Sortation
Also known as: Package Sorting, Sort Process, Parcel Sortation
Definition
Sortation is the process of separating packages, items, or orders based on specific criteria such as destination, carrier, service level, or delivery route. It’s a critical step in both warehouse fulfillment and carrier hub operations.
Types of Sortation
Outbound (Fulfillment)
Sorting picked orders for shipping:
- By carrier (USPS, UPS, FedEx)
- By service level (Ground, Express, Priority)
- By delivery zone
- By manifest/truck
Inbound (Carrier Hub)
Sorting packages for delivery:
- By delivery route
- By driver/vehicle
- By delivery window
- By residential vs. commercial
Sortation Technologies
| Technology | Speed | Investment | Best For |
|---|---|---|---|
| Manual sorting | Low | Low | Low volume, complex items |
| Tilt-tray sorter | Medium | Medium | Varied package sizes |
| Cross-belt sorter | High | High | High volume, mixed sizes |
| Bomb bay sorter | Very high | High | Flat items, envelopes |
| Robotic sorting | Flexible | Medium-High | Growing operations |
Carrier Sort Facilities
Major carriers operate massive sort centers:
- USPS - Processing and Distribution Centers (P&DCs)
- UPS - Worldport (Louisville) processes 2M+ packages/day
- FedEx - Memphis SuperHub
- Amazon - Delivery stations and sort centers
Sortation Accuracy
Accurate sorting is critical:
- Missorts - Packages sent to wrong destination
- Impact - Delays, extra handling, customer complaints
- Target - 99.9%+ accuracy for high performers
Sort Plan
A sort plan defines:
- Number of sort destinations
- Assignment of zones/routes to lanes
- Timing of sort waves
- Handling of exceptions
Sortation Metrics
- Throughput - Packages sorted per hour
- Accuracy - % correctly sorted
- Jam rate - Frequency of equipment jams
- Recirculation rate - Packages requiring re-sort
- Damage rate - Packages damaged during sort
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