111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US008063332B2
`
`c12) United States Patent
`Bowers et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,063,332 B2
`Nov. 22, 2011
`
`(54) MAIL PIECE CONSOLIDATION AND
`ACCOUNTABILITY USING ADVANCED
`TRACKING METHODS
`
`(75)
`
`Inventors: Brian C. Bowers, Mundelein, IL (US);
`Steven J. Krejcik, Brookefield, IL (US);
`Walter S. Conard, Lake Villa, IL (US);
`Michael R. Swift, Libertyville, IL (US)
`
`(73) Assignee: Bell and Howell, LLC, Durham, NC
`(US)
`
`EP
`
`5,475,603 A
`6,101,487 A
`6,135,292 A
`6,303,889 B1
`6,311,892 B1
`6,501,041 B1 *
`
`12/1995 Korowotny
`8/2000 Yeung
`10/2000 Pettner
`10/2001 Hayduchok et a!.
`1112001 O'Callaghan et al.
`12/2002 Burns eta!. ................... 209/584
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`0 481 569 A
`4/1992
`
`OTHER PUBLICATIONS
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 386 days.
`
`(21) Appl. No.: 12/078,499
`
`(22)
`
`Filed:
`
`Apr. 1, 2008
`
`(65)
`
`Prior Publication Data
`
`US 2008/0179225 Al
`
`Jul. 31, 2008
`
`European Search Report issued in European Patent Application No.
`EP 05025368.1 dated Jan. 27, 2009.
`
`(Continued)
`
`Primary Examiner- Terrell Matthews
`(74) Attorney, Agent, or Firm- McDermott Will & Emery
`LLP
`
`Related U.S. Application Data
`
`(57)
`
`ABSTRACT
`
`(62) Division of application No. 11/199,259, filed on Aug.
`9, 2005, now Pat. No. 7,741,575.
`
`(60) Provisional application No. 60/629,407, filed on Nov.
`22,2004.
`
`(51)
`
`Int. Cl.
`G06K 9100
`(2006.01)
`(52) U.S. Cl. ......... 209/584; 209/552; 209/583; 209/900
`(58) Field of Classification Search .................. 209/552,
`209/584, 900; 382/101, 102
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`5,249,687 A
`10/1993 Rosenbaum eta!.
`5,419,440 A
`5/1995 Picoult
`5,459,670 A * 10/1995 Johnson eta!. ............... 700/224
`
`Mail processing methods and techniques for sorting and com(cid:173)
`mingling mail from various mail sources including the track(cid:173)
`ing of the mail pieces through the processing. Such tracking
`entails uniquely identifying each mail piece, received in
`batches from the mail sources, and recording the unique
`identification of each mail piece. The received mail is sorted
`and commingled in a first pass, to form first collections, and
`each first collection is loaded into a uniquely identified mail
`container. For each respective mail piece, the tracking entails
`recording an association of the unique identification of one of
`the mail containers into which it is likely the respective mail
`piece is sorted on the first pass. After processing is complete,
`postal and client reports can be adjusted based on actual final
`pass counts.
`
`8 Claims, 12 Drawing Sheets
`
`Page 1
`
`RMI EXHIBIT 2048
`CBM2014-00116
`
`

`

`US 8,063,332 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`6/2003 O'Callaghan et al.
`6,575,358 B2
`12/2003 Engarto eta!.
`6,655,683 B2
`6,674,038 B1
`112004 Latta
`6,697,500 B2 *
`2/2004 Woolston eta!. ............. 382/101
`6,749,194 B2
`6/2004 Hanson eta!.
`6,793,136 B2 *
`9/2004 Wells et al .................... 235/385
`6,826,548 B2 *
`1112004 Hungerpiller et al ......... 705/401
`6,998,558 B2 *
`2/2006 Forella eta!. ................. 209/584
`7,048,191 B2
`5/2006 Park eta!.
`7,397,010 B2
`7/2008 Wilke
`7,522,971 B2 *
`4/2009 Brehm eta!. ................. 700/219
`7,745,754 B2 *
`6/2010 Conard et al ................. 209/584
`2002/0053533 A1
`5/2002 Brehm eta!.
`2003/0200113 A1
`10/2003 Latta
`2004/0049316 A1
`3/2004 Pintsov eta!.
`2004/0054552 A1
`3/2004 Amonette et a!.
