This Maintenance Management Order (MMO) supersedes MMO-021-91, dated July 10, 1991, and MMO-029-91, dated August 13, 1991. Many items and figures from MMO-021-91 are used, but are clarified and updated. Also all workhour estimating guidelines from subsequent Maintenance Criteria MMOs have been included. This MMO provides guidelines (see attachment) to be used to estimate workhours in each functional area. Guidelines contained herein are current as of April 23, 1997 and are derived from existing approved handbooks, MMOs, other source documents, and established historical data bases. All mechanized offices must estimate maintenance workhours by using the attached guide. The Senior Maintenance Official must be personally aware and involved in applying this guide. The Senior Maintenance Official is also responsible for maintaining this document so that it reflects all changes in guidelines distributed in subsequent issues of MMOs and MS Handbooks. Copies of the completed maintenance workhours estimating package must be available for review MAINTENANCE TECHNICAL SUPPORT CENTER / MAINTENANCE POLICIES & PROGRAMS ENGINEERING / UNITED STATES POSTAL SERVICE maintenance management order SUBJECT: Maintenance Workhour Estimating Guide for All Mechanized Offices June 2, 1997 MMO-028-97 DATE: NO: FILE CODE: TO: 1. Senior Maintenance Official, Maintenance Capable Offices 2. Manager, In-Plant Support, Area Offices M bgri:MM9554AE
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This Maintenance Management Order (MMO) supersedes MMO-021-91, dated July 10, 1991, and MMO-029-91, dated August 13, 1991. Many items and figures from MMO-021-91 are used, but are clarified and updated. Also all workhour estimating guidelines from subsequent Maintenance Criteria MMOs have been included. This MMO provides guidelines (see attachment) to be used to estimate workhours in each functional area. Guidelines contained herein are current as of April 23, 1997 and are derived from existing approved handbooks, MMOs, other source documents, and established historical data bases.
All mechanized offices must estimate maintenance workhours by using the attached guide. The Senior Maintenance Official must be personally aware and involved in applying this guide. The Senior Maintenance Official is also responsible for maintaining this document so that it reflects all changes in guidelines distributed in subsequent issues of MMOs and MS Handbooks. Copies of the completed maintenance workhours estimating package must be available for review during maintenance surveys conducted by Area Maintenance Support Office, the Maintenance Technical Support Center (MTSC), or the Inspection Service.
MAINTENANCE TECHNICAL SUPPORT CENTER / MAINTENANCE POLICIES & PROGRAMS
Bulk Mail Centers (BMCs) should continue to be staffed using Interim Bulk Mail Center Maintenance Staffing Guidelines and Criteria , dated August 16, 1979. These BMC guidelines address fixed mechanization and additions to MS-1, Operation and Maintenance of Real Property, and MS-47, Housekeeping Postal Facilities, criteria. BMCs must apply MS-1, MS-47, and other appropriate sections of this guide to determine their total staffing.
Changes to and clarifications to MMO-21-91 are as follows:
1. Operational maintenance guidelines are determined by specific equipment type and local operating conditions.
2. Current maintenance guidelines are identified and summarized.
3. Equipment inventories are updated to include all other equipment that has been added and supported nationally.
At all locations, estimated maintenance workhours developed from MMO-021-91 shall be revised according to the above changes. Information and assistance in applying and interpreting this guide can be obtained from Area Maintenance Support.
The Senior Maintenance Official is responsible for reviewing the maintenance workhour estimating package annually. If the total workhours identified to support a given function varies from the previous study by more than one man year, either positive or negative, the study or affected portion(s) thereof should be revised, updated, and submitted to the reviewing/approving authority.
A computerized (softcopy) version of this workhour estimating guide is enclosed. The computerized package is designed to provide a similar look and feel as the paper package. This MMO with attached worksheets and tables represents official documentation of approved maintenance criteria. In the future, all workhours packages should be generated using the computerized package which reflects the maintenance criteria contained in this MMO.
Questions or comments regarding staffing criteria and use of the software package should be referred to your Area Office Maintenance Support group.
Questions concerning software errors in the Workhour Estimator Program should be referred to the MTSC HelpDesk at 405-573-2123 or 1-800-366-4123.
Rex M. GallaherManagerMaintenance Technical Support CenterMaintenance Policies and Programs
Attachment: Maintenance Workhour Estimating Guide
Enclosure: Maintenance Estimating Program, Release 1, Version 1.0 (7 diskettes)
Maintenance Technical Support Center MMO-028-97
ATTACHMENT
MAINTENANCE WORKHOUR ESTIMATING GUIDE
REVISION __00__________________
DATE __June 2, 1997 ________
Maintenance Technical Support CenterP.O. Box 1600
Norman, OK 73070-6708
Attachment 1
MMO-028-97 Maintenance Technical Support Center
Table of Contents
MAINTENANCE WORKHOUR ESTIMATING GUIDE METHODOLOGY......................................Introduction................................................................................................................................General Instructions and Guidelines..........................................................................................
SECTION 1 - APPROVALS, RECOMMENDATIONS, AND SUMMARY.......................................Instructions.................................................................................................................................Approvals Document..................................................................................................................
SECTION 1-A, CRAFT POSITION RECOMMENDATIONS.........................................................SECTION 1-B, MAINTENANCE POSITION SUMMARY..............................................................SECTION 2 - POSTAL OPERATING EQUIPMENT......................................................................
Instructions.................................................................................................................................SECTION 2-A, MISCELLANEOUS POSTAL EQUIPMENT.........................................................SECTION 2-B, MAJOR MECHANIZATION/AUTOMATION.........................................................SECTION 2-C, ADDITIONAL REQUIREMENTS..........................................................................
