U.S. patent application number 09/966307 was filed with the patent office on 2002-01-24 for cushioning conversion system and method.
Invention is credited to Armington, Steven E., Booze, MacDonald C., Guth, Paul J., Ratzel, Richard O..
Application Number | 20020007618 09/966307 |
Document ID | / |
Family ID | 21959317 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020007618 |
Kind Code |
A1 |
Armington, Steven E. ; et
al. |
January 24, 2002 |
Cushioning conversion system and method
Abstract
A packaging system includes a cushioning conversion machine for
converting stock material into relatively low density cushioning
material or dunnage and a packaging system controller. The
packaging system controller provides packaging instructions related
to a part or parts to be packaged and instructs the cushioning
conversion machine to produce the cushioning material. In one
aspect of the present invention the packaging system controller
provides packaging instructions by retrieving a predetermined set
of packaging instructions associated with a particular part. In
another aspect of the present invention the packaging system
controller provides packaging instructions by determining an
optimized packaging methodology using one or more characteristics
of the part or parts to be packaged. The packaging system also
provides for automated inventory control and productivity
monitoring.
Inventors: |
Armington, Steven E.; (Gates
Mills, OH) ; Ratzel, Richard O.; (Westlake, OH)
; Guth, Paul J.; (Beachwood, OH) ; Booze,
MacDonald C.; (York, ME) |
Correspondence
Address: |
RENNER OTTO BOISSELLE & SKLAR, LLP
1621 EUCLID AVENUE
NINETEENTH FLOOR
CLEVELAND
OH
44115
US
|
Family ID: |
21959317 |
Appl. No.: |
09/966307 |
Filed: |
September 28, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09966307 |
Sep 28, 2001 |
|
|
|
09096123 |
Jun 11, 1998 |
|
|
|
60049346 |
Jun 11, 1997 |
|
|
|
Current U.S.
Class: |
53/472 |
Current CPC
Class: |
B31D 2205/0023 20130101;
B65B 57/00 20130101; B65B 61/22 20130101; B31D 2205/0047 20130101;
B31D 2205/0082 20130101; B65B 55/20 20130101; B31D 5/0047 20130101;
Y02P 90/02 20151101; B31D 2205/007 20130101; B31D 2205/0088
20130101 |
Class at
Publication: |
53/472 |
International
Class: |
B65B 023/00 |
Claims
What is claimed is:
160. A packaging system, comprising: a packaging material supply
device for supplying a packaging material; and a packaging system
controller in communication with the packaging material supply
device, the packaging system controller including a memory having
packaging instructions related to at least one part to be packaged,
the packaging instructions including instructions for directing the
packaging material supply device to provide packaging material for
the at least one part to be packaged.
161. A packaging system as set forth in claim 160, wherein the
packaging material supply device includes a conversion machine that
converts stock material into a dunnage product.
162. A packaging system as set forth in claim 161, wherein the
conversion machine includes a controller in communication with the
packaging controller for controlling the machine in accordance with
commands from the packaging controller.
163. A packaging system as set forth in claim 161, wherein the
conversion machine includes a conversion assembly for converting
sheet stock material into a strip of dunnage and a severing
assembly for severing discrete dunnage products from the strip of
dunnage, and the conversion machine controller controls the
operation of the conversion assembly and the severing assembly.
164. A packaging system as set forth in claim 160, further
comprising an output device connected to the packaging system
controller, the packaging instructions including an explanation of
packaging steps, and the packaging system controller operative to
output the explanation of packaging steps to the output device.
165. A packaging system as set forth in claim 164, wherein the
output device includes at least one of a display, a speaker, and a
printer.
166. A packaging system as set forth in claim 164, wherein the
output device is a display, and the packaging explanation includes
an illustration of a packing technique for the part being
packaged.
167. A packaging system as set forth in claim 166, wherein the
explanation of packaging steps includes a preview of the packaging
steps illustrating a technique of packaging the part being
packaged.