`2004/0188522 A1
`9/2004 Ashaari
`2005/0216119 A1 *
`9/2005 Hamilton ...................... 700/224
`
`2006/0102529 A1
`2008/0000817 A1 *
`2008/0179225 A1
`
`5/2006 Wilke
`112008 Kostyniuk eta!. ............ 209/584
`7/2008 Bowers eta!.
`
`OTHER PUBLICATIONS
`
`European Search Report issued in European Patent Application No.
`EP 05025368.1 dated Jul. 6, 2009.
`Partial European Search Report issued in European Patent Applica(cid:173)
`tion No. 05 02 5368 dated Dec. 18, 2008.
`United States Office Action issued in U.S. Appl. No. 111199,259,
`mailed Oct. 15, 2009.
`United States Notice of Allowance issued in U.S. Appl. No.
`111199,259 dated Apr. 15,2010.
`United States Office Action issued in U.S. Appl. No. 12/467,043
`dated Jul. 5, 2011.
`European Office Action issued in European Patent Application No.
`EP 05 025 368.1 dated Aug. 4, 2011.
`* cited by examiner
`
`Page 2
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 1 of 12
`
`US 8,063,332 B2
`
`on-site equipment
`
`t"'- !~
`
`on-site equipment
`
`Mailpiece production facility or -- Mailpiece production facility or
`'t\7- Produ~tlon '
`Production v9
`·;;22- . -·-· -
`'
`
`Production I' Production
`mail
`mail
`containers
`containers
`
`11
`
`19 ........._
`- ·-·- -·- . - . . -
`'
`'
`25 2 6 / /21A
`~ ~ Image lift
`.. 9
`-I ~ Electronic File
`
`mall
`containers
`"'
`
`1
`
`mail
`containers
`
`/218
`
`---+ Image lift
`
`Site Data
`Processor and
`
`Manager
`
`4
`
`-I
`:::r
`c;·
`r+ "
`:J
`CD
`C/1
`C/1
`1---
`en
`~ 0
`ro
`Sorter computer ~
`-
`...,
`control system
`'"C
`5'
`and electronic file
`...,
`collection
`CD
`~
`s::
`...,
`" CD
`...,
`
`"'T1
`CD
`CD
`c.
`...,
`CD
`
`'""T
`
`... "-'
`
`D)
`
`D)
`
`17
`
`"'T1
`10-._
`CD
`1- CD
`c.
`...,
`CD
`
`:::r
`c;·
`
`CD
`C/1
`C/1
`
`1\
`-
`T-..; ~ ~13
`II'/ (0
`-
`control system ... "-'
`
`-
`
`'"C
`:J. ~14
`;a.
`...,
`CD
`s::
`...,
`@
`...,
`
`D)
`
`f-.---15
`
`Sorter
`computer
`
`and electronic
`file collection
`
`17"""
`
`Tray tag
`printer
`
`Fig. 1
`
`Sort Bins -- - - -
`Off site mail v27
`..
`5 digit trays ~~
`~
`~
`Mixed AADC trays ~
`
`Tray tag
`printer
`
`--16
`
`~xternal Network
`9 connection
`
`consolidation Data
`Processor
`Cooperative or
`Independent site
`
`r---+
`
`Sort Bins
`
`3 digit trays
`
`AADC trays
`
`;3
`
`~Subsequent Pass sorting at same location~
`or at a mail consolidation location
`
`'
`
`I 5 digit trays
`~
`I 3 digit trays
`~
`I AADC trays
`~
`i I Mixed AADC trays ~
`
`Page 3
`
`

`

`~
`00
`•
`~
`~
`~
`
`~ = ~
`
`z 0
`
`~
`N
`N
`
`~
`
`mall "
`
`I
`
`I
`
`I
`
`I
`
`\\
`
`/
`
`I
`
`I
`
`I
`I
`I
`
`I
`
`I
`
`36
`
`I z?p d~g t"U9
`~
`~ 1 - - - - -
`3~--' (
`zfpd~ :,a~39
`h
`l AAOC trays
`Zip 700 to 999 U
`
`Fig. 2
`
`1
`,
`
`1
`
`f
`,
`
`5 d.!Qit trays
`Zip 700 to 999
`~ d.!QJt trays
`Z1p 700 to 999
`
`AADC trays
`Zip 700 to 999
`
`]
`
`~
`ij
`
`\. ____ __________ .J
`
`N
`
`0 ....