Worksheet W-1, Small Bar Code Sorter (SBCS)......................................................................Worksheet W-2, Bulk Belt Conveyor Systems..........................................................................Worksheet W-3, Computer Forwarding System (CFS-II)..........................................................Worksheet W-4, Delivery Bar Code Sorter (DBCS)..................................................................Worksheet W-5, Dual Pass Rough Cull....................................................................................Worksheet W-6, Package Bar Code Sort System.....................................................................Worksheet W-7, Letter Mail Labeling System (LMLM)..............................................................Worksheet W-8, Advanced Facer Canceler System (AFCS)....................................................Worksheet W-9, Facer Canceler (FC) and Edger Feeder (EF).................................................Worksheet W-10, Multi-Position FlatsSorting Machine (Model 881).........................................Worksheet W-11, Multi-Position Letter Sorting Machine (MPLSM)...........................................Worksheet W-12, Optical Character Reader Channel Sorter (OCRCS)...................................Worksheet W-13, Image Processing Subsystem (IPSS)..........................................................Worksheet W-14, Parcel Sorting Machine (PSM).....................................................................Worksheet W-15, Small Parcel & Bundle Sorter (SPBS)..........................................................Worksheet W-16, Air Contract Data Collection System (ACDCS)............................................Worksheet W-17, Military/International Dispatch and Accountability System (MIDAS).............Worksheet W-18, Postal Source Data System (PSDS) Time & Attendance.............................Worksheet W-19, Postal Source Data System (PSDS), Mgmt. Station....................................Worksheet W-20, Postal Source Data System (PSDS), Mod Scale.........................................Worksheet W-21, Sack Sorting Machine (SSM).......................................................................Worksheet W-22, Single Position Letter Sorting Machine (SPLSM).........................................Worksheet W-23, Tray Transport Conveyors............................................................................Worksheet W-24,.......................................................................................................................Table 1, Service Condition Classification..................................................................................Mechanization/Automaton Equipment Summary.......................................................................
SECTION 3 - WORKHOUR ESTIMATING GUIDELINES FOR FIELD MAINTENANCE...............Instructions.................................................................................................................................Field Maintenance Program Staffing Summary.........................................................................Sample Form 4942....................................................................................................................
SECTION 4 - WORKHOUR ESTIMATING PROCEDURES FOR BUILDING EQUIPMENT.........Instructions.................................................................................................................................Building Equipment Workhour Estimating Summary.................................................................
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Sample Worksheet, Maintenance Service Contracts (Current)..................................................Sample Form 4897....................................................................................................................Sample Form 4894....................................................................................................................Sample Form 4895....................................................................................................................Sample Form 4896....................................................................................................................Sample Form 4896-A.................................................................................................................Sample Form 4893....................................................................................................................
SECTION 5 - CUSTODIAL STAFFING.........................................................................................Instructions.................................................................................................................................Sample Form 4869....................................................................................................................Sample Form 4839....................................................................................................................Sample Form 4852....................................................................................................................Custodial Position Summary......................................................................................................
SECTION 7 - CRAFT POSITIONS................................................................................................Instructions.................................................................................................................................Sample Form 4840....................................................................................................................Maintenance Tour Coverage.....................................................................................................Area Office Address/Telephone Information..............................................................................
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MAINTENANCE WORKHOUR ESTIMATING GUIDE METHODOLOGY
INTRODUCTION
This document is a seven-section package that contains or identifies the forms and instructions necessary to determine the workhour requirements for maintenance support at an automated/mechanized mail facility. Sections 2 - 6 develop the workhours necessary to perform a particular aspect of the maintenance function. Section 7 assists in assigning positions to an appropriate tour based upon maintenance requirements. Section 1 contains the Workhour Summary Data from Sections 2 - 6 and the Summary forms.
The Maintenance Workhour Estimating Guide is assembled in sections to allow for its completion and submission by parts or as a complete package. Any section 2 - 6, when accompanied by Section 1, may be submitted for review and approval as a stand-alone package. The determination of the need for complete or partial submission is based upon changes from previously identified and approved inventory or criteria. Such changes must significantly affect the total workhours for a particular section before a revision is required to the package.
This Maintenance Workhour Estimating Guide does not address the requirement for Management or Supervisory positions within the Maintenance organization.
GENERAL INSTRUCTIONS AND GUIDELINES
Step 1. Prepare Accurate Inventories. Use previous staffing packages, maintenance operations support records, and physical inventories to ensure the accuracy of MARS.
Step 2. Apply Annual Workhours Per Unit. Eliminate the following from initial consideration:
a. Areas for cleaning or policing that are not occupied on a tour or weekends (i.e., office space or carrier section).
b. Building equipment that is currently under a service contract and building equipment that can be more economically contracted out.
c. All equipment supported under local/national maintenance contracts.
Step 3. Apply Deviations Separately.
Completion of this package which is based only on approved maintenance criteria will result in an estimate of workhours which will result in a theortical staffing by position and number of craft personnel. This theoretical result must be transformed into a practical staffing by considering any adjustments or exceptions required because of the number, age, and general condition of the machines; the distance between machines; the intensity of usage by mail processing; the length of maintenance window; the effectiveness of the preventive maintenance program; the experience level of mechanics and technicians; and the historical experience of the site.
Attachment 5
MMO-028-97 Maintenance Technical Support Center
When documenting requested deviations, address the following area:
a. Identify and substantiate each recommended deviation from the criteria included herein. These changes may include altered frequency of performance, higher or lower workhour allowance per unit. or the selected ratio of operational maintenance.
It is essential that the office provide a rationale and justification for any departure from time values stated herein. This is particularly applicable to Operational Maintenance not authorized in this package.
b. Determine cost or savings of each deviation in terms of annual workhours and dollars.
c. Provide benefits and possible alternatives.
