Information
-
Patent Grant
-
6587806
-
Patent Number
6,587,806
-
Date Filed
Friday, December 29, 200023 years ago
-
Date Issued
Tuesday, July 1, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Chaclas; Angelo N.
- Malandra, Jr.; Charles R
-
CPC
-
US Classifications
Field of Search
US
- 702 128
- 700 216
- 700 231
- 700 236
- 700 237
- 705 29
- 705 34
- 705 39
- 209 584
- 209 900
- 271 314
- 271 401
-
International Classifications
-
Abstract
A system and method for estimating an amount of time required to complete a mail processing job. A control module receives and maintains real time data of quantity of mailpieces and time to sort the quantity of mailpieces during a first sort. A progress module processes the data to determine an estimated time to complete one or more second sorts of the mailpieces. Depending upon the estimated time of completion of the one or more sorts, the progress module advises an operator on whether to change the job schedule.
Description
BACKGROUND OF THE INVENTION
The invention relates to determining time of delivery of mailpieces. More particularly, the invention relates to a system and method for determining an amount of time required to complete a mail processing job.
Typical mailpiece sorting equipment incorporates a feeding mechanism for feeding mailpieces, a separating mechanism for separating the mailpieces from each other, a reading means for reading the information on the mailpieces, a mailpiece transport mechanism for transporting the mailpieces to compartments or bins, compartments or bins for receiving the mailpieces, and software for making choices regarding placement of the mailpieces into the compartments and a control device.
The operation of automated sorting equipment typically entails an operator placing an armload of mail that has been edge aligned onto the feeder portion of the system. The mailpieces are fed into the sorting system and sorted into bins or compartments. Often, when one or more bins become full, the sorting system stops, and the bins are emptied into a mail tray. From the mail tray, the mailpieces are sorted again, in which case the sorting apparatus is restarted and sorting continues.
Typically, mailpieces are sorted multiple times because there are fewer bins in a sorting system than delivery points (for example addresses). So, in a first sort (rough sort) each bin may represent all the mailpieces addressed to a particular neighborhood. In a second sort (fine sort), each bin may represent all of the mailpieces addressed to each street from one neighborhood. In a third sort, each bin may represent all of the mailpieces addressed to each street from another neighborhood. Delivery points will almost invariably outnumber the number of bins in the sorting apparatus, which forces at least a second pass (or sort). For example, a neighborhood having 50 addresses, 5 streets and 10 addresses per street, and a sorting system with 10 bins, cannot possibly sort mailpieces for each address in a single sort. To compensate for this, the sorting apparatus is programmed to have a first sort based upon the street where the addresses of the mailpieces are directed. Thus, bin 1 can collect mailpieces destined for the first street of the neighborhood. Bin 2 can collect mailpieces destined for the second street, while bins 3, 4, and 5 can collect mailpieces for streets 3, 4, and 5, respectively. Once the mailpieces have been sorted by street, the mailpieces from each bin (street) can be sorted a second time by address, where each bin now represents a particular address. This process is referred to as a “job” and each “job” and has its own sort scheme (e.g. several passes), as described above. Often a job has a specific time requirement where the mailpieces need to be sorted in time for pickup by a mail delivery truck. In these situations a job may be 30% through its first pass and the delivery truck will be showing up at any minute. If it is going to take 40 minutes to finish the first pass, then the delivery truck will have to wait or leave without any mailpieces, since the fine sorts have not been started. What is needed is a method and a system for estimating the amount of time required to complete a mail processing job so that sort schedules (jobs) can adjusted to meet schedules.
SUMMARY OF THE INVENTION
Deficiencies in the prior art are overcome, and an advance in the art is achieved with a system for estimating a time to sort mailpieces for a job. The system has a control module for receiving and maintaining real time data of a quantity of mailpieces and a time to sort the quantity of mailpieces during a first sort. It also has a progress module for estimating a time to complete one or more second sorts of the mailpieces, based upon the quantity of mailpieces and the time to sort the quantity of mailpieces during the first sort.