`....
`
`('D
`('D
`
`rFJ =(cid:173)
`.....
`N
`0 .....
`....
`N
`
`d
`rJl
`
`00 = 0'1 w w w
`N = N
`
`46
`__)
`
`47
`
`l z?paABar;rf9- · ]
`ij
`[
`zfP a.lBg Fc:'l39
`l Zfg'.H,~ Fc:'l39
`~
`
`I
`1,
`
`E ::a.-.zz=
`zi'P''d'i~n
`l ~w~·t~~3
`l
`
`AADC trays
`Zip 0 to 399
`
`I
`
`ij
`~
`ij
`
`Page 4
`
`

`

`Chicago Region
`
`~
`00
`•
`~
`~
`~
`
`~ = ~
`
`z 0
`
`~
`N
`N
`
`~
`
`/
`
`/
`
`/
`
`/
`
`.
`Sorting location C
`\South Chicago/ /i~
`.
`.
`I
`··-··-··-···-··-··-/
`50
`
`Fig. 3
`
`N
`
`0 ....
`....
`
`rFJ =(cid:173)
`.....
`
`('D
`('D
`
`(.H
`
`0 .....
`....
`N
`
`d
`rJl
`
`00 = 0'1 w w w
`N = N
`
`Page 5
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 4 of 12
`
`US 8,063,332 B2
`
`50
`
`Input mail
`for sortation
`and sorting
`center
`
`51
`
`\ r----------..J!'-'Member site shiPping data ___ _,
`
`Mailpiece ID dara
`
`52
`
`mail consolidation
`server
`receives first pass and/or
`subsequent P,ass data
`from an members and
`performs analysis to
`determine the optimal
`(for postage discounts)
`redistribution of mail
`among members based
`on members
`redistribution agreements
`
`Hold 5-digit
`trays for local
`submission
`and
`int~gratiqr
`w1tfi ma1
`consolidation
`member mail
`
`56
`
`ye
`
`Create
`additional 5
`digit and 3-
`digit local and
`national mail
`trays
`
`57
`Hold 5-digit
`trays for lpcal
`subm1ss1on
`and integration
`with mail
`consolidation
`member mail
`
`53
`
`Ship non(cid:173)
`local 5-digit,
`3-djgit,
`AADC"and
`mixedAADC
`trays to mail
`consolidation
`member
`
`Distribution ontrol data
`
`58
`
`At member site, sort
`remaining mail
`based-on
`redistribute
`!-------!agreements ~nd zip
`ranges cons1stent
`with each members
`location and
`analysis of mail
`consolidation server
`
`Generate data files
`that represent the
`mair for local
`submission to Postal
`Authority and for
`delivery to mail
`consolidation
`members
`
`data
`
`62
`
`\
`
`mail
`
`59
`
`mail
`
`mail
`
`Fig. 4
`
`Page 6
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 5 of 12
`
`US 8,063,332 B2
`
`Mail from mail
`consolidation
`members
`
`Member$.
`local mall
`
`74
`
`75
`
`Run sort sc:;hemes and
`prepare mail to dispatch
`to Postal Authority
`
`Site Server
`Create sort schemes to
`process combi~;~e~ mail
`and 11_arse maiiP1ece
`identificaJ~~ tracking Sort scheme
`
`71
`
`Durin_g sortati9n runs perform positive
`tracKing of all mail~leces processed
`based on-10 data.
`
`76
`
`Mailpiece t eking data
`
`77--
`
`yes
`
`Fig. 5
`
`!;'erf9rr., recQnciliation analysiJ to identifv
`'------1 If m1ssmg p1eces are the result of doublli
`feeds or missing trays or pallets.
`
`Identify location of missing trays or
`pallets 6Y. ana yzlng final run daU\ with
`each member's sllQ llerver 22 or With the
`ma1 conso dation server 51
`
`Generate Postal Author~ repQrts for the
`mail
`be dis
`tched.
`Calculate malf consolfc ation sortation
`savi_ngs an~ report to members.
