1. Nacha rules allows you to solely post from account number, but you have the ability to look at rejected transactions to correct if you are able to determine the true recipient. now, if you have 25 clients named John Doe, you're going to have a hard time determining which one is correct. but if the name on the account is Heinrich Lieberman then chances are you only have 1 and can post like that by name. but you are not required, you are free to return using uing R03 - no account, unable to locate account, where the account number is valid for the bank but does not meet the customer name.
2, you should not be using R05 for this return, your client has said this is unauthorized, so you should be returning using r10 - customer advises not authorized, they will need to complete a WSUD.
3. if you have an item coming in that does not match a customer account, why would you not return it? you're just going to randomly debit a customer? Use R03 as noted above to return.
Your ACH department should have written procedures to handle routine ACH issues such as this, and the A in ACH stands for Automated, so I would steer them towards eliminating the manual lookup and manual posting and let the automated process work. if the account is not valid, the item is returned next day, no questions asked.
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