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Re-engineering the humble envelope and a manual processes achieves savings through a fully automation solution for Mitsubishi.


Mitsubishi’s Field Services Team send high priority letters advising customers of faults with the potential to cause injury or worse. They send these as Registered Post, requiring proof of delivery signature as evidence they’ve been received.


The problem was a painful manual process, albeit an important one and went something like this.

  • Sort data, print and insert letters as normal pre-sort mailing.
  • Purchase rolls of Pre-paid Registered Mail Labels from Australia Post and manually apply to envelopes.
  • Print the database to hardcopy labels.
  • Peel off the secondary tracking barcode label from the Registered Mail Label.
  • Attach the secondary tracking label to a hard copy list against the correct recipient.
  • Supply the hard copy list to Mitsubishi for reference.


Applying some great problem solving, our direct mail (DM) team re-engineered a window-faced envelope enabling a fully automated solution.

  • Re-engineer existing re-usable standard window face envelope by extending the window.
  • Manage the artwork approval process with Australia Post which incorporated the Registered Mail Label as part of the design.
  • Negotiate with Australia Post to organise a range of Registered Mail numbers.
  • Manipulate the Registered Mail data sequence to generate a Registered Mail number and barcode to Australia Post specifications.
  • Test the barcode and gain approval by Australia Post.
  • Redesign the letters to incorporate the Registered Mail barcode as part of the variable print.

Mitsubishi’s Field Services Team achieved a fully automated solution, removing all manual processes and in the process made them look great.

Got a tricky DM problem? Let the fertile minds in our DM Team go to work and push the envelope on your problem too!

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