`ComP.,Iete mallpldce trackin~ results
`analysis Jnd prerare. client r !POrts by
`site and overal ma11 conso fdatlon
`operation
`
`Distribute
`dispatch
`confirmation data,
`client data3 and
`memberuata
`
`78
`
`Prepare Postal
`Authority reports
`and dispatcti mall
`
`79
`
`80
`
`81
`
`Di,patch mall
`With reports
`
`Page 7
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 6 of 12
`
`US 8,063,332 B2
`
`N
`
`N
`
`A2
`Identify
`AQproximate
`Th1ckne~s
`Per Mall
`Batch
`
`A4
`Print a Batch
`of Unique
`Transpiration
`ID Tray Tags
`
`Yes
`
`A5
`Induce Mail M----__.
`Into Sorter
`
`Ye
`
`A7
`We~h Each
`1ece
`
`Ye
`
`A9
`Measure
`Thickness of
`Mail Piece
`
`A11
`Mark Trailing
`Edge of Lasl
`Two Pieces
`in Tray
`
`A13
`S_p,ray UBique
`Piece I on
`Piece.
`
`A15
`Print
`Tranm>ortatio
`n ID Tray Tag
`
`A16
`Scan
`Transpoft¥tion
`ID Tray ag
`
`A17
`Automatically
`Associate ana
`store Mail
`Characteristics
`an~T~ay 10 with
`arlp1eces
`
`A18
`Move Tray To
`Staging Area
`
`Fig. 6
`
`Page 8
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 7 of 12
`
`US 8,063,332 B2
`
`81
`Scan
`Transportation
`ID Tray Tag on
`Pallet Scanner
`
`84
`Move Tray to
`Correct Pallet
`
`N
`
`83
`Scanner
`sounds
`warnin~ beep
`and 1ght
`
`Yes
`
`85
`Acceptance
`Indication
`
`86
`Pallet Placard
`Scanned &
`Loaded on
`Truck &
`Transftorted
`to Des ination
`Site
`
`87
`Pallet Placard
`Scanned in at
`Destination
`
`812
`Move mail To
`Correct
`Sorter or
`Cross dock or
`Other Area.
`
`89
`Ye Move Trays
`to Correct
`Pallet.
`
`810
`Scan Each
`Tray at
`Destinating
`Pallet/staging
`area Scanner
`
`0
`
`813
`Scan trays at
`Sorter
`
`814
`Mail
`Processed on
`Second Pass
`on Sorter
`
`815
`Qualification
`Adjusted
`Based on
`Actual
`Second Pass
`
`816
`Missing
`Pieces &
`Adjusted
`Postal
`Reports
`
`Fig. 7
`
`Page 9
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 8 of 12
`
`US 8,063,332 B2
`
`Mail
`Pieces
`
`301
`
`303
`
`Mail
`Container
`
`302
`
`Pallet
`
`Fig. 8
`
`Page 10
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 9 of 12
`
`US 8,063,332 B2
`
`Staging Area 1
`
`402
`
`403
`
`Staging Area 2
`
`Staging Area 3
`
`405
`
`406
`
`408
`
`409
`
`Fig. 9
`
`Page 11
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 10 of 12
`
`US 8,063,332 B2
`
`902
`
`901
`
`903
`
`904
`
`Measuring Device
`
`123 Main Street
`Anytown USA 60513
`
`Fig. 10
`
`Page 12
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 11 of 12
`
`US 8,063,332 B2
`
`I
`
`601
`
`First Pass
`
`l
`Mail Batch 1
`~--------------------------------~r--602
`r-----~ I
`I
`60516
`I
`I
`Seq # 2
`I
`I
`604,............------ ~05
`
`60513-1603-05
`Seq # 1
`
`60520-3345-27
`Seq#3
`
`60545-5765-23
`Seq #4
`
`J
`603
`Mail Batch 2
`___...
`~----------------------------------~
`607
`r-----~ I
`I
`I
`60516
`I
`Seq # 6
`I
`I
`/ ______ J
`
`60412
`Seq # 5
`
`60537-4565-45
`Seq#?
`
`60566-6790-40
`Seq# 8
`
`606
`
`608
`
`609
`
`61
`
`611
`
`Subsequent Pass
`
`~619
`
`+L-
`
`60513-1603-05
`Seq# 1
`
`60545-5765-23
`Seq#4
`
`60537-4565-45
`Seq#?