Step 4. Additional Requirements (Written justification must be provided for each entry. Use Section 2-C.):
The following are examples that apply:
a. Any locally purchased equipment.
or e b. Equipment unique to your facility not covered by national guidelines.
cb. Any additional complement required for tour coverage
Step 5. Consider the following (to be done by the Senior Maintenance Official):
a. Should automatic allowances be made because of excessive leave (AWOL, LWOP, etc.), or can the basic problem be remedied?
b. Is lowered performance the result of physical limitations in a section, or are they due to inadequate (numbers) or poor (quality) supervision? How much supervisor time is spent on the floor? How much at a desk?
c. Are increased frequencies made necessary in building cleaning because of the personal habits of occupants?
d. Is the appropriate number of personnel assigned to a task? Does crew size ensure safe task performance, considering size, bulk, awkwardness, and weight?
e. Can operation time be spread over a greater number of pieces of equipment? What are the consequences of simultaneous breakdowns? How frequently do they occur?
f. Is the HVAC control board monitored constantly?
NOTE
Continuous attendance of HVAC control boards is not authorized. (See MS-1, Appendix 13-C.)
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g. Is there a large deviation from the frequencies for routine preventive maintenance routes? Why?
h. Are prescribed methods and equipment being used in each task for which a deviation is recommended?
i. Is the proper service code (light, moderate, severe) assigned to mail processing equipment?
Attachment 7
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SECTION 1
APPROVALS, RECOMMENDATIONS, AND SUMMARY
This section consolidates the workhour recommendations to maintain an automated/ mechanized office and its associated facilities.
Consolidate the positions identified on the Maintenance Tour Coverage Forms, Section 7, pages 113 to 115, and enter the values in the "Recommended Staffing" column of "Craft Position Recommendations", Section 1-A, as appropriate.
NOTE
The subtotals and grand total values identified in Section 1-A may not exceed the positions identified in Section 1-B, "Maintenance Position Summary."
Once the "Recommended Staffing" is complete, indicate the "Net Change" (either plus or minus) in the appropriate column.
Subtotal and total all figures as indicated by the form. The "Grand Total" figure on line 39, page 12, is a total of all maintenance craft positions.
The completed workhour estimating package should be forwarded through appropriate channels for final review and approval.
When approved by the officials indicated below, the "Recommended Complement," as indicated in Sections 1-A and 1-B, will become the authorized complement for this facility. When the survey package has been approved at the Area level, appropriate action for implementation may be taken.
REVIEWED BY:
_______________________________________ ___________________________Senior Maintenance Offical Date
APPROVED BY:_______________________________________ ___________________________Plant Manager/Postmaster Date
_______________________________________ ___________________________Manager, Maintenance Support DateArea Office
6. Section 6, TABLE 2, Recommended Distribution - Maintenance Support Positions(Enter Number of Authorized Positions, page 108): __________________
7. GRAND TOTAL MAINTENANCE CRAFT POSITIONS (Sum lines 5 + 6): __________________
Operational maintenance as identified in this package is considered necessary and cost effective.
Attachment 13
Prepared/Reviewed by: Senior Maintenance Official,Signature, Title, and date:
__________________________________________
Plant Manager/Postmaster,Signature, Title, and date:
___________________________________________
MMO-028-97 Maintenance Technical Support Center
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SECTION 2
POSTAL OPERATING EQUIPMENT
This section allows calculation of the workhours necessary to maintain "Miscellaneous Postal Equipment" (Section 2-A) and "Major Mechanization/Automation" (Section 2-B). The section "Additional Requirements" (Section 2-C) allows for request of work hours for locally unique equipment that is not covered by national maintenance criteria.
When developing the inventory for these sections, the manager should include all equipment that is supported by the maintenance staff.
The "Equipment Description" column defines the equipment requiring maintenance. This column also contains "Qualifying Remarks" and other references to help identify the equipment. Equipment is to be listed in alphabetical order according to its "official" MARS Acronym.
The "Reference Documents" column provides information on references available that may define maintenance requirements, provide a picture, or otherwise provide data on the item listed. Items with blanks in this column have no specific maintenance criteria standards published; local, historically developed criteria should be used.
The "Service Condition" column (used only with Section 2-B, "Major Mechanization/Automation") provides a means of determining maintenance workhours dependent on severity of operation. When indicated, refer to Section 2, Table 1, page 72, to determine the service condition of the inventoried item.
"Additional Requirements", Section 2-C is used to document equipment that does not have approved maintenance criteria. This would include locally purchased equipment, equipment located at detached facilities not normally maintained by maintenance craft personel, etc.
Worksheets W-1 through W-24 are provided for those items where "Maintenance Workhours" is a variable depending on machine operating hours, number of days utilized per week, number of stackers, etc. The worksheets provide for request of operational maintenance hours. All operational maintenance hours must be justified.
The summary data from the Mechanization/Automation Equipment Summary on page 73 should be entered in Section 1-B, page 13.
NOTE
There may be occasions when the workhour summaries will not provide enough positions for adequate tour coverage to support Mail Processing requirements.. To assist in verifying this coverage, use Form 4840, Operation - Maintenance Schedule when posting the tenetative staffing levels to the Maintenance Tour Coverage forms (see Section 7.) Review tour coverage and make the necessary adjustments in Section 2-C.