168. A packaging system as set forth in claim 166, wherein the
packaging explanation includes a single packaging step associated
with packaging the part being packaged.
169. A packaging system as set forth in claim 11, further
comprising an input device for providing a part identification for
the part to be packaged.
170. A packaging system as set forth in claim 16, wherein the input
device includes at least one of a keyboard, a touch screen, a radio
frequency tag reader, a mouse, a bar code reader and a
microphone.
171. A packaging system as set forth in claim 160, wherein the
memory includes a database containing packaging information for at
least one part to be packaged, the database including a plurality
of instructions stored at various locations in the memory and at
least one of a look up table and an algorithmic search engine for
use by the packaging controller to select one of the plurality of
instructions corresponding to the part to be packaged.
172. A packaging system as set forth in claim 160, wherein the
packaging instructions include at least one of selecting a
particular container, generating one or more units of packaging
material in a predetermined order, and an explanation regarding how
to utilize the container or the one or more units of packaging
material in a predetermined manner.
173. A packaging system as set forth in claim 160, wherein the
packaging instructions comprise at least one of a video output, an
audio output, a printed output, a text output and a graphical
output.
174. A method of packaging parts, comprising the steps of:
identifying at least one part to be packaged; retrieving packaging
instructions associated with the at least one part to be packaged;
and controlling a packaging material supply device using the
packaging instructions.
175. A method as set forth in claim 174, wherein the step of
identifying a part to be packaged includes the steps of: inputting
a part number associated with the part to a packaging controller;
and matching the part number with a corresponding part number in a
memory.
176. A method as set forth in claim 175, wherein the step of
inputting the part number includes at least one of entering the
part number using a keyboard, reading a bar code representing the
part number using a bar code reader, identifying the part number
from a parts menu on a display, and identifying the part number
using optical character recognition or video pattern
recognition.
177. A method as set forth in claim 176, wherein the step of
identifying the part number using the parts menu includes using a
pull-down menu to identify the part number using at least one of a
mouse, a keyboard and a touch screen.
178. A method as set forth in claim 175, wherein the step of
inputting the part number includes: inputting a part number into a
microphone; and converting the microphone output into a digital
signal corresponding to the part number using a voice recognition
algorithm.
179. A method as set forth in claim 174, wherein the step of
retrieving the packaging instructions comprises the step of
accessing a particular set of packaging instructions from a
plurality of packaging instructions stored in a memory.
180. A method as set forth in claim 174, wherein the step of
retrieving packaging instructions includes retrieving instructions
for manipulating the piece of cushioning material.
181. A method as set forth in claim 174, wherein the step of
controlling the packaging material supply device includes the steps
of: dictating a quantity of one or more pieces of packaging
material; and dictating an order in which the one or more pieces of
packaging material are supplied.
182. A method as set forth in claim 174, wherein the step of
controlling packaging material supply device includes operating a
cushioning conversion machine to produce a quantity of cushioning
material dictated by the packaging instructions.
183. A method as set forth in claim 182, wherein the step of
operating the cushioning conversion machine includes at least one
of generating a strip of cushioning material, severing a discrete
length of cushioning material from the strip of cushioning
material, and providing the cushioning material for packaging the
identified part.
184. A method as set forth in claim 174, further comprising the
step of providing at least one of an audible and a visual output of
at least a portion of the packaging instructions to an operator,
wherein the provided packaging instructions indicate a preferred
packaging methodology for the at least one part to be packaged.
185. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes
indicating a preferred container for packaging the part.
186. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes
indicating a quantity of packaging material required to package the
part.
187. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes providing
an orientation of one or more pieces of packaging material within a
container.
188. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes providing
an orientation of the at least one part within the container.
189. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes providing
an order for packing the at least one part using a plurality of
pieces of cushioning material.
