21 st century mail 4-state code implications for flats mailers & the idealliance process...

21st Century Mail4-State Code

Implications for Flats Mailers

& the IDEAlliance Process

Jonathan PhillipsChair, IDEAlliance Intelligent

Mail Barcode Task ForceJuly 24, 2007

4-STATE CODE

Postnet and Planet

– 22 bars/inch

– 62 and 72 bars in the code

– Full bar 0.115in to 0.135in

4 State Code

– 22 bars/inch

– 65 bars in the code

– Full bar 0.134in to 0.230in

4-STATE CODE

Postnet and Planet

– Simple algorithm, direct correlation

– Readily visually read

4 State Code

– Complex encryption algorithm

– Cannot be read without scanner

What’s the fuss about ?

Primarily:

Size

4-STATE CODE

Industry Position

Many printers use 8-line 0.167in-pitch raster inkjets

Many printers use 1in binary array inkjets.

In both cases, code heights above 0.125in mean less lines of text are available.

Politics of position A synopsis of the situation that presented itself is very simple.

As the USPS move from POSTNET to the 4sc it is imperative that existing technologies deployed and controlled within the printing industry, representing an estimated total replacement cost of 250,000,000 dollars can print the new code satisfactorily, and that the USPS does not burden industry with these costs. The proposed international standard for 4sc the USPS were planning to adopt would have necessitated machine replacement.

As a result of this state of affairs and in acknowledgement of the IDEAlliance communications on the issue. work was carried out over a number of years by the USPS, with ongoing assurances from the USPS that all printer technology would be accommodated.

This was planned to be accomplished through a change to the height and other related dimensional specification of the Barcode.

In Feb 07 the USPS shocked the publication printing market when they announced that the 4sc would remain at the international specification height and specifically citing failure of UFSM machines in testing the modified specification as the cause.

The USPS Feb 2007 communication extract

Most Testing started Summer 2006

Testing on AFSM 100 & APPS

– Testing showed no degradation @ .125” height

Testing done on UFSM

– Significant read rate decline at .125” height

• 95+% at .134” height

• ~25% at .125” height

As a result, flat specification can not be adjusted below .134” at this time

Establish a specification that allows the use of existing predominant technologies to print the 4-state barcode without compromising, yield, productivity, or flexibility.

1.Determine the optimal inkjet 4-state barcode specification through field evaluation of the UFSM with current inkjet technology

2.Pressure the USPS to change the 4-state barcode specification to allow printing with current inkjet technology

IDEAlliance technical team 4SC

4-STATE CODE

IDEAlliance Practical Evaluation

Specific barcode items for consideration

Height

Non-linearity

Address block

Height - Overall

Raster printer bar height impacted by

non-printer variables:

– Book thickness (+/-1/8in for selective)

– Book curvature (esp. stitched)

printer variables:

– Head height

– Operator settings

Height – Overall

Where is the bar measured in practice?

Effective bar height

measure point

Height - Voids

Information from USPS-B-3200 and Pub. 25

0.0050.005

Current specification is 0.005in

Height - Voids

Constructive use of voids

– Permit taller bar with less drops (greater speed or less skew)

– Reduce implications of drop-diameter on code quality

Drop0.0150

Void0.006

Void0.004

Drop0.0165

Diagram showing void and drop diameter comparing MEK and Acetone fluids with same 0.180in bar height.

Height - Voids

Example

– 9dp at full spec height 0.230in

– Shows voids ~0.012in

Height

Action

Determine height sensitivity

Determine impact of voids


Non-linearity (skew)

Linear skew


< +5° max > -5° max

CL

CL

Baseline skew

< +5° max > -5° max

CLCL

Bar skew

Non-linearity (curve)

Curve

– Formation of the raster means each drop travels a different distance

Diagram from UPU S18d-5

Non-linearity (hook)

Hook

– First drop slows more than subsequent ones due to aerodynamic effects

Non-linearity

Action

With samples of each skew type:

– Determine the perceived center line of the bar (bar-pitch)