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MMO-028-97 Maintenance Technical Support Center
SECTION 2-A
MAINTENANCE WORKHOUR ESTIMATING GUIDELINEMISCELLANEOUS POSTAL EQUIPMENT
ACRONYM CLASS
EQUIPMENT DESCRIPTION(QUALIFYING REMARKS)
MISCELLANEOUSPOSTAL EQUIPMENT
REFERENCEDOCU-
MENT(S)
ANNUALWORK-HOURS
AUTH/UNIT
UNITSINVEN-TORIED
ANNUALWORK-HOURS
BLDG M Cabinet, Filing, Letter/Legal - All Sizes Item Nos. - 434, 435
0.1
BLDG M Cabinet, Storage Item No. 212-B or Equivalent
0.1
BLDG M Fan, Table or Pedestal, Oscillating or Nonoscillating - All Models
0.2
BLDG M Locker, Clothing - All Sizes, Item Nos. 302-B1, B2, B3, B4
0.02
BLDG M Recorder, Time (Simplex or Cincinnati)
15.0
CACM AA Canceling Machines, All Models Pub 47 125.0
CBOX AA Collection Boxes, All Types & Models (Repaired In House)
Pub 47* 2.0
CBOX AA Collection Boxes, All Types & Models (Not Repaired In House)
Pub 47* 1.0
CCTV A Closed Circuit TV, Camera - All Models
6.6
CCTV A Closed Circuit TC, Monitor - All Models
4.6
COMM EA Communications, Intercom, Solid State (Per Station)
1.0
CONT AA Container Repair, Over the Road, Aluminum OTR--3910 (Alum), 3910-A (Amtrak), 3917 (Steel)
Pub 47*MMO-43-82
2.1
CONT AD Container Repair, Over the Road, GPMC 3909
Pub 47* MMO-43-82
1.5
CONT AE Container Repair, Over the Road, ERMC--3921
1.6
CONT AI Container Repair, Over the Road, Mesh Container--1923B
MMO-43-82 1.6
CONT AJ Container Repair, Over the Road, Reg Mail--Bonus Built
1.6
CONT AK Container Repair, Over the Road, Con-Con Security-- 3920
0.4
CONT BA Containers, In House, Hamper--1046
Pub 47* MMO-43-82
1.0
CONT BB Containers, In House, Hamper--1033
Pub 47* MMO-43-82
0.3
* Pub 47 provides pictures to identify equipment items.
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SECTION 2-A
MAINTENANCE WORKHOUR ESTIMATING GUIDELINEMISCELLANEOUS POSTAL EQUIPMENT
ACRONYM CLASS
EQUIPMENT DESCRIPTION(QUALIFYING REMARKS)
MISCELLANEOUSPOSTAL EQUIPMENT
REFERENCEDOCU-
MENT(S)
ANNUALWORK-HOURS
AUTH/UNIT
UNITSINVEN-TORIED
ANNUALWORK-HOURS
CONT BD Containers, In House, Utility Cart--1075
Pub 47* MMO-43-82
0.4
CONT BE Containers, In House, BMC In-House Container--3924
1.0
CONT BI Containers, In House, Seven-Shelf Tray Cart--1226C
0.5
CONT BJ Containers, In House, A-Frame Tray Cart--1226D
0.5
CONT ZZ Container, Post Con Item No. 3907 1.5CONT ZZ Container, Wire Mesh Item Nos.
CFS EA Computerized Forwarding System - Mechanical Term-Display-KB & Transport
MMO-18-90 See W-3 Worksheet
0.0
CFS FA Computerized Forwarding System - Flats Forwarding
MMO-18-90 See W-3 Worksheet
0.0
CSBCS AA Carrier Sequence Bar Code Sorter IBM
See W-24Worksheet
0.0
CVA AA Conveyor, A Series MMO-5-79 0.0CVAA AA Conveyor, AA Series MMO-5-79 0.0CVB AA Conveyor, B Series MMO-5-79 0.0CVC AA Conveyor, C Series MMO-5-79 0.0CVD AA Conveyor, D Series MMO-5-79 0.0CVE AA Conveyor, E Series MMO-5-79 See W-2 0.0CVG AA Conveyor, G Series MMO-5-79 0.0CVH AA Conveyor, H Series MMO-5-79 Worksheet 0.0CVPR AA Conveyor, PR Series MMO-5-79 0.0CVPRS AA Conveyor, PRS Series MMO-5-79 0.0CVR AA Conveyor, R Series MMO-5-79 0.0CVSP AA Conveyor, SP Series MMO-5-79 0.0CVSPS AA Conveyor, SPS Series MMO-5-79 0.0CVSR AA Conveyor, SR Series MMO-5-79 0.0CVSRS AA Conveyor, SRS Series MMO-5-79 0.0CVY AA Conveyor - All Other Bulk
Conveyor SystemsMMO-2-73 OE-29-71
0.0
DBCS AA Delivery Barcode Sorter - ECA Model 990 with 102-306 Stackers
MMO-054-94 See W-4 Worksheet
0.0
DBCS AB Delivery Barcode Sorter - ECA Model 990 with 102-306 Stackers+MKS
MMO-054-94 See W-4 Worksheet
0.0
DBCS BA Delivery Barcode Sorter - MM Model 925
MMO-50-94 See W-4 Worksheet
0.0
DBCS BB Delivery Barcode Sorter - Martin Marietta Model 925 with 100-300 Stackers+OKS
MMO-50-94 See W-4 Worksheet
0.0
DBCS CA Delivery Barcode Sorter - ECA Model 994 with 100-302 Stackers
* Repair maintenance estimates based on 30% of preventive maintenance** Based on 10% of total preventive maintenance and repair*** Based on 110% of total preventive maintenance
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WORKSHEET W-4DELIVERY BAR CODE SORTER (DBCS)
(Reference Staffing Criteria from MMOs as stated on the following corresponding charts)
For the purpose of calculating preventive maintenance criteria, a six-day operation is assumed for this table. To obtain a Maintennace Hours/Year total for a five-day or seven-day operation, subtract 69 hours for a five-day operation and add 69 hours for a seven-day operation.
Corrective maintenance is estimated at 50% of preventive maintenance hours. Nonproductive time is estimated at 10% of the sum of preventive maintenance and corrective maintenance.
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Maintenance Technical Support Center MMO-028-97
Attachment
MAINTENANCE HOURS/YEAR FORMARK-II FACER CANCELER MODEL 3501
For the purpose of calculating preventive maintenance criteria, a six-day operation is assumed for this table. To obtain a Maintenance Hours/Year total for a five-day or seven-day operation, subtract 43 hours for a five-day operation and add 43 hours for a seven-day operation.