190. A method as set forth in claim 174, wherein the step of
providing packaging instructions to the operator includes:
identifying a container for accommodating the at least one part;
identifying one or more pieces of packaging material to be utilized
for securing the at least one part within the container;
illustrating an order in which the packaging material and the at
least one part are placed within the container; and illustrating an
orientation in which the at least one part and the packaging
material are placed and secured within the container.
191. A method as set forth in claim 174, further comprising the
step of providing a preview of the packaging instructions to verify
that the packaging instructions are appropriate for the at least
one part to be packaged.
192. A method as set forth in claim 191, wherein the step of
providing a preview of the packaging instructions includes the step
of displaying a plurality of steps in packaging the part.
193. A method as set forth in claim 192, wherein the step of
displaying the plurality of steps in packaging the part includes
the steps of: identifying a container for accommodating the
identified part; identifying one or more pieces of packaging
material to be utilized for securing the at least one part within
the container; illustrating an order in which the packaging
material and the at least one part are placed within the container;
and illustrating an orientation in which the at least one part and
the packaging material are placed and secured within the container.
Description
RELATED APPLICATION DATA
[0001] This application is a divisional of U.S. application Ser.
No. 09/096,123 filed on Jun. 11, 1998, which claims priority of
U.S. Provisional Application No. 60/049,346 filed on Jun. 11,
1997.
FIELD OF THE INVENTION
[0002] The present invention relates to a cushioning conversion
system which converts sheet stock material into cushioning
material. More particularly, the present invention relates to a
cushioning conversion system including a packaging controller,
wherein the system is adapted to provide recommended packaging
and/or packaging information to an operator based on the parts to
be packaged, and further to provide for monitoring of packaging
supply inventories. Features of the invention, however, have a more
general application to packaging systems using various types of
dunnage products and packaging supplies.
BACKGROUND OF THE INVENTION
[0003] In the process of shipping a part from one location to
another, a protective packaging material is typically placed in the
shipping container to fill any voids, provide blocking and bracing,
and/or to cushion the part during the shipping process. Some
commonly used protective packaging materials are plastic or
cellulose foam peanuts, plastic bubble wrap, shredded paper or
cardboard, and converted paper pads. Converted paper pads, being
made from paper and particularly kraft paper, are biodegradable,
recyclable and composed of a renewable resource. Consequently,
converted paper pads have become increasingly important in light of
many industries adopting more progressive policies in terms of
environmental responsibility. The conversion of paper sheet stock
material into relatively low density paper pads may be accomplished
by a cushioning conversion machine, such as those disclosed in U.S.
Pat. Nos. 4,026,198; 4,085,662; 4,109,040; 4,237,776; 4,557,716;
4,650,456; 4,717,613; 4,750,896; and 4,968,291. (These patents are
all assigned to the assignee of the present invention and their
entire disclosures are hereby incorporated herein by
reference.)
[0004] By controlling the conversion machine, such as through the
use of a controller that may be programmed, pads of a variety of
lengths can be created. This feature allows a single machine to
satisfy a wide range of cushioning needs. For example, relatively
short pad lengths can be employed in conjunction with small and/or
unbreakable articles, while longer pad lengths can be employed in
connection with larger and/or fragile articles. Moreover, a set of
pads (either of the same or different lengths and/or different
configurations such as a star, a cross or a spiral/coil) can be
employed in conjunction with uniquely shaped and/or delicate
articles, such as electronic equipment.
[0005] In some instances, a manufacturer or shipping interest may
ship a wide variety of parts wherein each of the parts has
different packaging requirements. While a cushioning conversion
system, such as that described above, can provide a wide variety of
pads of different lengths at the request of the operator to meet
the differing requirements, it is often a time consuming process to
determine for each part presented the best way to package the part
and then to instruct the cushioning conversion machine to produce
the required number of pads having the appropriate lengths. Also,
the reliability of the packaging operation is oftentimes dependent
on the skill level of the operator, in particular the packer. In
the case of complex packaging systems involving the packaging of
many different types of product with different packaging
requirements, the necessary skill level may preclude the use of low
cost, low skill packers (or operators in general).