Operationally, the system measures a quantity of mailpieces and a time to sort the quantity of mailpieces during a first sort. It determines a time to complete one or more second sorts of the mailpieces, based upon the quantity and the time to sort the quantity of mailpieces during the first sort. Depending upon the estimated time of completion of the one or more sorts, the progress module advises an operator on whether to change the job schedule.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
presents a block diagram of a system in accord with the principles disclosed herein;
FIG. 2
presents a detailed diagram of control module of
FIG. 1
; and
FIG. 3
shows a flowchart of a process carried out in the system presented in FIG.
1
.
DETAILED DESCRIPTION
FIG. 1
shows components of a sorting system
102
, which incorporates a progress module
110
of the present invention. Sorting system
102
may generally have a control module
108
, a sorter module
106
, a feeder module
104
, and bin modules
112
.
FIG. 1
is an illustration of a 10 bin configuration. It should be realized that progress module
110
can be implemented in various types of sorting systems having various bins
112
, module configurations, and job requirements.
A job in the context of this illustration defines a series of sort schemes. Each sort scheme defines a relationship between delivery points of mailpieces, and final bin destinations defined for that particular sort. As mailpieces move through sorting system
102
, delivery points are determined and final bin destinations are evaluated based on the particular sort scheme being run. The first sort scheme is known as the rough sort, which breaks the sorting of the mail into logical groups of delivery points. Subsequent fine sorts can be run after the rough sort to further break these groups of delivery points into individual delivery points sorted to a bin. The job includes predefined job parameters, such as a time that an operator is expected to take to clear all of the mailpieces out of bins
112
, a time that the operator is expected to take to load sorting system
102
for the fine sorts, and a number of fine sorts (second passes) that must be performed to complete the job.
Control module
108
is a general-purpose computer having a processor, memory, counters, clocks, internal communications busses, a user interface such a mouse, keyboard and monitor, and a communications module for interacting with external modules. Also included in control module
108
is a number of software and hardware modules providing the functionality to control, communicate, and process information shared among the modules within sorting system
102
.
Referring to
FIG. 2
, control module
108
has a quantity counter
204
that is representative of a total quantity of mailpieces sorted during the sorting process. Every time a mailpiece passes through feeder module
104
, control module
108
receives a signal, from feeder module
104
, to update quantity counter
204
. Accordingly, as mailpieces are sorted through sorting system
102
, counter
204
is continuously updated.
Additionally, control module
108
includes bin counters
206
-
224
that represent real time quantities of mailpieces sorted to each bin
112
. Control module
108
receives a signal, from sorter module
106
, indicating that a mailpiece has been delivered to a particular bin. In response, control module
108
increases the appropriate bin counter
206
-
224
and stores the value in program memory.
Two clocks, a job clock
226
and an error clock
228
are included in control module
108
to track the run time and error time (down time) of sorting system
102
. When sorting system
102
starts sorting, control module
108
starts job clock
226
. Job clock
226
measures the time that sorting system
102
is running. Error clock
228
measures the time that sorting system
102
stops running during a job. Job and error clocks
226
-
228
toggle back and forth, depending upon whether sorting system
102
is running or not running. Control module
108
automatically starts job clock
226
when sorting system
102
starts the sorting process, and pauses job clock
226
when it receives, from sorter module
106
, a signal setting an error flag
230
to “error”. Control module
108
also has a clock
240
that represents actual time of the day. This clock is used to determine if the job is on schedule. Both error flag
230
and clock
240
are described in more detail below.
Error flag
230
, is set to “no-error” during normal running conditions of sorting system
102
, and is set to “error” when an error occurs in sorting system
102
. Sorter module
106
determines whether error flag
230
is set to “error” or “no-error”. When sorting system
102
starts running, error flag
230
is automatically set to “no-error” by control module
108
. If, during sorting, sorting system
102
encounters a failure or problem, sorter module
106
detects the failure or problem and sends an error signal to control module
108
. Control module
108
responds by setting error flag
230
to “error” and by switching sorting system
102
from running state to error state. This stops job clock
226
and starts error clock
228
. Control module
108
remains in error-state until it receives further signals indicating that the error has been cleared. Accordingly, while in error state, sorting system
102
stops sorting mailpieces. When control module
108
receives a signal from sorter module
106
setting the error flag to no-error, control module
108
stops error clock
228
, starts job clock
226
, and restarts sorting system
102
.