– Determine the effective bar width

– Determine the effective inter-bar gap

– Considerations for skew angle

Address block line-gap


PlaceStampHere

4.125

9.500

JOHN DOE 91 MAIN STREET ANYTOWN MD 01234-5678

UNITED STATES POSTAL SERVICE5501 ANYWHERE HWY MERRIFIELD VA 22082-8412

01 234 567094 987654321 01234 5678 91

.040 MIN.500 MAX

Align to the leftmostposition of the barcode

PlaceStampHere

4.125

9.500

PlaceStampHere

4.125

9.500



01 234 567094 987654321 01234 5678 91

.040 MIN.500 MAX

Align to the leftmost



01 234 567094 987654321 01234 5678 91

.040 MIN.500 MAX

Align to the leftmostposition of the barcodeposition of the barcode

Address Block Gap

Action

Test to determine if gap can be reduced from the current 0.040in to the inter-text gap of 0.028in


IDEAlliance Practical Evaluation with USPS

Testing has started at Carol Stream, IL USPS facility

UFSM1000 evaluation focus

Results show the UFSM will not read codes under .134”

However AFSM reads very well indeed

Merlin being modified

Establish a specification that allows the use of existing predominant technologies to print the 4-state barcode without compromising, yield, productivity, or flexibility.

1.Determine the optimal inkjet 4-state barcode specification through field evaluation of the UFSM with current inkjet technology

2.Pressure the USPS to change the 4-state barcode specification to allow printing with current inkjet technology


4-STATE CODE

USPS MTAC announced:

1. Reduced height minimum from 0.134in to 0.125in

2. Increased address block gap from 0.028in to 0.040in

3. Increased voids to .010”

Formal change expected by Feb 2008

Other Industry/USPS testing activities continue


4-STATE CODE

USPS Schedule – May 1, 2007

Intelligent Mail Barcode acceptable for automation discounts

OneCode Confirm for First-Class, Periodicals and Standard

OneCode ACS for First-Class, Periodicals (Standard – Fall ’07)

Intelligent Mail Barcode for Flats

USPS Schedule – 2007

Barcode acceptable for automation discounts at original heights.

Letter of dispensation required for lower heights

Codes below .134 will fail Merlin and UFSM

Intelligent Mail Barcode for Flats

USPS officially embeds new specifications into DMM “Intelligent Mail®” around Feb 08

FSS roll-out: From Oct 2008

IMB Flats Mandate: 2009

Postnet invalid 2009

CASS-DPV Mandate: July 2009

Intelligent Mail Timeline Future Events

JetArray – Anatomy Detail

Domino Amjet Incorporated

William Tell

1290 Lakeside Drive

Framingham

Gurnee

New York landing

IL, 60031

Each black line represents top most drop of JetArray Print

The 1st line on a JetArray can deflect further asThere is no line below to impede belowThus this line can be up to about .166” high.Taller bars will have print defects

.166667”

.166667”

.166667”

.166667”

.166667”

.166667”

.166667”.040” gap required here will reduce to .028”

Each arrow represents deflection direction

JetArray Use in IMB?

Minimum was .115” Add .010” to get .125”

Practical Maximum was .126”Due to equipment andAdjacent line limits

Practical Maximum becomes .138”worst case (printing into text)and more like .152” + when printingaway from text (Printing on line 1)

Summary 4 State and JetArray

Can the JetArray print 4sc = Yes

Best printed from Line 1 = Educate the customer

Conversion Packages may be required

Letter of Dispensation will be required for JetArray up until 2008 because .134” is not practical with a .040 gap in an 8 line address

CASS certified mail preparation software with 4sc algorithm will be needed

Selective book thickness of up to 3/16th inch can be accommodated with CAREFUL setup

Summary IDEAlliance tasks

1) 4sc manual “Intelligent Mail”

What you need to know

2) Managing the USPS for this need

Published dispensation process

Managing disputes (automation failures at remote sortation facilities)

Managing the 20 bar 24 bar limit on Scitex 5120 products

Managing the proposed new technical specification

3) Committee for the specification

Ensure the technical specification detail represents industry needs

4) Interim management

Letter of dispensation method

Read Rates (may be poor on UFSM despite letter Printers and Publishers need to manage relationship and communicate well prior to roll out of USPS equipment and modified specification)

Thank You!

21 st century mail 4-state code implications for flats mailers & the idealliance process...

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