[0006] Another consequence of shipping a wide variety of parts
having different packaging requirements is the variability of
consumption of packaging materials used the pack the part or parts,
such as dunnage stock material, tape, containers (cartons, boxes,
etc.), etc. Heretofore, the monitoring of packaging material
inventories was accomplished manually by a person checking the
inventory levels and reordering additional supplies when needed. In
the case of paper sheet stock rolls used in the aforesaid
cushioning conversion machines to produce dunnage pads, typically
an order for the stock rolls and/or other packaging materials would
be placed with a distributor. The distributor would then fill the
order from stock on hand or place an order with its supplier to
directly ship the packaging materials to the end user. Like in the
case of the end user, the monitoring of packaging material
inventories at the distributor's facilities was accomplished
manually by a person checking the inventory levels and reordering
additional supplies when needed. These existing systems have been
labor intensive and time consuming.
[0007] A need therefore exists for improvements in packaging
systems, and particularly in the efficient and effective packaging
of parts in containers and in the efficient and effective
maintenance of packaging material inventories.
SUMMARY OF THE INVENTION
[0008] The present invention provides a packaging system,
components thereof and associated method which enable, inter alia,
a) more efficient and/or effective packaging of a part or parts, b)
more efficient and/or effective maintenance of packaging material
inventories, c) more efficient and/or effective usage of packaging
material, d) more efficient and/or effective usage of low cost, low
skill labor for packaging of parts, e) more efficient and/or
effective monitoring and/or analyzing of packaging operations, and
f) more efficient and/or effective handling and/or monitoring of
the part or parts being packaged. Any one or more of these
objectives are met by one or more of the various aspects and/or
features of the invention which are hereinafter more particularly
detailed.
[0009] A packaging system and methodology is disclosed which
automatically provides packaging instructions to an operator as a
function of the part or parts to be packaged. As a consequence, a
packaging system, based on an identification of a part or parts to
be packaged, produces pads of specified lengths to meet packaging
requirements and instructs the operator as to the recommended
technique of packaging the part or parts.
[0010] The present invention provides a packaging system and method
including a packaging material generator and a packaging system
controller adapted to produce packaging material in accordance with
the packaging requirements of at least one part to be packaged. The
packaging system controller provides packaging instructions for an
optimized packaging of the part or parts. The system controller
preferably includes a device or other means for identifying the
part or parts (e.g., via a part number or a part identifier) to be
packaged, a memory containing predetermined packaging instructions
associated with the identified part or parts to be packaged and an
output peripheral for communicating the appropriate packaging
instructions to a system operator.
[0011] Provision is made for automatically supplying an operator or
an automated packing system with a predetermined amount of
packaging material along with detailed packaging instructions to
provide for consistency in packaging known parts. Due to the
provision of a predetermined amount of packaging material and
detailed packaging instructions, high quality packaging can be
provided without an operator possessing extensive packaging
training. In addition, the packaging system ensures an improved
packaging efficiency, thereby lowering packaging costs by
eliminating waste while concurrently reducing shipping damage by
ensuring an adequate amount and an effective utilization of the
packaging material.
[0012] The packaging system according to a particular embodiment of
the present invention relates to the packaging of a known item or a
standard group of parts (e.g., a parts kit). The packaging system
identifies the part or parts to be packaged and retrieves
predetermined packaging instructions which are used to generate one
or more pieces of packaging material of the proper length or amount
(such as dunnage) and provide detailed operator packaging
instructions which are displayed on a display monitor. By using the
supplied packaging material along with the displayed detailed
instructions, a consistent, highly efficient packaging process is
effectuated independently of the experience level of the
operator.