An operator clear time
234
, an operator load time
236
, and a number of fine sorts
238
are also included in control module
108
. Before an operator begins a job, job parameters are entered into control module
108
via the user interface. The parameters populate operator clear time
234
, operator load time
236
, and number of fine sorts
238
. These parameters are typically entered by a supervisor and are transparent to the operator of sorting system
102
. Alternatively, these parameters could be determined by the operator. For example, when an operator begins a job, using the user interface, he or she could enter a time that he or she expects to take to clear all of the mailpieces out of bins
112
. The operator could also enter a time that he or she expects to take to load sorting system
102
for the fine sorts. After the rough sort (first pass), the operator could enter the number of fine sorts (second passes) that must be performed to complete the job. This number would be determined by counting the number of bins
112
that have mailpieces.
Control module
108
also includes a job schedule
232
. t stores a time that a particular job is scheduled for completion. For example, if the job had to be complete by 10:00 AM for a mail truck pickup, then the operator would enter 10:00 AM into control module
108
, using the user interface.
Referring back to
FIG. 1
, sorter module
106
is generally responsible for monitoring the number of mailpieces delivered to each bin
112
, and monitoring sorting system
102
for errors. As mailpieces are delivered to each bin
112
, sorter module
106
sends a signal to control module
108
indicating that a particular bin
112
has received a mailpiece. Accordingly, control module
108
increments the appropriate bin counter
206
-
224
and, thus maintains a real time quantity of mailpieces per bin
112
. Sorter module
106
is coupled to numerous sensors located throughout sorting system
102
, which detect, for example, the quantity of mailpieces being sorted and the quantity of mailpieces, if any, delivered to each bin
112
.
More specifically, sorter module
106
monitors the transfer of mailpieces as they move through sorting system
102
to their bin destinations. As each mailpiece arrives at its bin
112
, they are detected by sensors and processed by sorter module
106
, which communicates to control module
108
, that a mailpiece has reached its destination and identifies which bin. As mentioned above, control module
108
keeps track of the quantity of mailpieces that have been sorted to their respective bins
112
. Accordingly, during the sorting process, bin counters
206
-
224
are updated in real time and their results are stored in program memory of control module
108
.
Another function of sorter module
106
is the monitoring of sorting system
102
for system failures or problems. If a failure or problem occurs in system
102
during sorting, sorter module
106
sends an error signal to control module
108
, which sets error flag
230
to “error”. As mentioned above, when an error signal is received by control module
108
, it pauses sorting system
102
, until further notification from sorter module
106
. When the error is cleared (e.g. sorting system
102
is repaired), sorter module
106
sends a “no-error” signal to control module
108
to clear the error state, so that control module
108
can restart sorting system
102
.
Feeder module
104
is responsible for feeding mailpieces into sorting system
102
. Included in feeder module
104
are sensors for detecting mailpieces that have begun the sorting process. Feeder module
104
processes sensor information and sends signals to control module
108
. The signals indicate to control module
108
that a mailpiece has begun the sorting process. In response to the signal, control module
108
increments quantity counter
204
, as described above. During the sorting process, signals are sent to control module
108
every time a mailpiece begins the sorting process. Accordingly, quantity counter
204
is updated in real time and, thus represents a running total of mailpieces being sorted. Quantity counter
204
continues to be incremented until the last mailpiece of the first pass of the job has been sorted. Until the last mailpiece begins the sorting process, sensors continually detect the quantity of mailpieces being sorted and feeder module
104
processes the sensors' information and communicates this information to control module
108
. At the time of completion of the first pass of the job, the quantity of mailpieces represents the total quantity of mailpieces for this particular job. Module
40
processes this information, where it is stored in memory of control module
108
.
