I don't think it's a file size issue in my case. Some of the email I am sending don't have an attachment and they are still failing. It's random, the programs that are failing run without issues on some days. This issue started for us around 1 month back. Per SAS, it's not a SAS issue and it's something to do with SMTP server. We have been on SAS 9.1.3 for a few years and we never had this issue, and so we can't justify upgrading to SAS 9.3 or 9.4 just to fix this one issue.
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