[0013] More particularly, such packaging system includes a
cushioning conversion machine for converting stock material into
cushioning pads which serve as packaging material, a packaging
controller and a packaging terminal. A known part to be packaged is
identified, for example, by entering the part's identification
number into the system via either a keypad, a pull-down menu, a bar
code reader, etc. Once the part is identified, the packaging
controller retrieves a predetermined set of packaging instructions
which are associated with the identified part to be packaged. The
packaging instructions are then used to generate the appropriate
lengths of cushioning pads in the appropriate sequence while
simultaneously providing textual and graphical packaging
instructions on the packaging terminal display which aid in the
proper packaging of the part by the operator.
[0014] The retrieved predetermined set of packaging instructions
may further include packaging material manipulation control
information. For example, in addition to the appropriate lengths of
cushioning pads being provided in the appropriate sequence, one or
more of the generated pads may be coiled as necessary by a coiler
to provide the packaging material in a proper coiled form for
particular packaging methodologies. Alternatively, or additionally,
packaging material manipulation control information may include
control data for an automated manipulator such a pick-and-place
control apparatus or a robotic insertion and placement device to
automatically retrieve one or more of the produced pads and place
it in a packaging container.
[0015] According to another embodiment of the present invention, a
packaging system includes a packaging material consumption
monitoring system and method which counts the number of packaging
containers, the amount of packaging material generated, and the
amount or number of other associated packaging supplies to thereby
maintain an inventory control function by monitoring the
consumption of the various packaging materials. The packaging
system compares the amount of consumed packaging materials to one
or more re-order thresholds and generates a re-order request for
the appropriate materials if the re-order thresholds are either met
or exceeded.
[0016] According to still another embodiment of the present
invention, a packaging system includes a productivity monitoring
system and method, wherein characteristics of the packaging process
such as the time required to complete each step in the
predetermined packaging procedures is monitored. The system then
utilizes the collected data to generate a productivity report which
provides packaging machine data, operator identification data and
productivity data reflecting the time required to complete the
various steps in the packaging process. The data may be further
processed to provided normalized productivity data, trending
analysis, etc.
[0017] According to another aspect of the present invention, a
packaging system and method is disclosed which includes a packaging
material generator and a packaging system controller adapted to
produce packaging material in accordance with the packaging
requirements of a part to be packaged. For an unknown part to be
packaged, the packaging system evaluates one or more
characteristics of the part and determines the packaging
requirements and instructions for an optimized packaging of the
part.
[0018] Such packaging system preferably includes a device or other
means for identifying at least one of the characteristics of the
part to be packaged. The packaging system also includes a database
containing a set of rules and data for use in determining the
appropriate packaging instructions based on the various
characteristics of the part. The packaging system, upon determining
the appropriate packaging requirements and techniques, communicates
the instructions to the packaging material generator to
automatically generate the proper amount of packaging material in
the proper order. In addition, instructions are transmitted to an
output peripheral such as a display which includes graphical and/or
textural instructions to provide directions to the operator in
packaging the part.
[0019] Thus, according to this aspect of the invention, the
packaging system is capable of receiving an unknown part to be
packaged and supplying an untrained operator with an appropriate
amount of packaging material and detailed packaging instructions to
provide an optimized packaging methodology, thereby providing high
quality packaging which prevents product damage without incurring
undesirable waste.
[0020] Such packaging system is well-suited for a private mailing
company which ships various items for individuals. An operator
brings in an item which is unknown to the packaging system (i.e., a
predetermined set of packaging instructions uniquely associated
with the item does not reside within the packaging system's
memory). Instead, the packaging system acquires one or more
characteristics of the item such as its size, shape, weight and
fragility. The system then applies rules within the system's memory
to the provided data and determines an optimized packaging
methodology for the part.
[0021] The optimized packaging methodology is transmitted as
control signals to a packaging material generator such as a
cushioning conversion machine which dictates the appropriate
container (e.g., size and type), the number of cushioning pads,
their length and their generation sequence. Additionally, the
determined optimized packaging methodology is communicated to the
operator in the form of graphical and textual instructions to
insure that the part is packaged in accordance with the optimized
packaging methodology.