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MMO-028-97 Maintenance Technical Support Center
Attachment
MAINTENANCE HOURS/YEAR FOREDGER FEEDER MODELS 500, 500A, and 501A
For the purpose of calculating preventive maintenance criteria, a six-day operation is assumed for this table. To obtain a Maintenance Hours/Year total for a five-day or seven-day operation, subtract 26 hours for a five-day operation and add 26 hours for a seven-day operation.
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* Locally assigned
Enter total maintenance hours in appropriate line items in Section 2-B, page 24, Multi-Position Flats Sorting Machine.
Service Condition
Routine Pm (hrs/yr)
Repair *(hrs/yr)
Total PM and Repair(hrs/yr)
Non-Productive
Time **(hrs/yr)
Total Maintenance Per Machine
(hrs/yr)
6 Days 581 58 639 64 703
7 Days 642 64 706 71 777
* Repair Maintenance estimates based on 30% of preventive maintenance.** Based on 10% of Total PM and Repair.
Problem/hrs Problems/yr Problem Isolation hrs/yrProblem Isolation
Per Telecommunication Link2.47 15.6 38.5
* Repair maintenance estimates based on 30% of preventive maintenance.** Based on 15% of Total PM and Repair.*** Values may not add up due to rounding.
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WORKSHEET W-17MILITARY/INTERNATIONAL DISPATCH AND ACCOUNTABILITY SYSTEM (MIDAS)
Note: For 1 to 9 stations, use 0.015; for 10 to 29 stations, use 0.01; and for 30 or more stations, use 0.0075.Enter total maintenance hours in appropriate line items in Section 2-B, page 25, Postal Source Data System.
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Note: For 1 to 9 stations, use 0.015; for 10 to 29 stations, use 0.01; and for 30 or more stations, use .0075.
NOTE: For 1 to 9 remote scales use 0.015. Enter total maintenance hours in appropriate line items in Section 2-B, page 25, Postal Source Data System, Time & Attendance, Phase 1, Management Station and MODS Scale.
Attachment
WORKSHEET W-19 POSTAL SOURCE DATA SYSTEM (PSDS)
PHASE 1, MANAGEMENT STATION(Refer to MMO-032-89)
LineNo.
Equipment Description
Number of Units
Inventoried
PMWorkhours
Per Unit
Total PMWorkhours(Col. 3 X 4)
Non-Productive Workhours
(10% of Col. 5)
Total Maintenance
Hours(Col. 5+ 6)
1Controller, IBM 3274 2.00
2 Display, Controller 1.34
3 Printer, Genicom 23.66
Total
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WORKSHEET W-21SACK SORTING MACHINE (SSM)
(Refer to PE-4-72, OE-37-71, and MS-23)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
EquipmentType *
DriveHorsepower Length
AnnualRun
Hours(ARH)
Operational Maintenance
(Local Justification) **
ServiceCondition
PM Hours From Maintenance
Checklist
RM Hours
100% of Col. 7
PM+RM Col. 7+8)
NP10% of Col. 9
Total Maintenance
Hours(Col. 9+10)
Totals ////////////// /////// //////// ////////// ////////////////// ///////// ////////// ////////* Equipment types consist of: Sack Sorting Machine-Carousel, Over-Under (SSM), Monorail Sack Sorter (MSS), and Belt-Type Sack Sorter (SSC)** Local justification for operational maintenance must be attached.
Enter total maintenance hours in appropriate line items in Section 2-B, page 26, Sack Sorting Machine.
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* Locally assigned
Enter total maintenance hours in appropriate line items in Section 2-B, page 26, Single Position Letter Sorting Machine.
MAINTENANCE HOURS/YEAR FORUBM SPLSM
Annual RunHours/Year
PM RM PM&RM NP TotalMaintenance
1040-2040 400.0 100.0 500.0 50.0 550.0
2040-3380 448.5 112.1 560.6 56.1 616.7
3380-5200 448.5 112.1 560.6 56.1 616.7
MAINTENANCE HOURS/YEAR FORBURROUGHS SPLSM
Annual RunHours/Year
PM RM PM&RM NP TotalMaintenance
1000-2000 155 40 195 20 215
2000-4000 215 55 270 30 300
4000-6000 215 55 270 30 300
Attachment
WORKSHEET W-22SINGLE POSITION LETTER SORTING MACHINE (SPLSM)
Enter totals for maintenance hours in appropriate line items in Section 2-B, page 22, CarrierSequence Bar Code Sorter (CSBCS).
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MAINTENANCE HOURS/YEAR FORCARRIER SEQUENCE BAR CODE SORTER
(Located in Maintenance Capable Office)(6 day Operation)
Routine PM *(hrs/yr)
Repair **(hrs/yr)
Total PM+Repair(hrs/yr)
OperationalMaintenance
Non-Productive Time ***(hrs/yr)
Total Annual Maintenance
(hrs/yr)
1st Machine 225 68 293 10% 88 380
All Others 223 67 290 10% 87 377
* 130 hours (SMP PM) plus 93 hours per ;machine plus 2 hours per site for station input PC.** Repair maintenance estimates based on 30% of preventive maintenance*** Non productive time based on 30% of total PM and repair. No travel time is allocated for a
CSBCS at a Maintenance Capable Office.
MAINTENANCE HOURS/YEAR FORCARRIER SEQUENCE BAR CODE SORTER
(Located in Remote Locations, Non-Maintenance Capable)
Routine PM *(hrs/yr)
Repair **(hrs/yr)
Total PM+Repair(hrs/yr)
Non-Productive Time ***(hrs/yr)
Total Annual Maintenance (hrs/yr)
1st Machine 95 29 124 43 167
All Others 93 28 121 42 163
* 93 hours per machine plus 2 hours per site for station input PC.** Repair maintenance estmates based on 30% of preventive maintenance.*** Non productive time based on 30% of total PM and Repair plus 6 hours travel for 3 corrective
action trips.
