OMR SPECIFICATION FOR INTELLIGENT MAILING SYSTEMS. 1. Introduction...Page OMR System, All Functions...Page Print Areas (by unit)...

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1 Contents OMR SPECIFICATION FOR INTELLIGENT MAILING SYSTEMS 1. Introduction...Page 2 2. OMR System, All Functions...Page 2 3. Print Areas (by unit)...page Printers Principles...Page Feed Unit Information...Page G3 Series OMR Specifications Issue 1 September 2013 Page 1

2 Section 1 Introduction This specification covers the requirements for OMR marking for all Intelligent Systems used on the machine. This specification relates to the OMR functions available, the mark size and positioning of marks on the forms. The full range of OMR facilities is referred to as the OMR System. This specification consists of 4 sections as follows: Section 1. Introduction (This section). Section 2. OMR System. This section describes all the OMR functions that are available. Section 3. Print areas. This section deals with the dimensional details and layout requirements for the marks for each of the OMR reading units. Section 4. Printers. This section describes the features of laser printers and continuous forms printers that are relevant to the type and positioning of OMR marks. Section 5. Feed Unit Information. This section describes the functions of the Collator, OMR Folder and OMR Feeder, and gives details of paper orientation etc. Section 2 OMR System 2.1 Principles As the OMR marks are read using a scanning Barcode head the following rules apply: a) There is complete freedom to position the OMR marks on the document in any position subject to the mechanical reading limitations of specific units (refer to section 5). b) Marks must be equally spaced with a pitch of at least 3mm. c) All marks must be contained in a continuous set of marks with equal spacing contained within a 100mm set, first to last. d) All marks are horizontal with vertical spacing on a portrait document. e) A mark set can be printed ascending or descending, and the gate mark must always be at one end of the set G3 Series OMR Specifications Issue 1 September 2013 Page 2

3 2.2 Function Descriptions Gate Mark 1 mark Within the sequence of OMR marks the gate mark must be the first mark of the set (ie. mark at position 1). This ensures that the position of the marks on the form is synchronised to the lead edge of the form, for reliable reading of the following function marks. Additionally, as the OMR system needs to find a gate mark on each page, it will detect unprinted blank pages. Note: The mark set may be printed either way up, i.e. gate mark at the top with marks descending or gate mark at the bottom with marks ascending. In either case, it must always be Mark at position 1 when defining the marks in the software Grouping of Multi-page Prime Documents 1 mark Multiple pages can be grouped together for insertion into the same envelope. The function mark required is one of the following: a) End of Group Mark. Printed on the last page of a group, it is the last sheet to be fed and stops the next page being collated with the group in the collate pocket. b) Demand Feed Mark. Printed on all the pages of a group except the last page. (Inverse EOG). c) First of Group Mark. Printed on the first page of a group, is fed but held at a hold point while the previous group is sent out of the collate pocket. d) Demand FOG Mark (inverse of FOG). Printed on every page of the set except the first page Parity Mark 1 mark The function of the parity mark is to check if the correct number of marks have been read. For example, if even parity is being used then on all pages there will be an even number of marks printed, which means that if all the function marks printed excluding the parity mark add up to an odd number, then the parity mark is printed. If all the function marks printed excluding the parity mark add up to an even number, then the parity mark is not printed. The options for the parity marking are: a) Even parity marking. b) Odd parity marking. c) No parity marking G3 Series OMR Specifications Issue 1 September 2013 Page 3

