Joined: 06 Jun 2008 Posts: 8214 Location: Dubuque, Iowa, USA
This is a failure in our production, so immediate assistance is really appreciated.
This is a forum -- if you need kind of response, you need to pay someone for support.
As your first message set indicates, the alternate index was built. If you did not do a delete before you reran the build, the alternate index name is already in the catalog and cannot be cataloged again. Hence your second error message.
Also, WHY is the alternate index not getting built? Someone did not do a good job of analysis if you have to keep expanding the alternate index record length! And, sooner or later, you'll hit the maximum at which point someone will have to completely redesign the process since the limit on primary keys in an alternate index is an absolute limit and cannot be changed.