`
`7
`
`612
`
`61
`
`r-- --~
`:
`60516
`I
`Seq# 2
`
`/ - - - __ J
`
`614
`
`615
`
`60520-3345-27
`Seq#3
`
`620
`
`60412
`Seq#5
`
`60566-6790-40
`Seq#8
`
`r--
`:
`60516
`I
`Seq# 6
`I _____ J
`
`617
`
`Fig. 11
`
`Page 13
`
`

`

`U.S. Patent
`
`Nov. 22, 2011
`
`Sheet 12 of 12
`
`US 8,063,332 B2
`
`/ 700
`
`Load Appropriate
`Sort Scheme
`
`'------.---------J
`
`Mail Piece is Sorted
`to Correct Bin
`
`Move Mail To
`Subseguent Pass
`Sorter
`
`Stage Mail
`
`705
`
`704
`
`701
`
`Yes
`
`Send Tray to USPS
`
`703
`
`Fig. 12 - Prior Art
`
`Page 14
`
`

`

`US 8,063,332 B2
`
`1
`MAIL PIECE CONSOLIDATION AND
`ACCOUNTABILITY USING ADVANCED
`TRACKING METHODS
`
`RELATED APPLICATIONS
`
`This application is a Divisional ofU.S. application Ser. No.
`11/199,259, filed Aug. 9, 2005, now U.S. Pat. No. 7,741,575
`and claims the benefit of U.S. Provisional Application No.
`60/629,407 Filed Nov. 22, 2004 entitled "Methods for Mail
`Piece Consolidation and Accountability Using Advanced
`Tracking Methods," the disclosures of which also are entirely
`incorporated herein by reference.
`
`TECHNICAL FIELD
`
`The present subject matter relates to techniques and equip(cid:173)
`ment to efficiently process mail prior to delivery to a postal
`authority in order to qualifY for postage discounts based on
`the work performed and to accurately track the mail piece
`processing.
`
`BACKGROUND
`
`In 1989 the United States Postal Service (USPS) started a
`work-sharing program, by which the Service intended to
`increase the amount of bar coded mail and reduce operational
`costs. To promote this end, private mailers were offered
`incentives to purchase high-speed Multi-Line Optical Char(cid:173)
`acter Reader (MLOCR) equipment and bar code and com(cid:173)
`mingle multiple mail streams. Certain make-up requirements
`were established that facilitated the input of the barcodedmail
`into the USPS processing stream. For performing this service,
`private entities were given a discount to process the mail.
`Volume discounts were instituted which provided incentives
`to private entities to increase volumes, thus paying a lower
`cost per piece in postage dollars. To achieve the required
`minimum volumes, presort entities were started which col(cid:173)
`lected and commingled mail from many mailers.
`While the USPS developed a complicated audit procedure,
`limitations of the production process prevented the USPS
`from performing an adequate audit on the mailings. One
`example of this is that a specific mail piece cannot be traced
`to a specific tray. Rather a mail piece was associated with a
`group of trays. Thus the acceptance clerk might have to look
`through 10,000 pieces of mail in over 60 trays to find one
`piece of mail.
`FIG. 12 defines the normal steps required to perform a 50
`multiple pass sorting operation needed to meet USPS per-sort
`requirements. A batch of mail is loaded into a mail sorting
`apparatus at 700, and the apparatus will sort mail to a series of
`bins or packets based on a set of rules called a sort scheme in
`step 701. A bin could be set up to contain one zip code
`destination called a finalized bin, as will be checked at 702 in
`the sort scheme. Since a sorting apparatus will have a finite
`number of bins, and there are many USPS separations
`required, some of the mail will have to be hatched into one
`bin, and re-run in a second or subsequent pass 705 to com- 60
`plete the sortation required to meet USPS requirements. A bin
`that is set up to receive multiple zip codes is called a repass
`bin. For example, a large mailing might require 3000 zip code
`separations of the mail in order to achieve the desired level of
`discount. In other words, mail destined for zip code 60513 65
`will need to be separated and placed in a separate container
`from mail for zip code 60514. The sorting apparatus will
`
`2
`make this separation by putting all mail with zip codes to
`60513 in one bin and all mail with zip codes to 60514 in
`another bin.
`A mail sorting apparatus typically could have around 253
`bins. 242 bins would be assigned to finish zip codes. This
`finished mail can then be removed from the apparatus, mail
`from each finish bin can be put into a postal container at step
`703, labeled and submitted to the postal authority. The mail
`for the other 2758 zip separations will be sorted into 11 repass
`10 bins 704 on the first pass. Each one of these bins will then be
`sorted out to 253 finalized separations in a subsequent pass
`705 on the sorting apparatus. This mail is then placed in postal
`containers 703, labeled and is ready to be submitted to the
`15 postal authority.