4 2.2.4 Diverting Forms Before Fold 2 marks The OMR System allows programming for up to 2 divert bins, which may be fitted to the output of the Accumulator System (Collator). The divert destination is defined by means of a Single Mark. Note: The divert mark can be assigned to bin 1 or bin Ink Mark 1/Jog and Ink Mark 2/Conveyor Control 2 marks Two marks are used here to achieve Ink Marking, jogging (on divert conveyor) and output conveyor control. Ink Mark 1/Jog is used for the existing ink marker A3204A. Ink Mark 2/ Conveyor is used to control the existing output conveyor E1620AA. Both Marks can be used to Ink Mark on the Vertical Envelope Stacker E1681AB. Ink Mark 1 also controls the Vertical Stacker (VS) jog Envelope Unseal 1 mark A single mark may be used to program the wetter to Unseal. If an OMR mark is detected in the Envelope Unseal position on the prime document, when that form is inserted into the envelope, the wetter is lifted clear to prevent sealing of the envelope. This facility could be used where additional manually inserted items need to be added to the envelope, or if an operator audit of the envelope contents needs to be carried out periodically G3 Series OMR Specifications Issue 1 September 2013 Page 4

5 2.2.7 Output Divert 3 marks A set of up to 3 marks may be used to define one of 6 output processing diverts as the destination of the filled envelope or a straight through path. Each mark independently controls a divert bin as shown below Selective Feeding of Inserts 15 marks The selective feed facility allows the selection of up to 15 inserts to be added to the prime document depending on the OMR marks printed on the prime document. The maximum number of selective feeds is limited to the maximum number of additional feed units fitted G3 Series OMR Specifications Issue 1 September 2013 Page 5

6 2.2.9 Form Sequence within a Job 5 marks The purpose of this mark function is to code each page of a print run with a number sequence running from 0 up to 31 and then restarting at 0. This number sequence is printed on each page of a print run, in sequence, regardless of the document sets and customer identities. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 5 marks and printing them as a binary sequence as shown below. If a smaller number of marks is required then it is possible to use either four, three, two or one mark, in which case the numbering goes from 0 to 15, 0 to 7, 0 to 3 or 0 to 1 respectively. It is not generally recommended to use less than three marks. The 1200 OMR System can check the numbering in either a count up sequence, or a count down sequence. Additionally, if the forms are printed with no zero, for example, 1 to 7, or 1 to 15, then the checking system can be programmed to exclude zero from the number sequence. Page Sequence Mark No FSN Mark No. 1 FSN Mark No. 2 FSN Mark No. 3 FSN Mark No. 4 FSN Mark No. 5 Cont... Page Sequence Mark No FSN Mark No. 1 FSN Mark No. 2 FSN Mark No. 3 FSN Mark No. 4 FSN Mark No G3 Series OMR Specifications Issue 1 September 2013 Page 6

7 Form Sequence within a Group 4 marks The purpose of this function is to code each page of a group of forms with a number sequence running from 0 up to 15 and then restarting at 0 for groups, which exceed 16 pages. This number sequence is printed on each page of a group, which is to be inserted into an envelope. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 4 marks and printing them as a binary sequence as shown in the table below. On some of the infeed units, the forms are fed from the back of the form stack, i.e. in reverse order. In these cases the numbering should be in the feed order of the forms. So, for a five page group, the last page should be numbered 0, with the page count increasing towards page one of the group. If the forms are printed with no zero, i.e. starting at a count of one, then the checking system can be programmed to exclude zero from the number sequence. Note: The normal security system for ensuring that all the printed pages are processed correctly is Form Security Numbering. Group Security Numbering should only be considered when Form Security Numbering cannot be used. Page Sequence (In Page Feed Order) Mark No GSN Mark No. 1 GSN Mark No. 2 GSN Mark No. 3 GSN Mark No G3 Series OMR Specifications Issue 1 September 2013 Page 7

8 Group Sequence 4 marks The purpose of this function is to code each group of forms with a number sequence running from 0 up to 15 and then restarting at 0 for the next group. This group sequence is printed on each page of a group, which is to be inserted into an envelope. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 4 marks and printing them as a binary sequence as shown in the table below G3 Series OMR Specifications Issue 1 September 2013 Page 8

