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June 14, 2003

HOME > ARTICLES > MERLIN



USPS Implementation of M.E.R.L.I.N.
at Northwest Mailing Service

It is important to Northwest that you have accurate and relevant information concerning MERLIN. This site contains the gory details for several audiences:

  1. Client of Service Bureau
  2. Mail piece Designers
  3. other Mailers

The first section, Clients of Service Bureaus, is directed toward our clients. It defines the balance of responsibilities in the perspective of achieving flawless MERLIN verification

"Mail piece Designers" is important to everyone because poor design directly affects the efficiency of the mail production on all levels. Ideally, it is best to land this information in the hands of the graphic Designer or whomever is the furthest up stream in the process.

We include "The Mailers Guide to MERLIN" for all mailers, including ourselves. This is a reprint of a document provided by USPS for our education. Please take in consideration that Northwest has already successfully implemented all of the extensive preparations for MERLIN.

Finally, in return for assembling all this information in such and easy to use format, here online, we invite our clients and future clients to benefit from sending work to Northwest. For more than 50 years, we have been pushing the envelope for higher mail quality. Simply-put, when Northwest is tested by MERLIN or by anyone else, we feel confident we will continue to succeed.

Contact us Today

   

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1. Client of Service Bureaus:


Your choice in a mailing service who is focused on DMM book regulations and proven Quality Control is your best defense against poor mail quality. MERLIN's main goal is to increase the quality of mail. Increasing mail quality has been common ground between USPS and Northwest Mailing Service for more than 50 years.

These are the largest threats caused by poor mail quality:

  • delays in mail processing
  • delays in delivery
  • increase in processing costs
  • increase in postage costs
  • delayed USPS delivery times

As a purchaser of service and an executive advisor to a mailing campaign, we urge you to grasp the concepts brought to the table by MERLIN. Without going into the goriest of details (see Mail Piece Designers for this), here are some things to keep in mind:

The type of stock you use. Porous stocks may cause barcodes to bleed, test newsprint and textured stocks for bleeding as well as uncoated corrugated mailers.

The background of your mail panel. The piece background has to allow a contrast between the paper and the barcode to ensure readability. Watch for recycled and security papers, dark-colored backgrounds or screens. Be sure to review your pieces with the Northwest team to lessen potential problem areas.

Consistent fold or trim areas. Pieces should have consistent fold or trim areas; significant variations in lds or size can trigger alerts. Also be sure that stock is not curled or torn.

Leave enough room for barcode clearance. When designing a piece, be sure to leave sufficient room for barcode clearance.

Last, but not least, the accuracy of your address list is always an important factor in mailings. This is a requirement from the USPS. For tips and further explanation, see Business Mail 101: addressing. Northwest Mailing Service provides excellent service for CASS-certification and NCOA.

   

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2. Mail piece Designers:


These are the details for designing mail for Northwest Mailing Service. Please note that most of what you will hear about MERLIN will be concerning tedious barcode specifications. We did not give you these specifications on this site because we are responsible for the quality of imprinting the postal barcodes. However, there are several factors, like positioning, that may hinder our capability in printing barcodes. Here you will find issues that we know of when this article was written.

Sizes for classes

Sizes for Letters

You probably have a picture in your mind of what a "letter" is. Possibly you're using a standard No. 10 envelope for your letter, so that's easy to picture. However, if you decide to create a mailpiece with its own special envelope or if you are designing a piece that will be folded to letter-size, be sure to keep in mind the following size requirements for letters:

To be eligible for mailing at the postage rates for letters, a piece must be:

  • Rectangular
  • At least 3-½ inches high x 5 inches long x .007 inch thick.
  • No more than 6.125 inches high x 11-½ inches long x ¼ inch thick.

Sizes for Cards:

  • Rectangular
  • At least 3-½ inches high x 5 inches long x .007 inch thick
  • No more than 4-¼ inches high x 6 inches long x .016 inches thick

If your mailpiece does not meet the dimensions above, then the Postal Service considers it a letter (and charges letter rate postage). With Standard Mail, there is a little more flexibility -- there is no separate (lower) postage rate for cards, so you don't have to worry about your postcard being too big -- because you're paying letter rates anyway. But make sure that your card is no larger than 6-1/8" x 11-1/2" x 1/4" thick. Larger than any of those dimensions and you will have to pay flat (non letter) postage rates.