Progress module
110
monitors the progress of a particular job being processed by sorting system
102
. During the sorting process, progress module accesses various counters
204
-
224
and clocks
226
-
228
, described above, for use in various computations that determine the progress of the current job. Advantageously, progress module
110
performs various real time calculations, such as an average amount of time sorting system
102
take to sort each individual mailpiece moving through the system, and of an average error time per mailpiece. Progress module
110
continuously polls counters
204
-
224
and clocks
226
-
228
so that the calculations represent the current status of the mailpieces being sorted by sorting system
102
. To illustrate the type of functions that may be employed by progress module
110
, consider the set of variables:
B1=Bin Counter 1
B2=Bin Counter 2
through to
B10=Bin Counter 10
Q=Quantity Counter
J=Job Clock
E=Error Clock
F=Number of Fine Sorts
Oc=Operator Clear Time
Ol=Operator Load Time
S=Job Schedule
These variables represent data entered by the supervisor, operator and/or data detected by the various modules, all of which are maintained by control module
108
, and are described in the above paragraphs. The following formula is used to determine the average time for a mailpiece to be processed by sorting system
102
for a particular job:
Average Time Per Mailpiece=Total Running Time/Total Number Of Mailpieces
Average Time Per Mailpiece=
J/Q
Q=Quantity Counter
J=Job Clock
Because the variables are continuously polled, this calculation will change, if either variable J or Q changes. Variable Q (quantity counter) is incremented every time a mailpieces begins the sorting process. Variable J will change from one polling cycle to another if there is an error with sorting system
102
and job clock
226
(variable J) is paused. During the sorting process, sorting system
102
may malfunction or jam, causing sorting system
102
to momentarily pause. If this occurs, the calculation of the average time per mailpiece will be skewed. To compensate for this possibility, progress module
110
provides the functionality to calculate an average error time per mailpiece. The following formula is provided to calculate an average error time per mailpiece:
Average Error Time Per Mailpiece=(Total Time In Error State)/(Total Quantity Of Mailpieces)
Average Error Time Per Mailpiece=
E/Q
E=Error Clock
Q=Quantity Counter
Thus, to determine the average time for a mailpiece to be sorted, while compensating for any temporary malfunctions or jams of sorting system
102
, the following formula is utilized by progress module
110
:
Total Time Per Mailpiece=(Average Time Per Mailpiece)+(Average Error Time Per Mailpiece)
Total Time Per Mailpiece=(
J/Q
)+(
E/Q
)
Progress module
110
continuously determines values for these functions in order to maintain a real time value of the total time for a mailpiece to be sorted. Knowing the total time for a mailpiece to be sorted, the quantity of mailpieces being sorted, and the job schedule, progress module
110
can calculate whether sorting system
102
will complete the job on schedule. Progress module
110
uses the following formula to determine the time to fine sort all mailpieces:
Time To Fine Sort All Mailpieces=Number Of Fine Sorts×(Operator Clear Time+Operator Load Time)+(Quantity Of Mailpieces×Total Time Per Mailpiece)
The result of the above formula provides the time to fine sort all mailpieces. This time is compared to job schedule
232
to determine whether sorting system
102
is on schedule to complete the job. Depending upon the results of this comparison, control module
108
presents, via the user interface, instructions to the operator. For example, if the results of the comparison are such that the time to fine sort all mailpieces is greater than the job schedule
232
, then control module
108
will present the operator with a message indicating that the rough sort (first pass) should be stopped and a fine sort (second pass) started.
The following discussion discloses an operational schema where sorting system
102
performs a particular job, and progress module
110
monitors the progress of the job to determine whether sorting system
102
is on schedule.
Referring to
FIG. 3
, at block
302
, an operator loads sorting system
102
with mail and enters a job schedule set for 10:00 AM into control module
108
, via the user interface. The job schedule time (10:00 AM) is stored in job schedule
232
of control module
108
. The supervisor enters a “job”, which populates operator clear time
234
and operator load time
236
. For the purposes of this illustrative embodiment, the operator clear time
234
is 60 seconds and the operator load time
236
is 30 seconds.