9 Matching 5 marks When personalised documents are being fed from more than one OMR station for insertion into the same envelope, it is possible to code the individual pages with the same 5 mark pattern to indicate that the pages belong together. In this situation the OMR marks are read on each individual page at each of the OMR stations. When the two, or more personalised sets of marked documents are merged on the insert track the control system checks if the match marks are the same. If there is a mismatch of the match marks the machine stops with an error message displayed. For the system to continue operation all the forms with OMR match marks which are to be inserted together into one envelope must have the same match code. Any difference in the match code on any page indicates that that page does not belong with the others and stops the inserter until the operator corrects the problem and restarts the system. The match codes can be generated randomly, no particular sequence or order is required. In the table shown on the following page, all of the 32 possible mark combinations are shown with their numerical values. Equivalent Numeric Value Mark No Match Mk. 1 Match Mk. 2 Match Mk. 3 Match Mk. 4 Match Mk. 5 Cont... Equivalent Numeric Value Mark No Match Mk. 1 Match Mk. 2 Match Mk. 3 Match Mk. 4 Match Mk G3 Series OMR Specifications Issue 1 September 2013 Page 9

10 Halt Function 1 mark The halt function consists of one mark which when detected by the OMR system completes the collation of the document group and all other actions until the document set is ejected on to the track. It then stops the inserter without indexing the track. This allows operator intervention for whatever purpose, for example, to periodically confirm correct operation of the mailing run. Note: If the document with the halt mark also has a divert mark, then as that document never reaches the insert track, it will not cause the system to stop, hence the halt mark should not be used in a set of documents which are marked for diversion Force Fold 1 mark This mark is used with multi-page documents, when it is required to break the document group into specific sets, earlier than the maximum fold limit which has been set. When the page with the Force Fold mark arrives in the collator part of the feed unit, the document set up to that page is immediately sent to the folder and on to the track. The track shuttle will not move as the complete set of documents up to the form with the end of group mark has not been processed. The remainder of the forms of the group will be fed and folded in sets equalling the max for fold number programmed as a default for the job until the end of group is seen. Then the track shuttle will hand over the group to the next track section Page Count Verification 4 marks This is a security facility where binary coding is used to ensure that the correct number of pages has been fed from the hopper. The pages are fed from the hopper until the End of Group mark is detected. The number of pages that have been fed will be compared with the Page Count Verification marks, and if there is a discrepancy between these two numbers an error will be indicated. The total page count can appear on any page of the set and will be a number between 0 and 15 (if using 4 marks, as per the table below). If the number of pages in the group is greater than 15, then marks 5 & 6 can be defined allowing up to 31 pages per group if using 5 marks, and up to 63 pages per group if using 6 marks. Number of Pages in The Group Page Count No Page Cnt. Mk.1 Page Cnt. Mk.2 Page Cnt. Mk.3 Page Cnt. Mk G3 Series OMR Specifications Issue 1 September 2013 Page 10

11 Autoend 1 mark This mark may be used at the end of the job when it is required to automatically enter the Autoend mode. The system operates by detecting this mark in the last document set, and then setting the Autoend mode so that the marked document set is the last to be enveloped and ejected on to the output conveyor. This mark may also be used when there is a requirement to interrupt a job into well defined parts, for example to batch work by post code, or any other defined criterion Franker Control 2 marks Franker 1 This mark is used to control the franker 1 bit. 1 = ON (bit set) or 0 = off (bit not set). This allows the four groups to be controlled by a dynamic franker (when used in conjunction with Franker 2). Franker 2 This mark is used to control the franker 2 bit. 1 = ON (bit set) or 0 = off (bit not set). This allows the four groups to be controlled by a dynamic franker (when used in conjunction with Franker 1). Example: Franker Franker Group Machine Control By Document Criteria The machine can change the control mode for a number of non-omr, document related criteria. The document criteria of a specific group can be used to control the following modules: a) Divert Before Fold This can be controlled by setting the maximum number of prime document pages to less than the maximum for folding. b) Halt On Track This can be controlled by setting ranges by number of prime document pages or weight groups so that a change in range causes the machine to halt with a message Group is out of range. All the groups downstream of the out of range group will be processed and ejected out of the machine. The out of range group will be stopped at the insert station. The operator can then choose to: 1) Continue job with new number of prime documents/weight group 2) Remove out of range group and continue job with same number of prime documents/weight group c) Output Processing Divert The output processing diverts can be controlled by number of prime documents/weight group range G3 Series OMR Specifications Issue 1 September 2013 Page 11