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TABLE 1SERVICE CONDITION CLASSIFICATION
EQUIPMENT OR SYSTEMSERVICE CONDITIONS - BASED ON
ANNUAL MACHINE RUN HOURS
LIGHT MODERATE SEVERE
Bulk Belt Conveyor - Power Turns,Traveling Deflectors 1000-2500 2500-5000 5000-7500
Multi-Position Letter Sorting MachineMPLSM - All Models
1000-2000 2000-4000 4000-6000
Parcel Sorting MachinePSM - All Models 1000-2500 2500-5000 5000-7500
Sack Sorting MachineSSM - All Models 1000-2500 2500-5000 5000-7500
If machines are used only in Peak Seasons, do not allow total annual staffing.
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MECHANIZATION/AUTOMATION EQUIPMENT SUMMARY
Attachment
LINE TOTALS FROM ANNUAL WORKHOURS
1 Miscellaneous PostalEquipment (Ref. page 20)
2 Major Mechanization/Automation (Ref. page 26)
3 Additional Requirements(Ref. page 27)
4 TOTAL WORKHOURS (Lines 1+2+3)
5 Multiply Line 4 by 1.14(This adds 8% for Modifications, and 6% for Alterations and Training)TOTAL STAFFING HOURS
6 Divide Line 5 by 1760TOTAL NUMBER OF Man Years
Prepared/Reviewed by: Senior Maintenance Official
Signature and Title
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SECTION 3WORKHOUR ESTIMATING GUIDELINES FOR FIELD MAINTENANCE
Field Maintenance Program (FMP) staffing is based on historical need as identified by Form 4942, Field Maintenance Office A/P Report. Using the data from the last 13 consecutive accounting periods, complete the entries on the Area Maintenance Office (AMO) staffing form. All entries are to be in hours, rounded to the nearest tenth of an hour. The entry on line 12 of the Field Maintenance Program Staffing Summary (page 76) will be utilized in Section 1-B.
A six-month history to define workload as delineated in MS-45 and Administrative Support Manual, Section 536, should be used if no history exists, or if workload is performed by Processing and Distribution maintenance staff.
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FIELD MAINTENANCE PROGRAMSTAFFING SUMMARY
Provide the data indicated by summing the line "Hours" figure from the Form 4942 entries for the last 13 consecutive accounting periods:
LINE
1. AMO Repairs Performed at Home Office (Line 4-A) _______________________
2. Work Performed at Associate Post Offices (Line B-4) _______________________
3. AMO plus "Other" Overtime (Line B-7, sum both entries) _______________________
4. AMO Work by Non-AMO Personnel (Line E "Labor" only) _______________________
5. Work Performed at other AMOs (Line F) _______________________
11a. Multiply line 11 by 1.1 (TOTAL WORKHOURS) (Adds 10% for Modifications, Alterations and Training) _______________________
12. Divide line 11a by 1760 = Man Years Required _______________________
NOTE
The line references indicated above are for the July 1979 version of Form 4942. Other versions of the form have the same information, but the referenced lines may vary.
Prepared/Reviewed by: Senior Maintenance Official
Signature and Title
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U.S. POSTAL SERVICEAREA MAINTENANCE OFFICE A/P REPORT
DATE A/P
TO:GENERAL MANAGERMaintenance Management Div.U.S. Postal Service_____________________________(city)
Attn:
FROM: (Area Maintenance Office)
INSTRUCTIONSEach Area Maintenance Office complete this form at the end of eachAccounting Period. AMO Postmaster: Submit original to Regional MaintenanceManagement Division: Duplicate to District Manager,. Retain one copy for file.COST ITEMS NO. HOURS COST
AMO Repairs 1. Work Requests Beginning A/PPerformed 2. Work Orders Complete A/P
A. At Home Office 3. Work Requests End A/PWithout Travel 4. Labor (AMT/AMS)
5. Contract Services $ SUBTOTAL
1. Work Requests Beginning A/P2. Work Orders Complete A/P3. Work Requests End A/P
Work Performed 4. Labor (AMT/AMS)B. At Associate 5.Contract Services
Post Offices 6. Paid Travel Time AMT/AMS
7. Overtime AMT/AMS Other
8. Per Diem ( )9. Lodging10. AMO Vehicle11.Other $ Subtotal
C. Repair Parts, Materials, SuppliesD.Record Keeping, Parts Exchange, Inventory Control, Etc. AMT/AMS______________Hrs; B. Other______________Hrs.E. AMO Work Performed by Other than AMT/AMS Labor
TravelF. Work Performed by Other AMO's(Specify AMO's)___________________________________________G. Total AMO WorkH. Non-AMO Work Performed by AMT/AMSI. Training Time (Specify)J. AL-SL-LWOP-Holidays
GRAND TOTAL DOLLAR COST PREPARED BY(Signature) SIGNATURE(Senior Maintenance Official) DATE
PS Form 4942July 1979 U.S. Government Printing Office 1985 457-E11/28002
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SECTION 4
WORKHOUR ESTIMATING PROCEDURES FOR BUILDING EQUIPMENT
Building Equipment workhours are estimated in accordance with Section 13 of HBK MS-1, TL-4, Operation and Maintenance of Real Property. Section 13 must be read and understood prior to attempting to complete the required forms.
The basic procedure is:
1. Complete a Building Equipment Inventory, Form 4897 (sample on page 82).
2. Complete Maintenance Service Contracts, Sample Worksheet (sample on page 81).
3. Complete Annual Standard Workhour Requirement - Traveling Operating Routes (if requested), Form 4894 (sample on pages 83 and 84).
4. Complete Annual Standard Workhour Requirement - Stationary Operating Routes (if required), Form 4895 (sample on page 85).
5. Complete Annual Local Workhour Requirement for Building Equip. Preventive Maintenance and Operation, Form 4896 (sample on pages 87 and 88) or Form 4896-A (sample on pages 89 - 95).
6. Summarize these totals on Form 4893 (sample on page 97) by type of work. (E-Elect, A-HVAC, L-Elevator, M-Misc and P-Plumbing).
