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This usually means that the word processor has been told to expect a merge file with (for example) 10 values per row, and you gave it a merge file with more than 10 values per row.

There are different causes for this, some of which depend on which word processor you are using.

Assuming you are making your merge data file by Exporting from Sesame, one thing that can cause trouble is the presence of the delimiter in an exported value. For example, say you are exporting using a double-quote (") delimiter. If one of your values contains a ", then the file will have an "extra" value. This can be a problem if you export the field names as a header row, because there will be one less field in the header than in the actual data values row(s).