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附件2:外文原文
FRANCE
SEMI AUTOMATIC PREPARATION OF COLLECTION MAIL FOR FACER CANCELER
M. Didier Thieriot
La Poste
M. Laurent Baufreton
La Poste
Abstract Letter mail preparation is one of the last operations which is still done chiefly manually in France.
A study carried out on different scenarii of automation shows the need for less expensive, slower machines besides the traditional CFCs, that can be used in the major sorting centres. The main objective was to organise the tasks involved, which are today the weak link in the preparation process, where operatives work with large tables and rudimentary equipment.
To segregate and stack the mail, La Poste has chosen a semi-automatic device used in conjunction with the NEC Facer-Canceller (FC) machine. This device, named ‘APEC’, is located upstream of the facer-canceller-sorter machine.
The system helps the operatives to cull and stack the mail upstream of the automatic preparation of machinable mail.
This presentation describes the functions and performance of this equipment.
Introduction Context
In the year 1998, La Poste bought 11 NEC Facer Cancellers to prepare the mail collected from post boxes in sorting centres. These machines require at the input a stack of mail whose maximum size is C5 format and from which the thick mail items have been removed.
Currently, the mail collected from post boxes must be processed manually. This mail is composed of letters, flats, and non-machinable letters. Flats and non-machinable letters are about 8% of the total.
The manual operations principally consist of culling the flats and thick letters from the bulk mail flow, and then stacking letters for FC processing. This operation requires no special equipment, only a large table and some trays. The disadvantages of the present organisation are its low profitability and the fact that it is a non-industrialised process.
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Objective
La Poste has started work on a dedicated organisational structure to improve procedures in this part of the mail preparation unit. he target is to qualify and then to deploy the industrial organisation of work upstream of the 11 NEC Facer Cancellers.
Functional description
Process
The main thrust of development for the mechanisation of the mail preparation area equipped with NEC FCs is the following:
? Industrialisation of the mail preparation tasks
? Restructuring of the work area
? Improving the productivity of the work area
The functional analysis which we carried out gave the following breakdown of the tasks (Figure 1).
Post box mail reception
Flats storage
Culling
letter flow stabilisation
Stacking
Special letter storage
Non-machinable mail storage
Machinable letter storage (when FC stops)
NEC FC Feeding
Figure 1
Mail Preparation Breakdown
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The number of separations to be carried out on the mail, together with the morphological variety of the mail, means that a technical solution capable of coping with all situations would be both complex and expensive.
For these reasons it was decided to retain manual culling for its adaptability to the peculiarities of post box mail, and a comfortable seated workstation was designed with particular care to meet this need.
Mechanisation has mainly been applied to the function of stacking, and was developed by means of simple technical solutions in order to limit the costs of procurement and maintenance.
Technical description
? Floor space required for an APEC with 2 input stations: 5m80 x 4m70 (not including the FC)
? Mains supply: 220Volts / 16 Amperes
? Throughput of one culling station with 8 % of flats (without bulk loading):
14,000 letters / hour
? Throughput of the stacking module: 30,000 letters / hour
? Capacity of stacker upstream of NEC FC: 2m (approximately 1,600 letters)
NEC FC
Stacking module
Stabilising module
Tray for special letters
Feeding station
Culling station
Flats reject
Figure 2
APEC Machine
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APEC project in mail centre
The APEC has been installed and operating since November 2002.
The hoppers are fed by tipping the contents of the mail collection trays.
It was noted that the segregation operatives quickly got used to the device and appreciated the seated work position. The feed control, by means of a foot pedal, allows them to control the mail stream as it is unloaded onto the segregation belt. This is a wide, slow-moving belt, and the operatives have the possibility of stopping it, with a second foot pedal, to avoid any overflow. The mechanised mail is conveyed through the culling station without any action on the part of the operative.
Flats are cleared at the front in trays placed on a rolling conveyor. The full trays are pushed by the operative and collected manually in a structure placed at one end of the conveyor. The operative then replaces them with empty trays. A tactile check allows any thick object or object containing morphological peculiarities to be identified.
Mechanised mail is tipped onto a belt which receives the mail stream of both segregation input stations. This flow is fed through a small hopper and falls randomly onto a moving inclined belt. The action of this belt stands all the letters on their longer edge. They are then stacked and stored in a 2-meter moving stacker, which offers up the mail to the feeder of the NEC FC.
Installation
The APEC is easy to install because it supports a variety of configurations. It can therefore be adapted to the layout of the premises and the input stations and the flats output can be positioned to fit in with the existing mail stream.