At block
304
, control module
108
automatically sets error flag
230
to no-error, job clock
226
to 0, error clock
228
to 0 and counters
204
-
224
to 0. In response to the operators commands in block
302
, control module
108
sets the operator clear time
234
to 60 seconds and the operator load time
236
to 30 seconds. Progress module
110
reads the data stored in job schedule
232
, operator clear time
234
, operator load time
236
, for use in the calculations discussed below.
At block
306
, using the user interface, the operator starts the sorting process, which starts job clock
226
. Once the system is started, sorter module
106
monitors the number of mailpieces delivered to each bin
112
and monitors sorting system
102
for errors. Every time that a mailpiece is delivered to a bin
112
, sorter module
106
sends a signal to control module
108
indicating that a particular bin
112
has received a mailpiece. Control module
108
reacts by incrementing the appropriate bin counter
206
-
224
. This process continues until every mailpiece has been delivered to its appropriate bin
112
, or until control module
108
determines that the job will not be met on time, at which time control module
108
advises the operator to stop the rough sort (first pass) and start the fine sort (second pass) to meet the job schedule. For the purpose of this illustration, before the completion of the first sort (rough sort), sorting system
102
yields the following mailpiece sort:
|
Bin 1
100 mailpieces
|
Bin 2
200 mailpieces
|
Bin 3
no mailpieces
|
Bin 4
300 mailpieces
|
Bin 5
no mailpieces
|
Bin 6
100 mailpieces
|
Bin 7
no mailpieces
|
Bin 8
100 mailpieces
|
Bin 9
100 mailpieces
|
Bin 10
100 mailpieces
|
|
Concurrently, as the bin counters
206
-
224
are being updated, feeder module
104
is detecting the number of mailpieces being sent through sorting system
102
. Additionally, feeder module
104
sends a signal to control module
108
, which increments quantity counter
204
. Moreover, sorter module
106
monitors sorting system
102
for errors. Errors can be for example paper jams, or equipment failure. If sorter module
106
detects an error, the module sends an error signal to control module
108
indicating that an error occurred. Control module
108
reacts by setting error flag
230
to error, starting error clock
228
, stopping job clock
226
, and pausing sorting system
102
.
Continuing from the above illustration, during the sorting process a mailpiece got jammed in feeder module
104
and sorter module
106
reacted by sending an error signal to control module
108
, which resulted is a stoppage of sorting system
102
. Typically, under this circumstance, the operator removes the jammed mailpiece. While the operator is working on removing the mailpiece, error clock
228
is timing the “down time” of sorting system
102
. Accordingly, job clock
226
is pause so that job clock
226
does not represent any “down time”.
To continue with this illustration, if it took the operator
120
seconds to clear the jam and restart sorting system
102
, then the error clock
226
would have a value equal to 120 seconds. Additionally, the error flag
230
would be reset to no-error, and the job clock
226
would continue from the time that it left off at when sorting system
102
was paused.
Continuing with the illustration, quantity counter
204
is 1000 mailpieces, job clock
226
is 900 seconds, job schedule
232
is 10:00 AM, operator clear time
234
is 60 seconds, operator load time
236
is 30 seconds, and bin counter 1 through bin counter 10 have the values shown above.
At block
308
, progress module
110
reads each of the counters
204
-
224
, clocks
226
-
228
, job schedule
232
, and operator clear time
234
, operator load time
236
, in control module
108
.
At block
310
progress module
110
performs calculations to determine whether the job is on schedule, or whether the rough sort (first pass) of the job should shortened or changed to meet job schedule
232
. The data read in block
308
is applied to the following formulas:
Average Time Per Mailpiece=
J/Q
J=job clock
226
is 900 seconds, and
Q=quantity counter
204
is 1000
Progress module
110
performs the above calculation and determines that sorting system
102
takes an average of 0.9 seconds for each mailpiece to be sorted.
Next, progress module
110
calculates the average error time using the following formula:
Average Error Time Per Mailpiece=
E/Q,
E=Error Clock
226
is 120 seconds, and
Q=Quantity Counter Value
204
is 1000 mailpieces.