Sizes for Large Envelopes and Flats (Non letters)

The Postal Service uses the words "flats" and "non letters" to refer to large envelopes, newsletters, and magazines. The words are interchangeable. Whatever you call them, flats must:

  • Have one dimension that is greater than 6-1/8 inches high OR 11-½ inches long OR ¼ inch thick.
  • Be no more than 12 inches high x 15 inches long x ¾ inch thick.

Sizes for Parcels

If your mailpiece isn't a card, letter, or a flat (large envelope), then it's a parcel. You may be surprised to find out that "parcels" are not just big boxes. Many mailers send small parcels in all classes of mail. Parcels offer some of the best value for your postage dollars.

All parcels fall into one of two categories: machinable and non machinable. These categories are determined by size and weight.

Machinable Parcels

"Machinable" parcels fit through the Postal Service's automated parcel sorting machines. They must measure:

  • At least 3 inches high x 6 inches long x ¼ inch thick, and at least 6 ounces.
  • No more than 17 inches high x 34 inches long x 17 inches thick, and no more than 35 pounds (25 pounds for books or other printed matter).

Non machinable Parcels

Non machinable parcels have at least one dimension (including weight) that exceeds the limits for a machinable parcel. Other parcels are non machinable based on content, weight, or other physical characteristics.

Non machinable parcels are more difficult and costly for the Postal Service to process and deliver. To cover those extra costs, there is a surcharge for non machinable parcels.

Balloon and Oversized Rates for Parcels

Some parcels may be subject to specialized rates. Priority Mail and Parcel Post parcels that are large but very light (less than 15 pounds) get charged a balloon rate. Very large Parcel Post parcels (over 108 inches but not more than 130 inches in combined length and girth) get charged an oversized rate.

Window positioning clearance

Window tap test (unacceptable)

Address Perpendicular to Bound Edge or Final Fold

Address Parallel to Bound Edge or Final Fold

Illustration showing address parallel to final fold

An acceptable but less desirable address location is one parallel to the bound or folded edge as shown above. In either case, the address may be placed on the front or back cover of the publication.

Enveloped Flats

On flats other than magazines, catalogs, and other bound-edge flats (such as First-Class and third-class enveloped flats), the front center of the mailpiece at least 1/8 inch (0.125 inch) below the top (3 inches preferred) is designated as the address block location (see below). This is similar to the address block location on letters. It does not matter whether the flat is oriented in the portrait or landscape mode.

For enveloped flats, the front center of the mailpiece is designated as the address block location.

Address Block

Illustration of area on an envelope that's best to use for an address block

Placement of Tabs and Wafer Seals

This graphic show the placement of tabs and wafer seals.

Double Postcard:

Tabs 1 (middle)
Folded Edge Top or Bottom
Sheets Single
Basis Weight 75 lb.

This graphic shows a double postcard.

Folded Self-Mailer:

Tabs 2 (start < 1 inch from edges)
Folded Edge Top or Bottom
Sheets Single
Basis Weight 20 lb.

This graphic shows a folded self-mailer Basis weight 20 lb.

Folded Self-Mailer:

Tabs 1 (middle)
Folded Edge Bottom
Sheets Multiple
Basis Weight 24 lb.

This graphic shows a folded self-mailer basis weight  24 lb.

Folded Self-Mailer:

Tabs 1 (middle)
Folded Edge Bottom
Sheets Single
Basis Weight 28 lb.

This graphic shows a Folded Self-Mailer Basis weight 28 lb.

Folded Self-Mailer:

Tabs 1 (middle)
Folded Edge Right
Sheets Single
Basis Weight 75 lb.
Note: Pieces 7 inches or longer
must be sealed on the top and bottom;
the middle tab is optional

This graphic shows a folded self-mailer basis weight 75 lb.

Folded Self-Mailer:
(Invitation Fold)

Tab Address Label
Folds Top and Bottom
Sheets Multiple or Single
Basis Weight 20 lb.

Folded Self-Mailer:
(Continuous Glue Strip)

Open Edge Top
Folded Edge Bottom
Sheets Single
Basis Weight 20 lb.

This graphic shows Folded Self-Mailer (Continuous Glue Strip).