The noise level of the APEC is lower than 68 dBA. It is powered by 240V at
16A and does not require any other power source.
Project management
La Poste built a prototype (Figure 3) equipped with a single input station. Following the encouraging results of the trials carried out, the equipment was installed in the Nantes sorting centre to qualify the performance of each of the functions in real conditions of operation. The APEC system was tested using real mail items.
The project was tendered to several suppliers, and the FIMEC company was chosen to build the first APEC ahead of series production. The device was installed in the Nantes sorting centre, with two input culling stations, in order to validate the design for industrial production.
The rest of the equipment will be installed after the validation of the first
APEC.
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Figure 3
Prototype APEC
FRANCE
The first trials showed there was a quality deficiency in the creation of the stack. The origin of this defect was identified with the increase of the stream.
La Poste and FIMEC have made modifications to achieve the target performance in throughput and in the quality of the stack. These are currently under observation and will be included by FIMEC in their series production. The validation of the correct operational procedure will be carried out at the beginning of June.
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Savings We propose to compare the profitability of 2 types of mail preparation area, depending on the proportion of flats and non-machinable letters. We studied the bulk mail flow from post boxes, in which there is no mail neatly stacked in trays, at the entry point of the mail preparation area.
1. APEC device coupled with a Facer-Canceller: The unit cost in series production of one APEC with 2 culling stations is lower than 60,000 euros.
2. Culler-Facer-Canceller machine: The unit cost in series production of the culling section is estimated at 180,000 euros
.
Number of work stations on the equipment:
number of operatives for APEC + FC number of operatives for CFC
2 : segregation stations
1 : bulk mail feeding and feeder module
1 : stackers
2 or 3: rejected mail processing, according to the proportion of flats and non- mechanised mail
1 or 2: bulk mail feeding, according to the proportion of flats and non-mechanised mail
1 :stackers
2 or 3:rejected mail processing, according to
the proportion of flats and non-mechanised mail
Throughput characteristics:
APEC + FC CFC
The throughput of the Facer Canceller is
30,000 letters per hour, always higher than the APEC; APEC is the weak link in the system from the point of view of throughput.
The throughput of the APEC is up to 25,000 letters per hour. This throughput tends to decrease progressively, depending on the capacity of the culling operatives to eliminate manually the flats and non-mechanised mail as the proportion of these items rises.
The throughput of the CFC is up to 30,000 letters per hour. This throughput also decreases progressively, depending on the capacity of the culling section to eliminate automatically the flats and non-mechanised mail as the proportion of these items rises.
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Mechanised mail throughput
31000
letters per hours
29000
27000
25000
23000
21000
19000
17000
15000
0% 5% 10% 15% 20%
Flats and non-mechanised mail proportion
APEC_FC CFC
Figure 4
Proportion of Flats and Non-Mechanised Mail - Throughput
Profitability The APEC+FC solution is the more profitable when the proportion of flats and non-machinable mail is around an average of 10%. It is actually better because the culling operations are light, so the throughput is quite good. The high cost of an automatic culler is not justified.
The choice of automatic culling depends on the proportion of flats and non- machinable mail in the bulk mail flow and is financially justified when:
? either the proportion of non-machinable mail is very low: in this case, the throughput of the CFC is higher, the APEC’s throughput is limited by the simple technology to a maximum of 25,000 letters/hour,
? or the proportion of non-machinable mail is high: in this case, the throughput of the CFC becomes better than the APEC+FC.
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Profitability level
4.0
3.5
3.0
year
2.5
2.0
1.5
1.0
0.5
0.0
?
0% 5% 10% 15% 20%
Flats and non-mechanised mail proportion
APEC_FC CFC
Figure 5
Proportion of Flats and Non-Mechanised Mail – Profitability
Conclusion The APEC is a simple device. Manual segregation enables all atypical cases met in the letter-box mail flow to be processed. This solution offers a high degree of flexibility of adaptation to the variations in the mail stream: it is all the more effective since it is placed upstream of any mechanisation. The segregation operatives can rapidly master the skills required and this allows them to be polyvalent in a mail production unit where the tasks are very diversified.
The possibility of modifying the configuration of the APEC allows it to be adapted to the various layouts and the organisation of the mail stream at different sites.
Modifications can be made so that the flats separated at the segregation station are cancelled on-line.
Lastly, the moderate cost of investment and the high performances guarantee the early profitability of the APEC.
Glossary
APEC:
special equipment designed by La Poste to prepare the mail
CFC:
upstream of a Facer Canceller machine
Culler-Facer-Canceller machine
FC:
Facer-Canceller machine
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