`Since the introduction of work sharing, there has not been
`an adequate method to audit a mailing, since the mail submit(cid:173)
`ted to the USPS is commingled, i.e. pieces of different weight
`and pieces with different postage affixed (stamped, metered,
`20 permit ... ) are all mixed together in the sorted mailing.
`Previously mail was separately grouped by the piece weight
`and by the type of postage affixed. Hence auditing was easier,
`since all pieces in the mail group being evaluated, had the
`same characteristics. The old method of weighing the mailing
`25 would no longer identify if the reported piece counts were
`accurate if there were variable weight pieces in the mailing.
`Mail is randomly removed from the bin and put into trays.
`This limited the audit of a mail piece, since any piece could no
`longer be tracked back to a specific tray. The non-identical,
`30 commingled pieces have varying thickness so tray breaks
`could not be calculated by the system. Another issue is that
`USPS reports are calculated at the end of first pass. The
`computer system will produce the required subsequent pass
`schemes to sort the specific mail to meet the applicable postal
`35 regulations, but there are no regulations or methods in place
`today to confirm that the mail was actually sorted in subse(cid:173)
`quent passes. Mailers that do not have adequate capacity or
`time could claim the mail is sorted, and the computer gener(cid:173)
`ated reports would quantify this, yet the mail sortation may
`40 never have been completed.
`Today a mailer will exchange mail between sites to
`increase volume densities and lower the average postage cost
`per piece. Sophisticated operational processes such as these
`were implemented by the mailing industry to increase opera-
`45 tiona! efficiency and reduce the postage per piece. As pro(cid:173)
`cessing complexity increases, so does the likelihood that
`errors will occur, which reduces the accuracy of the reports
`and increases the likelihood of large USPS fines and client
`billing problems.
`A need still exists for improved mail processing techniques
`and equipment that resolve many of the quality issues and
`ensure accurate reporting for mail processed in a sorting
`operation. A related need exists for a method of processing
`and preparing a mailing that ensures a valid audit and USPS
`55 revenue protection.
`
`SUMMARY
`
`Sorting and commingling mail from various mail sources
`will include tracking of the mail pieces through the process(cid:173)
`ing with a high degree of integrity. Such tracking entails
`uniquely identifying each mail piece, received in batches
`from the mail sources, and recording the unique identification
`of each mail piece. The received mail is sorted and com(cid:173)
`mingled in a first pass, to form first collections, and each first
`collection is loaded into a uniquely identified mail container.
`For each respective mail piece, the tracking entails recording
`
`Page 15
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`US 8,063,332 B2
`
`3
`an association of the unique identification of one of the mail
`containers into which it is likely the respective mail piece is
`sorted on the first pass.
`The exact accuracy of the association of each mail piece to
`a container will vary with the system implementation. For
`example, with a system that provides a marker at appropriate
`break points, the association may be precise in almost all
`cases. In other implementations without the marker or other
`means to insure that collections are accurately swept in the
`containers, the tracking accuracy may off by one tray or so,
`for pieces at or around the break points.
`In the examples, the first collections from the containers
`are sorted on a subsequent pass. The additional sortation may
`be at the same location, e.g. on the same or a different sorting
`system, or the additional sortation may be performed at a
`remote location. Typically, additional sorting enables the par(cid:173)
`ties to share the benefit of additional levels of postal dis(cid:173)
`counts.
`In such instances, the sorting, commingling and tracking
`methodology further involves sorting mail pieces from at
`least some of the mail containers, in a subsequent pass, into a
`subsequent collections based on intended destination infor(cid:173)
`mation and in accord with postal authority rules. For each
`mail piece sorted into a subsequent collection, the processing
`entails recording a result of the sorting in the subsequent pass.
`The tracking data in the recordings can then be processed to
`generate a report of processing results for substantially all of
`the received mail pieces. Techniques are discussed later to
`reconcile the reports to reflect any losses or additions of mail
`pieces. The report may enable verification of sorting integrity
`for postage accounting. As another example, the report may
`provide verification of mail piece characteristics that effect
`postage due, such as thickness, weight, type of postage
`affixed, etc. for each finished mail piece. The characteristic
`data may be either automatically measured, entered by the
`operator or read off the mail piece during first pass sorting and
`tracked with the mail piece throughout each subsequent pass.