12 Second Gate Mark (Gate 2) Within the sequence of OMR marks the 2nd gate mark must be the last mark of the set. Each new document must have the mark printed on it. When defined along with a Gate mark this function checks that the OMR marks read always start and end with a valid mark. Example; 5 mark set l000l both gate and gate 2 present If of either the gate marks are not present a fault will be installed This feature helps to ensure that the correct mark is detected as the gate mark (prevents false reading) Advanced Security a) Minimum Number of Marks This feature can be used to check that the reader always decodes the specified minimum number of marks. A fault will be installed if the minimum number of marks is not read. This feature helps to ensure that the correct mark is detected as the gate mark (prevents false reading) G3 Series OMR Specifications Issue 1 September 2013 Page 12

13 Track OMR Support for 2-track OMR is provided to accommodate existing customers jobs that use this system. 2 track OMR is only supported when using an Autoread camera system on a DS1200-G3 inserter and SPR 0069, (# Y) is ordered. Two new functions have been added for 2-track OMR. These are Basic 1 and Basic 2. These two functions combine to give the following options:- A B A B A B A B Basic Basic Function Feed /Accumulate End of Group (EOG) / Insert EOG and Sheet Divert 2 EOG and Sheet Divert 1 Example of a typical 2-track OMR code and the functions supported: Track A Track B Basic command 1 Feed / EOG / Basic command 2 Sheet Divert 1 or * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Output Control ( VS Jog) * Undefined (for DS1200-G3) * Halt * No Seal * Form Sequence in a Job * Form Sequence in a Job * Form Sequence in a Job * Parity (Even) * : These marks are optional. If the mark is printed in Track A there cannot be a mark in Track B and visa versa. Notes 1. See section 4 of the OMR specification for details of the mark density pitch etc. that is supported. 2. All other OMR functions (except Gate or any grouping function) are supported, not just the ones in the above example. 3. Security check performed on the number of marks read. 4. Security check performed to check that OMR marks in track B are the inverse of the OMR marks in track A. 5. Basic 1 and Basic 2 are only supported when using 2 Track EOG OMR G3 Series OMR Specifications Issue 1 September 2013 Page 13

14 Track OMR Support for 1-track OMR is provided to accommodate existing customers jobs that use this system. 1 track OMR is supported when using any OMR reader on a DS-1200-G3 inserter and SPR 0084, NISL Part number R is ordered. Two new functions have been added for 1-track OMR. These are Grouping & Divert 1 and Grouping & Divert 2. These two functions control the grouping and the sheet divert of documents. When either of these marks is a 1 then no grouping mark will be on the document. Example of a typical 1-track OMR code and the functions supported Track A Gate Grouping Insert / Accumulate Group & Divert Group & Divert * Halt * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Selective Feed * Output Control (VS Jog) * Undefined (for DS-1200-G3) * Halt * No Seal * Form Sequence in a Job * Form Sequence in a Job * Form Sequence in a Job * Parity (Even) * Undefined (for DS-1200-G3) * : These marks are optional. Notes 1. See section 4 of the OMR specification for details of the mark density pitch etc that is supported. 2. All other OMR functions are supported, not just the ones in the above example. 3. All Sequence Marks directions can be defined (incrementing /decrementing) as well as the roll over point / start point (1 or 0) G3 Series OMR Specifications Issue 1 September 2013 Page 14

