Presort run completes

Output waits for the paperwork

Output sits in a folder until someone notices it and starts the paperwork run.

Mail.dat drops in the hotfolder

Auto-detected & validated — job live in seconds

• › Detected, validated, version-identified and imported automatically.
• › Duplicates handled safely; every import is logged.

Supervisor releases it

The gatekeeper — makes the job visible to the floor

• › Stays hidden until the supervisor releases it to the floor.
• › Live → Done → Archived; stations only ever see Live jobs.

Print tray tags

Desktop app, laser printer

Send the entire run to a laser, then collate by tray order before anything can move.

Print pallet placards

Collate by pallet order

Print the full set on the laser and sort it into pallet order by hand.

Walk paper to the floor

Distribute to stations

Hand the right bundle to each station — anything misdelivered surfaces later as an error.

Component Equipment Station

Track components as they're built — no walking the floor

• › Scan components as they're built — a wrong job or segment is caught on the very first scan.
• › Tracks stacks, trays & package units; live in the Component Monitor.

Production runs

Sort through tag stacks

• › Operators dig through tag stacks to find each tray's tag.
• › Split a job mid-run and the preprinted stack must be split across stations — guess wrong and a station runs short or grabs a neighbor's tags.

Operator scans the piece IMb

Wedge or camera, at the Mailing Work Station

Resolves the piece to its tray via the CQT linkage on contact.

Tray tag prints on demand

USPS L-3216A at the station — no preprinted stacks

Prints at the workstation the instant the piece is scanned — no stacks to sort.

Pallet placard auto-prints

The last child tray triggers it — no manual step

The USPS DMM 204 placard generates automatically when the pallet completes.

Rerun required

Corrections are part of the work

A thickness correction, a list revision, an insert change — and the whole job runs again.

Find & destroy old tags

Find & destroy the old tags, reprint everything, walk it back out — once for every rerun.

Rerun required

Same trigger — different cost

A rerun still happens — corrections are part of the work. The difference is what it costs you.

Current data, instantly

Replaces instantly; nothing to recall because nothing was preprinted — operators just keep scanning.

~15 min, every cycle

234–560 hrs / yr

A conservative 15 minutes per cycle adds up to 234–560 hours a year that never move a piece of mail.

Error risks

Caught late, if at all

• ✕ Wrong tags, and old tags used after a data reprocess.
• ✕ Double-pulls, and surprises on the BCG Mailer Scorecard.

0 min paperwork

234–560 hrs / yr back

Zero minutes on paperwork — the hours come straight back to the floor.

Built-in protections

The scan is the safeguard

• ✓ Both stations visible from any screen — no walking the floor.
• ✓ Duplicates & mismatches flagged on contact; full chain of custody.