[0022] According to another embodiment of the present invention, a
packaging methodology preview is provided to the operator which
illustrates the materials to be used in the packaging process and
provides both the costs which will be incurred for the packaging
and the shipping of the part. The operator is then given an option
to proceed with the packaging process, wherein the generation of
the appropriate packaging material is commenced, or alternatively
end the process.
[0023] According to yet another aspect of the present invention, a
packaging system controller includes an "expert" system which
automates the decision making in the packaging methodology design
process. The packaging system controller preferably includes a
memory containing a plurality of expert based rules and packaging
data. The rules and packaging data are utilized in conjunction with
the data provided by the operator regarding the part to be packaged
to produce conclusions (i.e., an optimized packaging
methodology).
[0024] The expert system may represent the system knowledge in the
form of "ifthen" rules, wherein "if" certain conditions are true,
"then" certain conclusions should be drawn. In some cases, the
expert system may use several approaches for determining whether
certain conditions exist. The system may identify a condition
within an internal, established data base or use data from the data
base plus additional rules to establish the existence of a certain
condition. In addition, the system may ask the operator for
additional information in order to fill necessary gaps in order for
the system to make further progress in establishing the optimized
packaging methodology. In a preferred embodiment of the present
invention, the expert system uses inputs such as the part's size,
shape, weight and fragility to determine the appropriate container
and an optimized packaging methodology. In addition, a method of
shipment may also be utilized as well as an operator's preference
for either a packaging optimization or a cost optimization in
determining the packaging methodology.
[0025] According to yet another aspect of the present invention, a
packaging system and method is disclosed which includes a packaging
material generator and a packaging system controller adapted to
produce packaging material in accordance with the packaging
requirements of a plurality of parts to be packaged. For a
plurality of known parts to be packaged, the packaging system
evaluates a shipping order and obtains data relating to the parts
to be packaged. The packaging system then determines the packaging
techniques for an optimized packaging of the parts.
[0026] Such packaging system preferably includes a device or other
means for analyzing a shipping order to thereby identify the
plurality of parts to be packaged. The packaging system includes an
internal database and/or access to an external database containing
a list of the parts which may be packaged along with data related
to the parts, such as their weight, size, shape and fragility. The
packaging system also includes another database containing a set of
rules and data associated with the packaging material for use in
determining the appropriate packaging techniques to optimize the
packaging methodology. The packaging system, upon determining the
packaging techniques, communicates the instructions to the
packaging material generator to automatically generate the proper
amount of packaging material in the proper order. In addition, the
instructions are transmitted to an output peripheral such as a
display which includes graphical and/or textual instructions to
provide an explanation and directions to the operator in properly
packaging the plurality of parts.
[0027] Such packaging system of the present invention is
well-suited for a mail-order company or warehouse distributor which
retrieves multiple parts (products) and packages the parts together
for shipment to a customer. A packer (i.e., the operator) or the
packaging system receives a shipping order which is read by the
packaging system. The packaging system, using the order number,
identifies each of the parts to be packaged and retrieves
additional data associated with each part in the order from a
warehouse management database or an internal database. The
packaging system of the present invention then determines an
optimized packaging methodology based on the retrieved data which
includes the determination of the appropriate container (e.g., box,
carton, etc.) to package the order. In addition, the packaging
system determines the position and orientation (and thus the
packing sequence) of the parts to be packaged within the container
and generates the proper amount of packaging material in the proper
sequence to package the parts in accordance with the determined
packaging methodology.
[0028] According to another particular embodiment of the present
invention, the packaging system may include a pick list
verification system. In cases where parts are picked by one
individual and packaged by another, it is often required that the
packer confirm that the picked items are consistent with the
shipping order. The packaging system identifies all the parts that
should be in the shipping order and evaluates each part, preferably
with a reading device, to verify that the retrieved items match the
items in the shipping order before the packaging system determines
an optimized packaging methodology, thus saving time and money.