15 Section 3 Print Areas and OMR Mark Definitions This section details the position on the document where the OMR marks can be correctly read, and the definition of the marks in terms of width, length, spacing, set length and clear areas. The print area will be specific to groups of units using the same mechanisms as follows: OMR Modules Group A Group B Accumulator - OMR/Barcode Folder OMR/Barcode Feeder 1200 G3 Series OMR Specifications Issue 1 September 2013 Page 15

16 3.1 Group A Print Areas and OMR Mark Definitions NOTE: pitch can be as small as 2mm provided accuracy of pitch is better than 10% line-to-line and line-to-gate. Width must be minimum 8mm not including print tolerance errors (i.e. if print tolerance is +/- 2mm in same print run, then mark width must be 12mm) G3 Series OMR Specifications Issue 1 September 2013 Page 16

17 3.2 Group B Print Areas and OMR Mark Definitions NOTE: pitch can be as small as 2mm provided accuracy of pitch is better than 10% line-to-line and line-to-gate. Width must be minimum 8mm not including print tolerance errors (i.e. if print tolerance is +/- 2mm in same print run, then mark width must be 12mm) G3 Series OMR Specifications Issue 1 September 2013 Page 17

18 Section 4 Printers 4.1 Introduction The forms, which constitute the prime documents processed through machine will be printed either on laser printers or impact printers. Impact printers will in turn divide into two categories. The first: printers where each character is composed of an array of dots, and hence there is a graphics capability. The second: printers where, each character is printed as a single impact of one of a set of predefined characters, which generally does not include any graphics symbols. In both cases specific requirements for character type and quality are defined in later paragraphs. 4.2 Print Order and Orientation General All OMR and barcode requirements for the machine will always be read at the OMR/Barcode unit, which is downstream of any guillotine or merging devices, unless OMR reading is enabled in the CEM cutter. Subsequently, the forms are always in finished, cut-sheet form when being read and processed. Marks which are removed during on-line processing cannot be used, unless OMR reading is enabled in the CEM cutter Orientation and Order (Group A) All group A units require the paper to be fed face up, head first, eg. from page 1 first to page 10 last. This will ensure that page 1 always appears in the window of the envelope. If an OMR folder is being used, i.e. no accumulator fitted, it is possible to load the forms face down, tail first, eg. from page 1 first to page 10 last. It should be noted that the stack order here is reversed (i.e. this option allows for reverse order printing) Orientation and Order (Group B) All group B units require the paper to be fed face down, feet first, eg. from page 1 first to page 10 last. This requires the stack to be compiled in reverse order Orientation and Order using Turnover (Group B) The insert turnover option allows the forms to be loaded in correct print sequence, i.e. face up and head first G3 Series OMR Specifications Issue 1 September 2013 Page 18

19 4.3 Printed Characters Used as OMR Marks For laser printers, marks can be defined as shown on pages 12, 13, and described on page 16 (width >8mm, thickness >0.5mm). For impact printers the following characters are suggested: For Portrait printed documents, marks are horizontal. Therefore use: Underscore - Three underscores next to each other, usually no gaps between them. For Landscape printed documents marks are vertical. Therefore use: l Lower case L Three lower case L s (appearing as l ) on consecutive lines, with no line spacing, to produce a continuous line. Arial font must be used. Note that there are at present no other characters suitable for OMR marks for impact printers G3 Series OMR Specifications Issue 1 September 2013 Page 19

