Mail Sorting System With Individual Holders For Undecodeable Mail
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Solution Overview
Problem
Conventional mail sorting systems struggle to process mail pieces with addresses that cannot be decoded using OCR or bar code scanning, and those with physical characteristics that prevent machine sorting, leading to the need for manual sorting and merging, which is time-consuming.
Innovation Solution
A mail sorting system that loads mail pieces into individual holders, uses an automated conveyor system to reorder and sort them based on a predetermined scheme, and includes a control computer to manage the sorting process, allowing for the separation and reordering of mail pieces into subgroups and subsequent unloading into delivery trays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional automated sorting systems (OCR, bar code scanning) are used to sort mail, then machine sorting efficiency is improved, but mail pieces with undecodeable addresses or irregular physical characteristics cannot be sorted and require manual handling
Solution Approach 1:
The system segments mail handling into two distinct pathways: machine-sortable mail processed by conventional automated systems, and residual mail with undecodeable addresses or irregular characteristics routed to manual sorting stations. This segmentation allows each subsystem to operate optimally within its capability range while maintaining overall system efficiency.
Solution Approach 2:
The system introduces an intermediary classification stage that identifies and separates residual mail from machine-sortable mail. This intermediary process acts as a bridge between automated and manual sorting systems, ensuring that only appropriate mail types are directed to each processing mode.
2Adaptability or versatility
If manual casing is used to sort residual mail to delivery slots, then all mail types can be sorted, but the time required for casing and merging operations greatly slows down delivery
Solution Approach 1:
The system performs preliminary sorting of residual mail by carrier route before final delivery. Mail is pre-organized into carrier-specific groups at the sorting facility, so that during delivery, carriers only need to perform minimal final sorting rather than complete sorting from scratch, significantly reducing delivery time.
Solution Approach 2:
The system merges machine-sorted mail and manually sorted residual mail into unified carrier delivery groups. By coordinating the output of both sorting subsystems, the system consolidates mail streams so that carriers receive combined batches already organized by delivery route, eliminating the need for separate handling and merging operations during delivery.
3Adaptability or versatility
If carriers take mail from three separate stacks (letters, flats, manual mail) during delivery, then all mail types can be delivered, but the delivery process is greatly slowed down
Solution Approach 1:
The system reorganizes mail sorting to create a universal carrier delivery bundle that includes all mail types (letters, flats, and previously manual residual mail) in a single integrated stack organized by delivery route. This allows carriers to retrieve all their delivery mail from one consolidated source rather than accessing three separate stacks, significantly improving delivery efficiency while maintaining the ability to handle diverse mail types.
Data Source
AI summary
A method for sorting mail pieces includes the steps of loading mail pieces to be sorted into individual holders, sorting the holders using an automated system that stores and reorders the holders so that the holders are ordered according to a sort scheme for the mail pieces, storing the sorted holders in a storage area during sorting, and then unloading the mail pieces from the holders in order according to the sort scheme. The storage step occurs during sorting in the sense that a series of reordered holders is gradually created in one of a variety ways by the sorting process, and a storage area is provided for this purpose. Preferably the method further includes steps of unloading the sorted holders from the storage area and transporting the holders to an unloading station at which the unloading step is carried out.