Booklet :

Tabs 2 (start < 1 inch from edges)
Spine Bottom
Sheets Multiple with Cover
Basis Weight 20 lb. (Cover)

This graphic shows a Booklet as described in text.

Folded Booklet:

Tabs 2 (start < 1 inch from edges)
Spine Top
Folded Edge Bottom
Sheets Multiple with Cover
Basis Weight 20 lb. (Cover)

This graphic shows a Folded Booklet as described in text.

Folded Booklet:

Tabs 2 (start < 1 inch from top edge)
Spine Top
Folded Edge Bottom
Sheets Multiple with Cover
Basis Weight 20 lb. (Cover)

Booklet:

Tabs 2 (start < 1 inch from top and bottom edges)
Spine Right (open edge left)
Sheets Multiple with Cover
Basis Weight 24 lb. (Cover)


BRM Business Reply Mail

Courtesy Reply Mail


Above found at http://pe.usps.gov/ USPS "Postal Explorer" and from DMM 57 (pdf 16.5 MB)

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3. for other Mailers:


The Mailers Guide to MERLIN

August 2002

What is MERLIN?

MERLIN, an acronym for Mail Evaluation Readability Lookup INstrument, is a tool used by the USPS to assist with the acceptance of business mail. It automates the previous manual acceptance process for First-Class Presort Mail, Standard Mail, and Periodicals mail to ensure that the mail qualifies for workshare discounts. MERLIN verifies mail against standards set in the Domestic Mail Manual (DMM) for proper postage discounts, proper sorting, proper barcodes, and proper piece counts along with other acceptance checks for both letter-size and flat-size mailings.

Guidance is current as of September 2002, and mailers are advised to review all available MERLIN information resources for the most up-to-date information (see Resources For More Information).

Importance of Mail Preparation Quality

Poor mail preparation can cause delays in the processing and delivery of your mail. Improving mail preparation quality can save rework costs, reduce confrontations over mail quality problems at the BMEU/ DMU, and reduce USPS transportation and processing costs. Higher quality mail results in improved USPS delivery rates. MERLIN gives you diagnostic reports for improving mail quality. This guide shows you how to prepare for and operate within the MERLIN environment.

What can be analyzed by MERLIN?

MERLIN can process letters, postcards and flat-size pieces that do not exceed 15 inches in length or 12 inches in height and have a maximum thickness of ¾ inch. MERLIN verifications will be performed on both automation and non-automation rate letter-size and flat-size mailings. MERLIN can process pieces weighing up to 16 ounces. Non-automation mail pieces do not have to be tabbed or sealed for MERLIN processing as the equipment is able to verify a wide variety of mail pieces.

What can MERLIN do?

MERLIN is capable of simultaneously verifying:

  • Presort/mail makeup.
  • Weight/piece count.
  • POSTNET barcode readability.
  • PLANET barcode readability.
  • Tray label accuracy.
  • Meter identification and date.
  • Address/barcode accuracy.
  • Carrier routes.
  • Walk sequence accuracy.
  • Line of travel.
  • Endorsements and rate markings.
  • Combined mailings.
  • Mail piece dimensions (height, length, and aspect ratio, as well as thickness).

MERLIN generates mail diagnostic reports and electronically transfers data to PostalOne!. It will benefit mailers by:

  • Identifying where improvements in mail quality are needed.
  • Improving the efficiency of Business Mail Entry Units (BMEUs) and Detached Mail Units (DMUs).
  • Bringing consistency, objectivity, and reliability to the acceptance of workshare-discounted mail.
  • Connecting with PostalOne!.

What MERLIN checks are "active" in terms of potential postage adjustments?

Verification results are divided into two categories: additional postage and diagnostic information. Currently, the USPS assesses additional postage for poor quality in:

  • Presort accuracy.
  • POSTNET barcode readability.
  • Shortpaid metered mail (First-Class Mail only).
  • Piece count (permit imprint) accuracy.

Each of these verifications must meet USPS acceptance rates within published tolerances.

Diagnostic reports

are used to evaluate a mailing and assist the mailer in correcting mailpiece problems. Diagnostic reports do not have a postage adjustment associated with them. MERLIN provides these diagnostic reports:

  • Address accuracy.
  • Mailpiece characteristics.
  • Carrier route sequencing.
  • PLANET barcode readability.
  • Meter date recognition.
  • Meter plate.

