Incompatibles Distribution Tool
A tool for operators to optimize the quantity and placement of Incompatible carts, utilizing the distribution of packages for a given day.
Context
Incompatibles are scanned and sorted at depots onto carts. These carts are designated to go to a specific outbound area (PD) to be loaded into a trailer. The distribution of packages per cart is different for each PD, so some PDs need more carts designated to them than others. Because of these flow discrepancies, these patterns need to be tracked and manipulated to the supervisor’s advantage, so that they are able to properly plan staffing.
Action
The tool utilizes daily Incompatible volume to visually represent the flow and distribution by Incompatibles (IR) depot. Operators can enter in PD numbers to represent carts and see the flow of volume, given the positioning and quantity of carts per PD. It also color-codes high and low volume (initially a volume bar that changes in size) to indicate a need for more or less carts for a given PD.
Result
Operators have a planning tool for their use to optimize the cart layout for Incompatibles by IR depot. As flows change by day and by month, Operations supervisors utilize this tool to plan staffing as well, especially if some IR depots receive more volume than others.
General UPS Context
Packages are processed through the facility in one of three main processes, based on the type of package: Cube, Small, and Incompatible.
| Package Type | Specifications | Process |
|---|---|---|
| Cube | - Larger than 16” x 16” x 7” (shoebox) but smaller than 5’ - Weight is below 70 lbs - Conveyable on automated belts without causing issues (e.g. jams) - Can be handled by a person with normal strength under normal conditions |
- Cube packages get processed using the automated belt system. - Each package is scanned through a camera tunnel and sorted based on the label to the correct outbound trailer. |
| Small | - Smaller than 16” x 16” x 7” (shoebox) - Weight is below 10 lbs - Small, thin envelopes |
- Because of its size, Small packages get processed at first through the automated belt system (in a tote or bag), then through the Smalls automated belt system, where the packages will be removed from any container then sorted into a bag. - The bag is then put into an outbound trailer in the automated belt system again. - The S.M.A.R.T. facility has five single-line sorters (SLS) to process Small packages. One SLS contains up to 110 bins, which means our sort can create bags for up to 550 unique destinations (which are typically specific cities across the U.S.). |
| Incompatible | - Larger than 5’ - Weight is over 70 lbs - Includes shapes incompatible with the belt system, such as tires, cylindrical packages, and flat envelopes |
- Incompatibles are named as such due to the incompatibility with the automated belt system that processes Cube packages (due to size, shape, weight). - These packages are taken to an Incompatible Depot, where employees scan and sort these packages onto carts. - These carts are then put onto trains for an Autonomous Guided Vehicle (AGV) to take to the correct part of the building. - Then, these carts are unloaded onto a belt, where an employee scans each package into the correct outbound trailer. |