A complete set of the above forms is required for the main office and each station and branch supported by the main office. Once those forms are complete, sum Total Annual Workhours from all Forms 4893 and enter this number where indicated on the "Building Equipment Workhour Estimating Summary" (page 80).
The apportionment of skill levels must consider the following variables/elements:
1. Workload in various skill areas.
2. Specialized or restrictive positions, e.g., painter, plumber, and carpenter are required only in large facilities where they can be effectively utilized 8 hours a day and 40 hours a week.
3. Need for developmental training and assignments.
4. Management flexibility.
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BUILDING EQUIPMENT WORKHOUR ESTIMATING SUMMARY
Building Equipment
Type ofWork
Total ProductiveWorkhours
Work Years Required(divide by 1760)
HVAC
ELECT
ELEV
MISC
PLUMB
PS FORM 4894
CORRECTIVE/ SPACE ADJUST
NON-POSTAL WORKHOURS
TOTAL
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SAMPLE WORKSHEET
MAINTENANCE SERVICE CONTRACTSCURRENT
DATE:
Post Office:Address:Description of Contract
(Type of Service)*
AnnualCost
Date of ContractFrom - To
ApprovedBy
LocationRequiring
Service
* Sample types of service contracts:Laundry ServiceAir ConditioningOffice Machines
Landscape MaintenanceTrash RemovalBoiler Service or InspectionOther Maintenance Supplies
Custodial SuppliesElevator Service or InspectionWindow Cleaning
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U.S. POSTAL SERVICEBUILDING EQUIPMENT INVENTORY
PAGE NO.
NO. OF PAGES
BUILDING CITY STATE GROSS AREA
PRINTED NAME SIGNATURE DATE PREPARED
EQUIPMENT EQPNUMBER
LOCATION DESCRIPTION AND REMARKS
PS Form 4897June 1974
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U.S. POSTAL SERVICEANNUAL STANDARD REQUIREMENT - TRAVELING OPERATING ROUTES
(For building systems) .0515 STEAM CONDENSATE RETURN SYSTEMS .0516 CENTRAL DRINKING WATER SYSTEMS .0617 COOLING TOWERS (Up to 500 tons) ONE .1018 HOT WATER SYSTEMS (1) .0519 HYDRO-PNEUMATIC SYSTEM (Including
fire protection systems)TIMEPER .08
20 PUMPS (Remote from other equipment) DAY .0321 PRESSURE REDUCING AND REGULATINGSTATIONS - STEAM AND WATER .0222 SECONDARY WATER SYSTEM
(Heating and cooling) .0323 SEWAGE EJECTOR .0524252627
NO. ELEVATOR LANDINGS IN EXCESS OF 6 PER ELEVATOR (i.e., if there are 2 elevators with 8 landings each, the entry under qty would be 4 & WH would be 24)
ROUTES PS FORM 48947 CORRECTIVE / SPACE ADJUST8 NON-POSTAL WORKHOURS9 Sub-Totals
10 Grand Totals
Remarks
(1) 8 Workhours per 1000 Gross Square Feet or Average Actual (2) 5 Workhours Per 1000 Gross Square Feet or Average ActualPrepared/Reviewed by (Sr. Maint. Official) Division Approval
Printed Name, Title and Signature Date Printed Name, Title and Signature Date
PS Form 4893, Jan. 1989 (Previous edition usable)
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SECTION 5
CUSTODIAL STAFFING
1. Complete custodial staffing for the main office and all stations/branches supported by the main office in accordance with the latest revised version of HBK MS-47, Housekeeping - Postal Facilities. Utilize Forms 4869 (sample on page 101), 4839 (sample on page 102), and 4852 (sample on pages 103 - 104).
2. Determine if the station/branch can be contracted by referencing the Memorandum of Understanding on Subcontracting of Cleaning Services in the current National Agreement.
3. If the station/branch custodial work cannot be contracted, it should be staffed with any combination of part-time regular (PTR) and/or full-time regular (FTR) positions necessary to provide the weekly workhours indicated on line J, Form 4852 (see HBK MS-47, Section 243.u - Use 1760 hour per year).
4. If the Main Office will be required to provide coverage for extended absences, give leave allowances for applicable stations and branches to the Main Office.
5. Absences not covered by relief from the main office will be covered by the following:
a. In offices with multiple custodial positions, the staff that is present can work additional hours, either extra hours for PTRs or overtime for FTRs.
b. In offices with single custodial positions, custodial duties may be performed by non custodial personnel: Mechanics, PT Flexible Clerks, PT Carriers, etc. This is also the procedure to be used in associate offices to compensate for custodial absences.
6. Custodial positions should be allocated based upon task requirements and Position Descriptions.
7. Make entries in the appropriate columns on the Custodial Position Summary form, page 105, as follows:
a. Enter the names of the facilities where the main office is responsible for custodial services (Main Office, VMF, Station or Branch). Do not include associate offices.
b. Enter the weekly workhours indicated on Line J of the Form 4852 for that facility.
c. Under "Full-time Regular Positions", enter the number of each type of position recommended for that facility.
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d. Under "Part-time Regular Positions", enter the number of each type of position recommended and the weekly workhours for each position.
e. If the facility is to have a contract cleaner, enter the weekly workhours for which the facility should be contracted.
f. Total the number of positions at the bottom of the form.