Verifications performed by MERLIN for which there is no postage adjustment at the time of this publication may become "active" in the future, and the USPS may begin to assess additional postage. Even now, some diagnostic reports may disqualify a mailing for a specific rate if the mailing does not meet applicable standards.

Preparing for MERLIN Deployment - and Beyond

Always take actions to ensure high quality mail preparation. In addition to those ongoing efforts, take the actions described below specifically to prepare for MERLIN deployment. Make every effort to pro actively prepare for MERLIN deployment, taking advantage of all the MERLIN education, training, and resources available from the USPS, industry trade associations, and vendors. see Resources For More Information

MERLIN Phases

The recommendations below are divided into the various deployment phases, with the first section comprised of actions to take during all phases of deployment. The subsequent sections include additional recommendations for actions you should take during that particular phase of MERLIN deployment.

Actions During All Deployment Phases Take the following actions during all phases of MERLIN deployment, including the period before deployment occurs (Pre-Deployment Phase), during the deployment (Deployment Phase), during the 60-day grace period (60- Day Grace Period Phase), and after deployment (Post- Deployment Phase):

  • Obtain and review Industry Best Practices Guide to Mail Quality - Obtain and thoroughly review the USPS publication Industry Best Practices Guide to Mail Quality, which provides general guidelines for achieving barcode quality on an ongoing basis. The publication is available from the MERLIN Web site, www.usps.com/merlin. In addition, contact equipment vendors, mail preparers, and industry trade associations for additional guidelines that are equipment specific, and other support materials.
  • Frequently monitor USPS Web sites, publications, etc., for program/policy changes - Closely monitor the USPS Web site, USPS publications, and other sources of information, including trade association newsletters and vendor communications, for information on MERLIN program or policy changes.
  • Utilize USPS Barcode Error Reference Guide - The USPS has developed a MERLIN Barcode Error Reference Guide to help mailers understand and resolve barcode quality problems detected by MERLIN. A copy of the guide is available on the MERLIN Web site at www.usps.com/merlin .
  • When printing barcodes, print to the DMM specifications - Use the barcode specifications shown in the DMM to set up your barcode printing specifications. Barcode specifications used by MERLIN, which can be found in the Barcode Error Reference Guide, are slightly less stringent than those in the DMM, but using the DMM specifications as a goal will allow more margin for error without risking additional postage assessment as a result of failing MERLIN barcode readability.
  • Pre-test samples for barcode readability - At any time - even before your company learns of its MERLIN deployment date - you can submit mailpiece samples for MERLIN barcode readability testing. Contact your local USPS BMEU or DMU to determine if samples can be pre-tested locally first. If not, submit samples to the MERLIN appeals/analysis site in Chicago. Instructions for submitting samples to Chicago can be obtained from the MERLIN Web site. Samples will be analyzed in the order they are received, except that in cases where resources are not available, samples from mailers that are within 90 days of MERLIN deployment will be given priority.
  • Communicate barcode quality concerns to your customers and staff - Your company staff, as well as your customers if your company is a mail service provider, should be thoroughly trained on mailpiece design specifications that can cause barcode readability problems. Internal procedures should be developed to identify high risk designs that may cause mailings to fail USPS acceptance and verification, including MERLIN. Customer communication, redesign, or further testing should be explored for these mailings. USPS Mailpiece Design Analysts (MDAs) are available for assistance in mailpiece design consultation. In addition, resources are available at http://pe.usps.gov/mpdesign/mpdfr_intro_all.htm.
  • Monitor all MERLIN test results - Even mailings that pass MERLIN checks - particularly if the score is close to the pass/fail threshold - should periodically be analyzed to help identify potential mail preparation quality problems. For instance, a mailing that passes MERLIN barcode readability with a score just above the pass/fail threshold (currently set at 90 percent for letters and 80 percent for flats) may be in danger of failing later as quality problems may worsen over time.
  • Review all MERLIN diagnostic reports - In addition to the reports that are generated by MERLIN when a verification fails, there are additional reports available. Request all MERLIN diagnostic reports that relate to the verification failure and periodically for mailings that pass MERLIN but results show potential problems in the future. A report request form is available from USPS acceptance personnel and also can be found on the MERLIN Web site at www.usps.com/merlin.
  • Conduct on-site reviews when mailings fail MERLIN - Local USPS personnel will contact your designated company representative if a mailing fails MERLIN. Ensure that an on-site review of your mail at the DMU/BMEU is conducted by your company personnel as often as possible when mailings fail MERLIN. The disposition of the mail will remain the same. The mailer may take the mailing back and rework it, pay the additional postage, and enter the mailing into the mail stream. The mailer always has the option to appeal MERLIN results (see Post-Deployment Phase).
  • Review MERLIN Operator Hotsheet - The USPS has developed a "hotsheet" that lists critical areas the operator should review when operating MERLIN. A copy of the hotsheet should be available from local USPS acceptance personnel and also can be found on the MERLIN Web site.
  • Review proper MERLIN mailpiece feeding techniques, speed settings, and mailpiece orientation - Different types of mailpiece characteristics may require different feeding techniques, speed settings, or mailpiece orientation to obtain accurate MERLIN results. Become familiar with the proper procedures and settings by reviewing the information available from the USPS. USPS Orientation Posters should be posted at all MERLIN sites.
  • Keep records - At DMU sites keep internal records, to the extent practical, of the number of MERLIN verifications - particularly during the 60-day grace period - the dates, machine down time, and any other problems encountered during the crucial deployment phases. Contact USPS as early as possible if excessive machine down time occurs during the 60-day grace period, or if not enough MERLIN verifications are being conducted.

