MAINTENANCE TECHNICAL SUPPORT CENTER / …

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Maintenance Management Order

SUBJECT: TO:

Operational and Preventive Maintenance (PM) Guidelines for AFSM100 (Automated Flat Sorting Machine) - Automated Induction (AFSM100-Ai)

All AFSM100-Ai Offices

DATE: NO:

FILE CODE:

June 14, 2006 MMO-063-06 H8C, H8D cdav:mm06044ac

This Maintenance Management Order (MMO) provides Operational and Preventive Maintenance Guidelines for the AFSM100 Automated Induction System. It is recommended that this MMO be performed during the AFSM100 PM window and completed 45 minutes prior to the start of the AFSM100 operation. The intent is to provide the Ai operation window for mail preparation prior to the start of the AFSM100. This will allow the Ai system to be sufficiently charged with ACT trays to maintain AFSM100 performance. The inability to provide sufficient ACT trays will cause the AFSM100 to starve for mail and reduce system throughput.

The work hours indicated in the Workload Estimate Attachment 1 reflect the maximum annual work hours required to maintain each system. Management may modify task frequencies to address local conditions.

The minimum maintenance skill level required to perform each task is included in the Minimum Skill Level column of each checklist. This does not preclude higher level employees from performing any of this work.

WARNING

Various products requiring Material Safety Data Sheets (MSDS) may be utilized during the performance of the procedures in this bulletin. Ensure the current MSDS for each product used is on file and available to all employees. When reordering such a product, it is suggested that current MSDS be requested. Refer to MSDS for appropriate personal protective equipment.

Web Access:

MMO-063-06

Maintenance Technical Support Center

WARNING

The use of compressed or blown air is prohibited. An alternative cleaning method such as a HEPA filtered vacuum cleaner, a damp rag, lint-free cloth, or brush must be used in place of compressed or blown air.

Direct any questions or comments concerning this bulletin to the HelpDesk, Maintenance Technical Support Center, P.O. Box 1600, Norman OK 73070-1600; telephone FTS 2000 (405) 573-2123 or toll free (800) 366-4123.

Earl J. Jones Manager Maintenance Technical Support Center Maintenance Policies and Programs

Attachments: 1. 2. 3. 4. 5. 6.

Summary of Workload Estimate Master Checklist: 03-AFSM100-**-001-M: Daily Master Checklist: 03-AFSM100-**-002-M: Weekly Master Checklist: 03-AFSM100-**-003-M: Monthly Master Checklist: 03-AFSM100-**-004-M: Semi-Annual Master Checklist: 09-AFSM100-**-005-M: Operational Maintenance

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Maintenance Technical Support Center

MMO-063-06

ATTACHMENT 1

SUMMARY WORKLOAD ESTIMATE

FOR AFSM100 - AUTOMATED INDUCTION SYSTEM

Attachment 1

1

MMO-063-06

Maintenance Technical Support Center

SUMMARY WORKLOAD ESTIMATE

FOR AFSM100 - AUTOMATED INDUCTION

Routine Operation Servicing Repair*

(hrs/yr) (hrs/yr)

5

434

130

6

496

149

7

557

167

Routine Servicing + Repair Time

(hrs/yr)

564 645 724

Total

Non-

Servicing

productive Per Machine

Time**

(hrs/yr)

(hrs/yr)

56

620

64

709

72

796

Operational Maintenance

2 Tours (hrs/yr)

130 156 182

TOTAL

750 865 978

NOTES Repair estimates based on 30% of servicing. Based on 10% of total servicing and repair.

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Attachment 1

Maintenance Technical Support Center

MMO-063-06

ATTACHMENT 2 MASTER CHECKLIST

03-AFSM100-**-001-M DAILY

TIME TOTAL: 71 Minutes

** CLASS CODES AD & AE

Attachment 2

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MMO-063-06

Maintenance Technical Support Center

U.S. Postal Service

Maintenance Checklist

WORK CODE

IDENTIFICATION

EQUIPMENT

CLASS

ACRONYM

CODE

NUMBER TYPE

0 3 A F SM1 0 0

* * 001 M

Equipment Nomenclature

Equipment Model

AFSM100 - Automated Induction

AFSM100 - Ai

Bulletin Filename

MM06044AC

Frequency

DAILY

** CLASS CODES AD & AE

Part or

Item

Component

No

Task Statement and Instruction (Comply with all current safety precautions)

Est. Min.