[0029] According to yet another particular embodiment of the
present invention, the packaging system controller includes an
expert system which automates the decision making in the packaging
methodology design process. The packaging system controller
includes an associated memory containing a plurality of expert
rules and packaging data which relates to the packaging material.
The rules and packaging data are used in conjunction with the data
associated with the parts to be packaged to produce conclusions
(i.e., an optimized packaging methodology).
[0030] The expert system may represent the system knowledge in the
form of if-then rules. Alternatively, the expert system may employ
a cubing concept, wherein each part to be packaged occupies (when
packaged) a cubic volume in the container. The expert system then
analyzes the various cubes corresponding to the parts to be
packaged and determines an optimized arrangement of cubes (i.e.,
parts) within the specified container, thus reducing an amount of
necessary void fill, extra boxes, etc.
[0031] The foregoing and other features of the invention are
hereinafter fully described and particularly pointed out in the
claims, the following description and the annexed drawings setting
forth in detail illustrative embodiments of the invention. These
embodiments, however, are but a few of the various ways in which
the principles of the invention may be employed. Other objects,
advantages and features of the invention will become apparent from
the following detailed description of the invention when considered
in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a block diagram illustrating a packaging system
according to the present invention;
[0033] FIG. 2 is an illustration of a packaging system according to
the present invention including a cushioning conversion machine and
a packaging system controller;
[0034] FIG. 3 is a block diagram illustrating a portion of the
packaging system controller according to the present invention;
[0035] FIG. 4 is a flow chart illustrating an operational flow
diagram of the packaging system according to the present
invention;
[0036] FIG. 5 is a flow chart illustrating a packaging routine
preview feature which allows a packer to verify whether the
appropriate packaging routine has been retrieved for the identified
part to be packaged;
[0037] FIG. 6a is an output peripheral display and user interface
illustrating a predetermined set of retrieved packaging
instructions for an identified part to be packaged;
[0038] FIG. 6b is an output peripheral display and user interface
which highlights a method of identifying or entering the parts to
be packaged according to one aspect of the present invention;
[0039] FIG. 6c is an output peripheral display illustrating in
greater detail a particular step of a predetermined set of
retrieved packaging instructions for the packaging of the
identified part;
[0040] FIG. 7 is a flow chart illustrating an operational flow
diagram for the generation of packaging material and the provision
of packaging instructions to an operator for the packaging of one
or more parts;
[0041] FIG. 8 is a flow chart illustrating the operation of the
packaging system including a packaging material manipulation
apparatus for either coiling generated packaging material and/or
initiating a pick-and-place control routine for automated
packaging;
[0042] FIG. 9a is a partial top view of the cushioning conversion
system of FIG. 2 employing a coiler attachment mechanism for taking
a length of generated packaging material and coiling it in
accordance with retrieved packaging instructions;
[0043] FIG. 9b is an enlarged partial side view of the cushioning
conversion system of FIG. 2 employing the coiler attachment of FIG.
9a, wherein the coiler attachment is operable to be rotated into
and out of the outlet flow path of the cushioning conversion
machine;
[0044] FIG. 10a is a side view of a cushioning conversion machine
employing a cushioning pad handling system such as a pick-and-place
apparatus according to the present invention;
[0045] FIG. 10b is a top view of the cushioning conversion machine
and cushioning pad handling system of FIG. 10a, wherein generated
cushioning pads are placed on a conveyor belt for conveying the
generated pads to a pick-and-place apparatus;
[0046] FIG. 10c is an isolated top view of the pick-and-place
apparatus of FIG. 10b according to the present invention;
[0047] FIG. 11 is a flow chart illustrating a method for providing
inventory control, inventory monitoring and automatic re-ordering
for packaging materials according to predetermined consumption
thresholds;
[0048] FIG. 12a is a flow chart illustrating in greater detail an
exemplary method of providing the inventory control method of FIG.
