Background

The U.S. Postal Service recently begun realigning its network by implementing Regional Processing and Distribution Centers (RPDC) to consolidate mail processing operations, reduce costs, and grow package business. To help support this strategy, the Postal Service deployed the Matrix Regional Sorter (MaRS). The MaRS is designed to increase package processing capacity and efficiency while using less floor space, a critical factor to the success of implementing the Postal Service’s network transformation and increasing their share in the growing package market.

The Postal Service designed and deployed the first two MaRS and expects to save in labor costs for each facility where a machine is deployed.

What We Did

Our objective was to evaluate the planning, deployment, and initial performance of the MaRS at the Atlanta and Chicago RPDCs. We conducted observations of the MaRS at the Chicago and Atlanta RPDCs in February, April, and May 2024.

What We Found

The Postal Service was able to quickly plan, design, and deploy the MaRS to help support its RPDC initiative and help meet its package sorting demands at the Chicago and Atlanta RPDCs. However, the Postal Service did not adequately plan and prepare for Postal Service maintenance personnel to accept maintenance responsibility from contractors for the MaRS. Also, the Postal Service overestimated the achievable efficiency of the machine, which can impact the expected savings from its operation.

The initial operation of the MaRS led to problems with processing packages as well as safety issues. Further, a lack of oversight led to packages being delayed.

Recommendations and Management’s Comments

We made three recommendations to address the planning and deployment of the MaRS; three recommendations to address damaged and delayed mail; one recommendation related to rehandling mail; and two recommendations to address local management oversight. Management agreed with all recommendations. The U.S. Postal Service Office of Inspector General (OIG) considers management’s comments responsive to all recommendations, as corrective actions should resolve the issues identified in the report.