Thresholds

Time Skill

Req Lev Run Pieces Weeks

(min)

Hours Fed

(000)

SAFETY STATEMENT

AI MACHINE

1. COMPLY WITH ALL SAFETY PRECAUTIONS. 5 All Disconnect power and apply lockouts when MIN required by this instruction. Refer to current local lockout procedures to properly shutdown and lockout this machine. Open equipment and inspect dust conditions. Check for suspicious dust or unusual debris. If any unusual substance is found notify supervisor prior to proceeding with any further action on the equipment.

THE USE OF COMPRESSED OR BLOWN AIR IS PROHIBITED. When cleaning is required, an alternative cleaning method such as a HEPA filtered vacuum cleaner or a damp rag must be used in place of compressed or blown air. A lintfree cloth or brush may be used on optical equipment only when other cleaning methods cannot be used. Report safety deficiencies to your supervisor immediately upon detection.

2. Perform system shutdown. Perform proper shut down of Ai Control PC prior to powering down Ai Power Distribution Cabinet.

4 8 MIN

3. Power down and lockout power. Power down 2 All the machine and lockout its electrical power as MIN prescribed by the current local lockout instructions providing lockout/restore procedures.

4. Mail search all Ai Modules.

15 6

1. Perform mail search of all modules beginning MIN

at Tilter and working toward prep stations,

follow Upper and Lower ACT conveyors.

Check for mail at each feeder module

including VRL units. Search for mail under

Incline and Spur conveyors trapped between

cover and belts.

2. During mail search, observe general condition of conveyor assemblies, squeeze rails, indicator lenses, and E-Stop switches. Check for missing motorized drive roller O ring belts.

3. Remove any debris found on conveyors and/or conveyor photocells.

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Attachment 2

Maintenance Technical Support Center

MMO-063-06

U.S. Postal Service

Maintenance Checklist

WORK CODE

IDENTIFICATION

EQUIPMENT

CLASS

ACRONYM

CODE

NUMBER TYPE

0 3 A F SM1 0 0

* * 001 M

Equipment Nomenclature

Equipment Model

AFSM100 - Automated Induction

AFSM100 - Ai

Bulletin Filename

MM06044AC

Frequency

DAILY

** CLASS CODES AD & AE

Part or

Item

Component

No

Task Statement and Instruction (Comply with all current safety precautions)

Est. Min.

Thresholds

Time Skill

Req Lev Run Pieces Weeks

(min)

Hours Fed

(000)

VERTICAL RECIPROCATING LIFT ? PREP/FEEDER (VRL-P/VRL-F)

5. General. Remove dust and debris. Vacuum and 2 6

clean any accumulation of dust or debris from the MIN

VRL Lift Table.

EA

HALF PREP STATION & PREP STATIONS UPPER & LOWER ACT TRANSPORT

CLEAN UP

6. General. Remove dust and debris. Vacuum and 3 6

clean any accumulation of dust or debris from the MIN

Work Table, Pivot Table motor, Pivot Table

EA

motorized drive rollers, and accumulation chutes.

7. General. Remove dust and debris. Vacuum and 2 6 clean any accumulation of dust or debris from the MIN Flexible Turning Units (FTUs) on the Upper and EA Lower ACT Transports. (This requires a thin attachment that allows access between the rollers on the FTU.)

8. Restore Ai to service. Restore power to the Ai 5 8 system as prescribed by the local lockout/tagout MIN procedure. Observe all indicators during power up for correct operation.

9. Clean up. Ensure all tools, lubricants, rags, etc., 5 All are removed from the work area. Report all MIN deficiencies to your supervisor.

Attachment 2

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MMO-063-06

Maintenance Technical Support Center

U.S. Postal Service

Maintenance Checklist

WORK CODE

IDENTIFICATION

EQUIPMENT

CLASS

ACRONYM

CODE

NUMBER TYPE

0 3 A F SM1 0 0

* * 001 M

Equipment Nomenclature

Equipment Model

AFSM100 - Automated Induction

AFSM100 - Ai

Bulletin Filename

MM06044AC

Frequency

DAILY

** CLASS CODES AD & AE

Part or

Item

Component

No

Task Statement and Instruction (Comply with all current safety precautions)

Est. Min.

Thresholds

Time Skill

Req Lev Run Pieces Weeks

(min)

Hours Fed

(000)

THIS PAGE BLANK

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Attachment 2

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