1. 1 DESIGN GUIDELINES for the Automation-Compatibility of FLAT-SIZE MAIL Joyce McGarvy & George Hurst Washington DC, February 6, 2003

2. 2 General Mailpiece Guidelines  Identify Flats Guidelines for Automation-Compatibility  Reduce Damage While Promoting Automation Awareness  Use Language that is Easy to Understand and Follow  Acknowledge Current Industry Capabilities & Customer Needs - Production Equipment / Cost / Creativity  Do NOT Create Additional Mailing Requirements

3. 3 MTAC Sub-Committee  Co-Chairs: Joyce McGarvy & George Hurst  Valassis  Time, Inc  AARP Publications  Brown Printing  Crain Communications  Time Customer Service  RR Donnelley  Quebecor World Logistics  Scholastic, Inc.  Publisher’s Clearing House  G&J USA Publishing  Quad/Graphics  Advance Magazine Group  America Online  PostCom  Computerworld  Newsweek, Inc  L.L. Bean  Our Sunday Visitor, Inc. Missing Representation ?

4. 4 6 Main Areas Being Reviewed 1. General Mailpiece Structure Thickness (.04” -.5”) Flexibility (Stiffness) 2. Envelope Recommendations Thickness (.5” maximum) Length (14-1/2” max) Selvage (1/2” Overhang, Loose) Stiffness (No Cardboard Inserts, Irregular Thickness) 3. Bound, Unbound, Folded Pieces Unfolded Thickness Loose Folds and Center Bowing Uneven Inserts Paper Sleeves Blow In Cards

5. 5 6 Main Areas Being Reviewed 4. Saddle Stitching Three Staples unless Digest Sized or Very Light Wt 5/8 Inch Staple vs ½ Inch Staple Tightly Crimped Stitches, Avoid Break Through Avoid Rolling or Rounded Stitches Consider Perfect Binding When 9+ Oz or 200 Pages Cover Strength Test, Lift by Cover Only, Check Damage 5. Cover Material Type, Age, Resilience (Resistance to Tearing, High Gloss) Basis Weight (50 Lbs – 80 Lbs, Particularly Over 6 Oz) Heavier Than Contents (On Other Than Thin Pieces) Cover Grain (Perpendicular To Backbone) Gatefold Covers (Tabbed) Weakened Spines (Excessive Compression-Whitening)

6. 6 6 Main Areas Being Reviewed 5. Cover Material (continued) Cover Friction (Cover Sliding Against Body) Aqueous Lacquer / UV Coating (Avoid High Gloss On Cover) Lacquer Vs. Perfect Bound (Consider - Over 6 Oz) Bleed Through (Avoid) Heavy Pieces / Low Friction (Consider Tabs) 6. Polywrap Mailpieces Current Standards (Okay, But Often Unmet) Low Blocking / High Secant Modulus Shrink Wrap Film (Not Meeting Standards) Good Seals (On Seams) Glue Outside Labels (Avoid Excessive) Selvage (1 ½”) Non-address Seams (Position On Opposite Side) Remelted Seams (Avoid Pieces Sticking Together)

7. 7 Timeline/Next Steps  Draft Guidelines Distributed  Written Comments Received  e-Mail Address Established “flatsize@email.usps.gov”  One Teleconference, One Meeting  Next Meeting Scheduled February 13 th  Targeted Completion, May 2003?