Smalls Lineup Optimizer
A tool for hub planners to optimize the placement and quantity of Smalls destinations based on volume trends by day of week.
Context
The S.M.A.R.T. facility utilizes 5 single-line sorters (SLS) to process Small packages, which can mean up to 550 unique bag destinations (or cities). The volume amongst these destinations vary from heavy to light flow. At least once a month, hub planners will optimize the SLS lineup so that heavy destinations are close to the bag tag printers (purple lines in the document) and light destinations are farther away. This process can be time-consuming given the sheer quantity of destinations to consider.
Action
This tool allows hub planners to sort destinations from highest to lowest volume and add more quantities of destinations based on flow per hour. The most useful aspect of this tool is that the planner can visually see the volume distribution as they are entering in destinations. This way, adjustments to the lineup can be made immediately as discrepancies are seen.
Result
Optimizing the SLS lineup became a much quicker and more intuitive task for hub planners. Especially given volume changes by day of week where multiple lineups need to be optimized, it allows the planner a swift way to look at volume distributions and plan accordingly.
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. |