Actions During Pre-Deployment Phase

This phase begins when you learn that MERLIN will be deployed in your DMU/BMEU. From that point until the deployment phase begins, you should take the following actions, in addition to those described in Actions During All Deployment Phases:

  • Establish internal quality control measures, using available tools - Establish internal measures to ensure mail preparation quality control. Review the USPS Mail Preparation Total Quality Management (MPTQM) program guidelines on its Web site (http://www.usps.com/ mptqm) for assistance and consider programs such as the Mailpiece Quality Control (MQC) program located at http://pe.usps.gov/mpdesign/mpdfr_mpqc_view.htm. For barcode readability quality control, use barcode template Notice 67 for letters (at the time of this publication a flats template is being designed), as well as a barcode eye piece reticule (vendors include Gage Line, 716-458-2000, http://www.gage-line.com).
  • Identify USPS contact points - Use the MERLIN Contact List to identify the USPS contact points for MERLIN questions and information. In most cases, this will be your local USPS Manager of Business Mail Entry. The Contact List also identifies the USPS area contact should there be issues that cannot be resolved locally. In addition to the USPS, questions can be directed to your industry trade association or vendor Who to Contact.
  • Determine deployment date - The USPS should notify all mailers of MERLIN deployment at least 90 days in advance. In addition, the USPS posts MERLIN deployment schedules on its Web site, www.usps.com/ merlin. By regularly checking the deployment schedule and communicating with local postal personnel, your company should be able to determine the MERLIN deployment date as early as possible.
  • Review USPS Site Preparation Guidelines - Become familiar with the USPS MERLIN Site Preparation Guidelines (DMUs only), available on the MERLIN Web site. By reviewing the site preparation guidelines, you can prepare for MERLIN deployment and formulate questions and areas of concern as early as possible. The District MERLIN coordinator will contact all DMUs receiving equipment and provide the mailer with a site preparation handbook.
  • Review USPS Site Activation Procedures - Review the USPS Site Activation Procedures, which describe key actions that need be taken by district and area USPS personnel before and during the deployment of MERLIN at a DMU. A copy of the USPS Site Activation Procedures are available on the MERLIN Web site. Additionally, use this Web site to obtain a copy the MTAC MERLIN Recommendations and pay particular attention to the "Customer Related Issues" section, which includes customer communications.
  • Attend the USPS site preparation meeting - Approximately 60 days prior to deployment of the first machine in your district, the USPS will invite DMU mailers receiving MERLIN equipment in their plant to send personnel to a site preparation meeting. Key personnel in your company should attend this meeting to discuss MERLIN deployment at your plant.
  • Review all MERLIN verification processes - Become familiar with the verification and sampling processes for all the checks MERLIN performs. This includes presort/ mail makeup, verification of piece counts (permit imprint), and shortpaid metered mail (First-Class Mail only), for which the postage adjustment phase begins immediately after deployment has been completed. More information on the checks MERLIN performs can be found on its Web site at www.usps.com/merlin and by contacting your local USPS BME personnel.
  • Become familiar with the MERLIN sampling procedures that will be used to verify your mail - Procedures may differ between BMEUs and DMUs, and a different sampling procedure is used for Drop Ship Management System (DSMS) mailers. In addition, there may be some local flexibility depending on the type and frequency of mailings your company produces. In all cases, however, the quantity of mailpieces verified on MERLIN should be 500 for mailings of less than 10,000 pieces and 1,000 for mailings of more than 10,000 pieces, for both letters and flats. It is the USPS's goal to verify as many mailings over 10,000 pieces as possible, depending on resources. For mailings under 10,000 pieces, the USPS verifies one in six mailings using a random sampling.
  • Establish a barcode quality testing plan for samples - Establish a testing plan that will encompass all types of mail that your company produces, including samples from all addressing/barcode printing platforms, samples with every available barcode font produced from each platform, and samples on as many paper stocks as possible. Include in your plan the analysis of test results, including borderline scores as well as failures.
  • MERLIN training/education - Ensure that the appropriate personnel within your company attend MERLIN training. The USPS offers to mailers the same training it gives its MERLIN trainers in Norman, OK. It is highly recommended that mailers send a company representative to the USPS training, particularly for mail service providers such as printers and lettershops. The cost, which includes the training, meals, and accommodations, is around $900 per person. More information can be found on the MERLIN Web site. In addition, many industry seminars on MERLIN are conducted. Contact your local Postal Customer Council (PCC), trade association, or vendor for information on industry seminars. Review all available USPS MERLIN information and resources Resources For More Information.