`In addition or as an alternative, the data processing can pro(cid:173)
`vide a report that informs the mail clients as to the processing
`of their mail pieces through one or more of the sorting passes.
`In the processing examples, the recordings comprise an
`electronic file of records of the mail pieces, such as a database
`or collection of flat files. The electronic file includes a record
`for each respective mail piece, which correlates the unique
`identification of the respective mail piece to the unique iden(cid:173)
`tification of one of the mail containers into which the respec(cid:173)
`tive mail piece is likely sorted on the first pass and/or to the
`result of the sorting in the subsequent pass for the respective
`mail piece.
`The tracking technique can be used in applications wherein
`the mail containers comprise mail trays. In such an imple(cid:173)
`mentation, and a number of the mail trays are loaded onto a
`uniquely identified pallet, and the tracking further involves
`recording an association of each mail piece expected to be in
`each of those mail trays with the unique identification of the
`pallet. The pallet can then be transported to a remote location,
`for performance of the sorting in the subsequent pass, and the
`tracking will indicate the location of the pallet and thus the
`mail pieces en route and/or upon arrival at the second loca- 60
`tion.
`Tracking data also enable validation of the identification of
`the mail trays loaded onto the identified pallet, before trans(cid:173)
`porting the pallet. In this way, a data processing system can
`inform an operator if any of the mail trays loaded onto the 65
`identified pallet contain mail that should not be transported
`with the pallet to the remote location.
`
`4
`As noted earlier, the data processing can reconcile the
`reports to reflect any losses or additions of mail pieces. For
`example, if the piece count after the subsequent pass does not
`match the electronic file or a read occurs for mail piece
`identification not recorded in the electronic file, then the piece
`is rejected as a double from the first pass sorting operation. It
`is also possible to in interpolate data from the mail before and
`after a failed read or small group of failed reads to positively
`identify the pieces that are not successfully read in the sub-
`10 sequent pass operations by comparing with the expected data
`from the electronic file. In this later implementation, the
`processing might entail detecting uniquely identified mail
`pieces from the mail containers, during the sorting in the
`subsequent pass, and detecting a mail piece that is missing
`15 from one of the subsequent collections based on detection of
`unique identifications of mail pieces expected to precede and
`follow the missing mail piece in the one subsequent collec(cid:173)
`tion.
`The present teachings also encompass a system for sorting
`20 mail from clients to obtain postal discounts. Such a system
`might utilize two sorting systems. A first sorting system at a
`first location, uniquely identifies each mail piece from
`batches of mail pieces received from the mail clients. The first
`sorting system also sorts and commingles the mail pieces
`25 from the batches of mail, in a first pass, into first collections,
`based on a first sort scheme. Typically, at least some of the
`first collections do not yet meet postal rules for a desired level
`of postage discounts. The second sorting system, at a different
`location, sorts and commingles mail pieces from the first
`30 collections that do not yet meet postal rules for the desired
`level of postage discounts received from the first sorting
`system together with additional mail pieces, in a subsequent
`pass. The subsequent pass sorting by the second system pro(cid:173)
`duces subsequent collections for transport to a postal delivery
`35 authority, that is to say sorted based on intended destination
`information so as to meet the postal rules for the desired level
`of postage discounts. A data processor system, in communi(cid:173)
`cation with the two sorting systems, maintains a record of
`each respective mail piece processed through the first and
`40 subsequent sorting systems based on unique identifications of
`mail pieces provided by the first sorting system. The data
`processor system stores data in each record regarding sorting
`of the respective mail piece in the first and subsequent sorting
`systems and of transport of the respective mail piece between
`45 the sorting systems. The stored data enables processing of the
`records to generate a report of sorting of all mail pieces.
`Systems of this type may be used in a number of different
`business models, where it is desirable to cooperate in multi(cid:173)
`pass sorting so as to gain an optimum postal discount. For
`50 example, the first and subsequent sorting systems may be
`implemented as cooperative service bureaus or mail produc(cid:173)
`tion facilities. Alternatively, the first sorting system may be a
`system of one of a number of service bureaus or mail produc(cid:173)
`tion facilities, in which case, the second sorting system is a
`55 hub system for receiving and consolidating mail initially
`sorted by systems of the service bureaus or mail production
`facilities.
`In a disclosed example, the first sorting system includes a
`feeder for feeding individual mail pieces from the batches of
`mail pieces received from the mail clients, a reader for read(cid:173)
`ing information from the individual mail pieces and a printer.