The above calculation determines that sorting system
102
has an average error (down time) of 0.12 seconds for each mailpiece being sorted. Progress module
110
then calculates the total time per mailpiece using the following formula:
Total Time Per Mailpiece=(
J/Q
)+(
E/Q
)=0.9+0.12=1.02 seconds per mailpiece.
At block
312
, progress module
110
reads the bin counters
206
-
224
(1 through 10) to determine which bins
112
require a fine sort to be run. As indicated above, bins 1, 2, 4, 6, 8, 9, and 10 each have mailpieces and, thus require a fine sort. Progress module
110
calculates the time required to fine sort all of the mailpieces that have already been rough sorted, using the following formula:
Time To Fine Sort All Mailpieces=(Number Of Fine Sorts×(Operator Clear Time+Operator Load Time))+(Quantity Of Mailpieces×Total Time Per Mailpiece)
Number Of Fine Sorts=7
Operator Clear Time=60 seconds
Operator Load Time=30 seconds
Quantity Of Mailpieces=1000
Total Time Per Mailpiece=1.02 seconds
The result of this calculation is 1650 seconds, or 27.5 minutes.
At block
314
, progress module
110
retrieves the time from job schedule
232
, which in this illustration is 10:00 AM. Progress module
110
subtracts the calculated time to fine sort all mailpieces from job schedule
232
. The result is a time that the rough sort should be started by, in order to meet the 10:00 AM time of delivery. In this illustration, to meet job schedule
232
, the time to start the rough sort is 9:32.5 AM, which is determined by 10:00AM−27.5 minutes. Advantageously, the operator can stop the rough pass (first pass) before its completion to allow time for fine sorts (second pass), so that there is at least some mailpieces to produce for the 10:00 AM deadline.
At block
316
, progress module retrieves the actual time of the day from clock
240
and compares it to the time that the rough sort must start (9:32.5 AM) in order to meet job schedule
232
(10:00 AM). When the time of day clock
240
equals 9:32.5 AM, control module
108
notifies the operator, via the user interface, that the rough sort must be started now, in order to meet the job schedule.
The above presents various principles and features of the invention through descriptions of various embodiments. It is understood that skilled artisans can make various changes and modifications to the embodiments without departing from the spirit and scope of this invention, which is defined by the following claims.
Claims
- 1. A method for determining a period of time to perform a sorting operation comprising the steps of:measuring a quantity of mailpieces to be sorted; measuring a first time interval to perform a first sort of the quantity of mailpieces; estimating a second time interval to perform a second sort of the quantity of mailpieces as a function of the quantity of mailpieces to be sorted and the first time interval; determining an average processing time interval for each mailpiece of the quantity of mailpieces the average processing time interval being a function of the quantity of mailpieces; determining a malfunction during a sorting process; calculating an average error time for each mailpiece that is a function of the malfunction and the quantity of mailpieces; modifying the average processing time interval as a function of the average error time to generate an-updated time interval; comparing the second Urns interval to the updated time interval; and outputting a message signal based on the comparing step.
- 2. The method as recited in claim 1, further comprising the step of determining a quantity of additional sorts based on the quantity of mailpieces.
- 3. The method as recited in claim 1, further comprising the steps of:setting a job clock based on the quantity of mailpieces; and setting an error clock.
- 4. The method as recited in claim 1, further comprising the steps of:establishing a sort time interval indicative of an expected time interval to complete the sorting operation; and updating the sort time interval as a function of first time interval.
- 5. The method as recited in claim 1, further comprising the steps of:establishing bin counters to calculate a quantity of mailpieces in a particular bin; and updating the bin counter as a function of the sorting process.
- 6. The method as recited in claim 1, further comprising the step of:establishing an operator load time period based on the quantity of mailpieces.
- 7. The method as recited in claim 1, further comprising the step of:establishing a sorting procedure such that mailpieces from bins with a largest number of mailpieces have priority.
- 8. The method as recited in claim 2, further comprising the step of:establishing a job sorting interval that is representative of the amount of time required to perform sorting of a selected quantity of mailpieces.
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