20 4.4 Optimising OMR Characters for Best Reading Performance Mark Density The greater the density the better the read Mark Line Depth (thickness) The thicker the line the better the read. A thicker line helps to prevent dirt, ghosting or other poor quality printing defects from being detected as an OMR?mark Mark Pitch The OMR/Barcode scanner deals only with fixed pitch, i.e. the distance between each successive mark must be the same for the whole mark set. The smaller the pitch the better the read. The reader head takes a snap shot of the OMR set as it passes under the scanner and the narrower the snap shot is the easier it is for the read head to interpret the results. A 3mm pitch is recommended Mark Depth to Line Depth Ratio The ratio between the line pitch and the line depth is recommended to be approximately 4:1. If a wide pitch is being used the line thickness may become too large. In this case it is recommended to at least have a line thickness of 1mm Pitch Tolerance The pitch tolerance is recommended to be better than the following: a) Pitch Tolerance Line to Line: 15% of the Pitch. b) Pitch Tolerance Each Line to Gate:15% of the Pitch Tolerance. For a 3mm pitch this allows an error of 0.5mm for one line relative to another (as per a) above. This is not a progressive tolerance (see b) above Mark Set Length The minimum mark set length achievable (distance between the first and last mark) is recommended. The maximum mark set length is 100mm Mark Width The width of each line should be greater than 8mm. This does not allow for print variations. If the OMR marks move relative to the edge of the page by, say, +/- 2mm then the line width should be increased to 12mm G3 Series OMR Specifications Issue 1 September 2013 Page 20

21 5 Feed Unit Information 5.1 Feeder Accumulator Folder Collation Collation of documents is carried out in the Accumulator of the systems unit and allows for up to 8 sheets to be collated together before fold (dependent on material, fold type and envelope capacity). Single page or multiple page sets can be diverted before fold in a Sheet Divert Unit if fitted. Sheet divert units allow for documents to be diverted for bad read, bad sequence, oversized groups or by OMR/Barcode control. A sheet divert unit is recommended for ease of operation. Collation of documents before fold maintains the production speed of the machine for group sizes of an average of 2 pages per set. Feed Orientation The feed orientation is always face up, head first (relative to the addressed face of the document). Print Sequence Print sequence is always first to last, i.e. page 1 is on the top of the printed stack. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document. This allows for duplex printed material with the OMR/Barcode on the reverse side of the document. 5.2 Feeder Reader Folder Collation Collation of forms is always on the Shuttle Bed (after fold). The number of sheets collated in a group is dependent on the material, fold type and envelope capacity. Collation after fold reduces the machine speed with the number of forms in the group. Feed Orientation The feed orientation (relative to the addressed face of the document) can be either: a) Face up, head first (using a Z fold) or b) Face down, feet first (using a C fold) Print Sequence Print sequence is dependent on feed orientation. If the document orientation is face up, as per a) above, then the print sequence is first to last, i.e. page 1 is on the top of the printed stack. If the document orientation is face down, as per b) above, then the print sequence is last to first, i.e. page 1 is on the bottom of the printed stack and the stack is inverted in the Hi-Cap feeder. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document G3 Series OMR Specifications Issue 1 September 2013 Page 21

22 5.3 Insert Feeder, Reading Collation Collation of forms is always on the shuttle bed. Feed Orientation The feed orientation is always face down, feet first (relative to the addressed face of the document). Print Sequence The print sequence is last to first, i.e. page 1 is on the bottom of the printed stack. The stack is inverted in the feeder so that page 1 is fed first. Reading Surfaces Reading is only carried out on the bottom surface of the document. End of Group Mark The end of group mark must appear on the last page of the set which is the last page to be printed. It is not possible to use First of Group (FOG) grouping with this hardware. Note: Where print sequence or feed orientation dictate that the forms must be fed face up and head first, then an OMR/Barcode folder with Turnover Fold Plate A A is recommended. General Notes a) The OMR/Barcode head and bracket assembly is not switchable by the operator between top and bottom reading. If reading on both surfaces is required then two reading heads and bracket assemblies must be fitted. b) If it is required to frequently change the OMR/Barcode head position between two different positions then it is recommended that two heads be fitted for ease of operation. c) The sheet divert unit is not a forms processor. The sheet divert is provided to reject exceptions only. Any diverted forms should not be reprocessed through the machine G3 Series OMR Specifications Issue 1 September 2013 Page 22