8. Staffing determined by this section should be summarized in Section 1B, Page 13.
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U.S. Postal ServiceBUILDING INVENTORY
Post Office Location Completed By Date
Room/Location
Description Type of Space
Sq Ftof Area Light Fixtures
(Type)
Vene-tion
Blinds
GlassInter ExterSq Ft Sq Ft
CasesCarrier Other
Floors Sq Ft(Type) Miscellaneous
TOTALS
PS Form 4869, June 1988 (Aug. 1982 edition usable)
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U.S. POSTAL SERVICELOCATION/FACILITY POST OFFICE DATE
2 PL FX 1.5 34 Dust FX3 Office Toilets CL FX 4.0 35 Dust FX4 Lunch/Swing
RoomsCL .032 36 Light Fixtures Wash FX
5 PL SF .0106 37 Wash FX6 WM SF .03 38 Wash FX7 Locker Rooms CL SF .024 39 Venetian
BlindsWash BL 30.0
8 PL SF .008 40 Dust BL 5.09 WM SF .03 41 Lobby Glass Wash SF .17910 Work Rooms CL SF .0106 42 Exterior Glass Wash SF .17911 PL SF .0053 43 Interior Glass Wash SF .17912 Offices CL SF .0375 44 Wkrm
Pipes/DuctsDust SF .069
13 Supply Rooms CL SF .012 45 Other Pipes/Ducts
Dust SF .048
14 Freight Elevators PL UT 10.0 46 Lookout Gallery
CL LF .48
15 Passenger Elevators
CL UT 20. 47 Carrier Case CL EA 4.0
16 Ext Police PL SF .0012 48 Other Case CL EA 1.517 Platforms CL SF .0106 49 Ext. Paved Sweep SF .00618 PL SF .0053 50 Ext. Paved Sweep SF .00419 Svc./Box Lobby CL SF .016 51 Ext. Paved Sweep SF .001220 PL SF .002 52 Active Storage CL SF .01221 WM SF .03 53 Inact Storage CL SF .01222 VS SF .0064 54 Resilient FL DM SF .01523 DM SF .015 55 INT SF .2424 Stairways CL UT 56 PERI SF .09625 PL UT 2.4 57 Terrazzo INT SF .2426 Corridors CL SF .006 58 PERI SF .1227 DM SF .015 59 Concrete INT SF .2428 VS SF .0064 60 PERI SF .09629 PL SF .002 61 Carpet Shamp SF .2430 Shop Areas CL SF .012 62 SPOT SF31 Jan. Closet CL EA 10.0 63 Wood INT SF .2432
Sub-Total 64 PERI SF .12
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WORKLOAD ANALYSIS AND SUMMARY (Cont'd)
JobRequirement
JobRequirement
AnnualMinutes
Work-hour Calculations 65 Lawns MOW SF .012 (o) (p) 66 Hedge/Shrub TRIM LF 1.2A Multiply total line 32 by 52 weeks Min/Yr 67 Snow Remove SF .015B. Enter total from line 77 Min./Yr 68 P.O. Boxes CL EA 2.0C Total lines A+B Min/Yr 69D Divide line c by 60 minutes WH/Yr 70E Multiply line D by............%(TRG) H/Yr 71F Multiply D by...............%(Breaks) H/Yr 72G Multiply line D by....%(Wash Ups) H/Yr 73H Total lines D+E+F+G WH/Y 74J Divide line H by 52 WHS per
Week75
K Divide line H by 1760 Work Years
76
L Total Employees 77Sub-Total
Reviewed By (MSC Mgr./Plant & Equip. Engineering Mgr.) Date Approved By (MSC Manager/Postmaster/BMC Manager)
Date
PS Form 4852 Apr. 1988 (Previous edition usable)
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CUSTODIAL POSITION SUMMARY
OFFICE, FORM FULL-TIME REGULAR POSITIONS PART-TIME REGULAR POSITIONS CONTRACTSTATION or BRANCH
4852LINE J
LABCUST
CUSTODIAN
CLEANEROTHER 1
LAB#
CUSTHRS
CUSTODIAN# HRS
CLEANER# HRS
OTHER 1____# HRS
WEEKLY WORKHOURS `1
POSITION TOTALS/////////////////////////////////////
//////////////////
//////////////////////
//////////
(1) (2) (3) (4) (5) (6) (7) (8)
1 - Other includes group leader, building maintenance custodian, fireman/laborer.Sum Columns 1 - 8
GRAND TOTAL OF ALL POSITIONS (USPS Craft)
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SECTION 6
MAINTENANCE ADMINISTRATION
Maintenance Operations Support - The maintenance support activity, as identified in MS-63, is required for day-to-day maintenance operations. The number of maintenance support positions depends on the workforce supported. Maintenance Support does not support security personnel, telephone operators, elevator operators, supervision, or other administrative personnel which do not require daily scheduling. Therefore, when determining the "Number of Positions Supported", normally include only those positions determined by Sections 1A of this staffing package.
To determine the "Number of Positions Supported", use line 5, Section 1-B, page 13 of this staffing package. Use TABLE 2, page 108 "Maintenance Support Positions," to determine the number of each type of job recommended for this workforce.
These positions will be summarized in Section 1.
Other Administrative Positions - There are some positions assigned to the maintenance section for administrative purposes only. Staffing for these positions will be at the discretion of the Area Office.
Distribution of authorized positions to be determined by Senior MaintenanceOfficial and entered in Section 7 on the Maintenance Tour Coverage forms,page 113 - 115.
NO. Craft Positions Supported Enter figure from Line 5, Section 1-B, Page 13 ___________________
NO. OF AUTHORIZED POSITIONS ___________________Select appropriate number from TABLE 2 above based on the number of positions supported.
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SECTION 7
CRAFT POSITIONS
Craft Positions
The number of man years by functional area have been identified, see Section 1-B, page 13.
To determine the distribution by tour and skill levels, the following steps should be taken:
1. Obtain from operations a completed Form 4840 (sample on page 111) Operation-Maintenance Schedule, that displays the operating plan for each major piece of equipment. This should be developed for each day of the week. (Reference MS-63).
2. Assign for each day and tour, by function, the necessary coverage to support operational and maintenance needs. Generally, Tour II, M-F, will have the majority of personnel performing Preventive/Corrective Maintenance and Project work.
3. Determine the skill level required and assign same by specific occupation code and/or position to the appropriate function, tour, and day on the " Maintenance Tour Coverage" forms on pages 113 - 115.
4. Post total by position to "Craft Position Recommendations" column of Section 1-A.