VERIFIED SOLUTION i

Resolve MailStream Plus putting pieces into a 5-digit tray going to the wrong destination

MailStream Plus™ - all platforms, all versions
 

Issue

The user found pieces to the wrong ZIP Code in 5 digit destination trays.

The situation was similar to this simple example-

The MailStream Plus™ *presort* results had trays of mail to these 5 digit destinations:
Tray 1 had 200 pieces to 5-digit 12345
Tray 2 had 200 pieces to 5-digit 12346
Tray 3 had 200 pieces to 5-digit 12347

They found that the *physical* trays had-
The tray to 12345 had 200 pieces in it, but the last 2 pieces in it were to 12346, which should have been in the next tray per the presort.
The tray to 12346 had 200 pieces in it, but the last 5 pieces in it were to 12347, which should have been in the next tray.
The tray to 12347 only had 195 pieces in it to 12347, instead of 200.

Cause

It turns out that the presort job was ran for 600 pieces as indicated by the presort.  Then, post-presort, the mailer was not printing some of the pieces of mail.  
They didn't print two of the 12345 pieces from Tray 1.  
And didn't print three of the 12346 pieces in Tray 2.

Then they sequentially printed the printed physical mail piece numbers on all the pieces, so that the Mailroom people would know what pieces to put into each tray.

For the first tray, they grabbed the first 200 pieces. Since they didn't print 2 pieces to 12345 that the presort had put into tray 1, the first 2 pieces of tray 2 (with ZIP Code 12346) got the numbers 199-200 and were put into tray 1.
Since they didn't print 3 additional pieces to 12346 that the presort had put into tray 2, then the first 5 pieces of tray 3 with ZIP Codes 12347 got the numbers 396-400, and were put into tray 2.
And that of course only left 195 pieces to go into tray 3

Or to put it another way-
When the people on the floor prepared the mailing per the presort and the numbers on the pieces, some pieces were being placed in earlier trays then the presort had them in.  
Two pieces to 12346 (199 and 200) that should have been in tray 2 were incorrectly put into the tray to 12345.
Five pieces to 12347 (396-400) that should have been in tray 3 were put into tray 2 to 12346.
And the last tray did not have as many pieces as it should have, only 195.

Resolution

UPDATED: March 14, 2019
The initial presort should be done on the records that will be included in the mailings.  (Spoilage, or any changes that need to be adjusted for, can be done using a post-presort Mail.dat editor, and then the contents of trays would have to be changed accordingly.)