Actions During Deployment Phase

(installation of MERLIN equipment)

The Deployment Phase is the period of time it takes for all MERLIN machines scheduled for a BMEU/DMU site to be installed. Take the following actions in addition to those described in Actions During All Deployment Phases:

  • DMU sites receiving MERLIN machines - Ensure that all site preparation requirements are completed on schedule. This includes electrical and wiring requirements.
  • Test mail (Chicago Test Center) - Test as much mail as possible by MERLIN during the Deployment Phase to ensure ample opportunity to identify and resolve problems before the postage adjustment phase begins. Follow established test plans (as described in Actions During All Deployment Phases) for as many different types of mail as possible, and analyze test results for all mailings that fail MERLIN verification as well as those that have borderline scores.
  • Become familiar with USPS "overwrite" procedures - Review the USPS procedures for overwriting erroneous barcode and presort errors reported by MERLIN. If you observe a questionable MERLIN barcode readability result, ask for a second level review by a USPS supervisor.
  • Establish internal appeal procedures - Establish an internal procedure and policy for filing MERLIN appeals prior to the completion of the Deployment Phase, since the postage adjustment phase for checks other than barcode readability commences immediately after the completion of the Deployment Phase (see the How to Appeal MERLIN Result).

Actions During 60-Day Grace Period Phase

Once the Deployment Phase has been completed, the postage adjustment phase for all active MERLIN checks see What is MERLIN? begins with the exception of barcode readability failure adjustments. There is a 60-day grace period before postage adjustments are made for mailings that do not pass the barcode readability threshold (set at 90% for letters and 80% for flats at the time of this publication). The 60-day grace period begins one week after the installation of the last machine in a site. You should receive notification from the USPS of the start date for the 60-day grace period.

During the 60-Day Grace Period Phase, take the following actions in addition to those described in Actions During All Deployment Phases:

  • Test mail - Continue to send mail to the Chicago Test Center to ensure you have ample time to identify and resolve problems before the postage adjustment phase begins for barcode readability.
  • Mailings tested - For DMUs, the target is to conduct MERLIN verifications on a minimum of 30 of your mailings during the 60-Day Grace Period Phase. Monitor the number of verifications being conducted and contact the USPS as early as possible if too few are being done.

Actions During Post-Grace Period Phase

Once the 60-day grace period has been successfully completed, additional postage will be assessed for barcode readability failures (see What is MERLIN? on page 4). Take the following actions on an ongoing basis:

  • Pre-test future mailings where possible for barcode readability - Continue to submit mailpiece samples for pre-testing of MERLIN barcode readability even after MERLIN has been fully implemented in your DMU/BMEU and the 60-Day Grace Period Phase has been completed. As new mailpiece designs are encountered, submit samples for testing in advance of the mailing so that problems can be identified and resolved in advance (see Pre-Test Samples for Barcode Readability).
  • Monitor the current MERLIN software version being used - The current MERLIN software version that should be used is found on the MERLIN Web site. Check this area regularly for information on software updates and then check the software version information on your MERLIN diagnostic reports to ensure that the correct version is in use by your DMU/BMEU.

