flats.

It was decided that we would try and coordinate the next meeting of our work group with a demonstration of the new stacking equipment at Muller Martini’s facilities in Bethlehem, PA.

The Postal Service also discussed a new accordion/collapsible style flat tub that could have multiple uses internally, but is still in the very early stage of development. A date for the next meeting was not set at this time, but we are targeting some time in May or June.