`The first system might also include a computer responsive to
`the reader, for deriving unique identifications for individual
`mail pieces where possible. The computer assigns unique
`identifications to any individual mail pieces for which infor(cid:173)
`mation read from the mail piece can not be used for unique
`identification. Upon assigning such an identification, the
`
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`US 8,063,332 B2
`
`5
`computer controls the printer to print the assigned unique
`identification on the individual mail piece for which informa(cid:173)
`tion read from the mail piece could not otherwise by used for
`unique identification of that piece.
`As noted, it may be desirable in some implementations to
`capture data as to characteristics of the mail pieces. For
`example, the first sorting system may further include a thick(cid:173)
`ness detector, for detecting thickness of individual mail
`pieces from the batches received from the mail clients.
`Tracking implementations are also disclosed in which it is
`desirable to mark mail pieces in sorted collections for break
`points, e.g. to mark tray breaks at which points an operator
`should sweep sorted mail from a sort bin into a mail tray type
`container. For such implementations, the first sorting system
`would further include a marker for marking an identified mail
`piece as a break, when the computer determines that one of
`the first collections will reach a thickness break point for a
`combined grouping of mail to fit in a tray or tub.
`The data processing for the tracking techniques disclosed
`herein may be implemented as methods, as one or more
`computer systems for performing the data processing and/or
`embodied in program products that might enable a data pro(cid:173)
`cessing system to implement a sequence of appropriate steps.
`For example a data processing method related to tracking
`processing of mail pieces of two or more mail clients, during
`mail sortation operations, might entail obtaining a unique
`identification of each respective mail piece from batches of
`mail pieces received from the mail clients. An individual
`record in a electronic file is created for each respective mail
`piece. Each such record includes the unique identification of
`the respective mail piece. The method also involves populat(cid:173)
`ing the mail piece records with information for tracking all of
`the identified mail pieces individually through and between
`multiple sortations prior to delivery to a postal authority.
`It is also envisioned that the information for tracking, 35
`which is populated in each individual record, would include
`one or more of a tray identifier, a pallet identifier or staging
`area identifier, indicating a current location of the respective
`mail piece. In the multi-pass sorting examples, the tracking
`information populated in each individual record also indi(cid:173)
`cates whether or not the respective mail piece has finished
`final sortation. The data also may indicate an association of
`the respective mail piece with one of the mail clients, from
`which the respective mail piece originated.
`The data processing methodology may be used to tracking 45
`of placement of the mail pieces into a series of containers for
`transport and/or further processing. In such an example, the
`operation of populating of the mail piece records of the elec(cid:173)
`tronic file involves receiving a unique identification of a mail
`tray into which each respective mail piece is likely sorted 50
`from among identifications of mail trays into which the mail
`pieces are sorted after at least one of the sortations. The
`received unique identification of the mail tray into which each
`respective mail piece is likely sorted can then be associated
`with the record for the respective mail piece in the electronic 55
`file. In some cases where transport of trays is desired, the
`populating of the mail piece records also involves receiving a
`unique identification of a pallet, onto which identified mail
`trays are loaded. The identification of the pallet is then asso(cid:173)
`ciated with each record of a respective mail piece in the 60
`identified mail trays loaded onto the pallet.
`The unique identification of the respective mail piece
`included in each individual record may be data from one or
`more barcodes or any other unique identifying mark read
`from the respective mail piece. Alternatively, the identifica- 65
`tion number may be a unique sequence number assigned to
`the respective mail piece. In addition or in place of the bar
`
`6
`codes, it is envisioned that the identification may utilize data
`read from RFID tags or other identification technologies.
`Reading technologies for Radio Frequency Identification
`(RFID) tags or RFID codes imbedded in the paper can be
`added to read the required data directly from the code or read
`an unique identifier from the code that can be referenced to an
`electronic file to acquire the necessary data about the mail
`piece. A larger RFID code can be used to directly contain
`descriptive data about the mail piece, thus avoiding a data
`1 o lookup. Alternatively, RFID sensitive ink can be used to mark
`the mail piece for identification. RFID codes can be used on
`mail piece, tray and tub tags and pallets. Both the paper, the
`ink and the detectors are available from INKODE Corpora(cid:173)
`tion. Similar tags may be used on or otherwise associated with
`15 mail containers, such as