How to Appeal MERLIN Results

Review mailings that fail MERLIN verification and consider filing an appeal if you have evidence that the results are inaccurate. When notified that a mailing has failed MERLIN, your representative should conduct an onsite review with USPS acceptance personnel, including a request for a next higher level review by the local USPS MERLIN supervisor, if deemed appropriate. If, after local efforts have been exhausted, you still believe that the MERLIN results are inaccurate, you should appeal to the next level.

For verifications other than barcode readability, follow the procedures outlined in DMM G020.3.0.

For barcode readability failures, follow the same procedures for local on-site review and next higher level review, if appropriate. If, after local efforts have been exhausted, you still believe that the MERLIN barcode readability results are inaccurate, you may appeal. The USPS will package the pieces that were tested on MERLIN and send them via Express Mail. Currently the USPS pays the Express Mail charges for the test mail shipped to the appeals facility in Chicago. Information on the appeals process can be found on the MERLIN Web site. Consider filing an appeal particularly if the MERLIN barcode readability score is just under the pass/fail threshold (set at 90 percent for letters, 80 percent for flats at the time of this publication). If the appeal site results are higher, a refund will be made; however, if the appeal site results are lower additional postage will be assessed beyond the local assessments.

Resources for More Information

The USPS has made available three Web site addresses with pertinent MERLIN information. Soon, mailers will be able to access all MERLIN information through one Web site address, www.usps.com/merlin.

Currently, the primary MERLIN information Web site is www.usps.com/merlin and contains:

  • MERLIN Deployment Schedule.
  • Procedures for using the MERLIN Pre-Testing Site (for barcode readability testing only).
  • Barcode Error Reference Guide (guide to MERLIN report error codes).
  • MERLIN training information for customers.
  • MERLIN frequently asked questions (FAQs) and answers.

The USPS Business Mail Acceptance Web site http://www.uspspostalone.com/bma/ contains:

  • The latest MERLIN software version that should be in use.
  • MTAC workgroup MERLIN recommendations (this includes a 129-page binder with a wealth of information, some of which is in draft form and some of which has been finalized).
  • MERLIN deployment schedules.
  • Procedures for using the MERLIN Pre-Testing Site (for barcode readability testing only).
  • MERLIN Standard Operating Procedures for a Business Mail Entry Unit (BMEU).
  • Document describing types of MERLIN reports available.
  • MERLIN Barcode Error Reference Guide (guide to MERLIN report error codes).
  • MERLIN Feedback and Questions (mailers can post MERLIN questions to the USPS).

The Mailers Technical Advisory Committee Web site http://ribbs.usps.gov/mits/docs/mquality.htm contains:

  • The latest information from the MERLIN MTAC Mail Quality workgroup.
  • MERLIN Standard Operating Procedures for a Business Mail Entry Unit (BMEU).
  • Procedures for using the MERLIN Pre-Testing Site (for barcode readability testing only).
  • MERLIN Deployment Schedules.
  • Document describing types of MERLIN reports available.
  • MERLIN Barcode Error Reference Guide (guide to MERLIN report error codes).
  • MERLIN Site Preparation Information.

In addition to the USPS Web sites listed above, check your industry trade associations, mail service providers, and vendors to find out what additional MERLIN resources are available.

Visit these Web sites and review the available MERLIN information from the USPS and others as early as possible in the MERLIN deployment process, in addition to regularly checking for updates to the MERLIN program or documentation.

Who to Contact With Questions

When you learn that MERLIN is coming to your DMU/ BMEU, utilize the MERLIN contact list provided by the USPS for your questions and concerns. Normally, the USPS MERLIN contact will be the District Manager, Business Mail Entry. Issues that cannot be resolved at the district level will be elevated to the USPS Area MERLIN Coordinator.

Also find out if your industry trade associations, mail service providers, and vendors have contacts for MERLIN concerns.


"The Mailers Guide to MERLIN", pages 4-9, United States Postal Service, September 2002, Mailers Companion magazine
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