11;
[0049] FIG. 12b is a flow chart illustrating in greater detail an
exemplary method of providing the inventory control method of FIG.
11;
[0050] FIG. 13 is a flow chart illustrating a method for monitoring
operator packaging productivity and providing a productivity report
according to the present invention;
[0051] FIG. 14 is a flow chart illustrating in greater detail an
exemplary method of monitoring productivity and generating the
productivity report of FIG. 13;
[0052] FIGS. 15a-15d are flow charts illustrating in detail the
operation of the packaging system of FIG. 2 according to one
embodiment of the present invention;
[0053] FIG. 16a is a block diagram illustrating a packaging system
according to an alternative embodiment to the present
invention;
[0054] FIG. 16b is an idealized side view of the packaging system
according to the present invention;
[0055] FIG. 17 is a flow chart illustrating an operational flow
diagram of the packaging system according to an alternative
embodiment of the present invention;
[0056] FIG. 18 is a flow chart illustrating the step of identifying
the part to be packaged by providing one or more characteristics
which characterize the part to be packaged;
[0057] FIGS. 19a-19c illustrate various methods of determining the
fragility of the part to be packaged using pull-down menus, a
selection of general categories, and automated techniques such as
pattern recognition, expert systems and neural networks;
[0058] FIG. 20 is a block diagram illustrating an expert system
associated with the packaging system controller according to the
present invention;
[0059] FIG. 21 is a block diagram illustrating various pieces of
data residing within the data base of the expert system according
to the present invention;
[0060] FIG. 22 is a decision diagram illustrating an exemplary
method of determining the packaging control methodology using an
expert system according to the present invention;
[0061] FIGS. 23a-23n are graphs illustrating dynamic cushioning
conversion curves used in the determination of the functional
cushioning requirements by the expert system according to the
present invention;
[0062] FIG. 24 is a graph illustrating a dynamic cushioning
conversion curve in greater detail, wherein use of the curve in
determining whether a particular cushioning product configuration
is capable of meeting the functional cushioning requirements
determined by the expert system;
[0063] FIG. 25 is a graph illustrating the buckling coefficient
dependence upon static loading for one type of packaging
material;
[0064] FIGS. 26a-26b are graphs illustrating the impact of
vibration upon the packaged product according to the present
invention, in particular, typical vibration frequencies for
differing types of transportation;
[0065] FIG. 27 is an operational flow diagram of the packaging
system for packaging a plurality of known parts according to
another aspect of the present invention;
[0066] FIG. 28 is a block diagram illustrating the packaging system
according to the present invention;
[0067] FIG. 29 is a flow chart illustrating a method of identifying
parts to be packaged and determining packaging instructions for the
identified parts;
[0068] FIG. 30 is a flow chart illustrating in a step of reading an
order number for a shipment of items;
[0069] FIGS. 31a-31d are block diagrams illustrating exemplary
cubing configurations according to the present invention;
[0070] FIG. 32 is a flow chart diagram illustrating the functions
controlled by the determined packaging instructions according to
the present invention; and
[0071] FIG. 33 illustrates the collection of data for generating
productivity statistics.
DETAILED DESCRIPTION OF THE INVENTION
[0072] The present invention will now be described with reference
to the drawings wherein reference numerals are used to refer to
like elements throughout. In one embodiment of the present
invention, an automated packaging system and method is disclosed
which includes a packaging material generator such as a cushioning
conversion machine and a packaging system controller. An operator,
wishing to efficiently package a known, identified part, interacts
with the packaging system to produce an appropriate amount of
packaging material in an appropriate sequence for packaging the
part within an identified container. In addition, the packaging
system and method provides detailed packaging instructions to the
operator in either a textual and/or pictorial format, thereby
providing packaging efficiency and consistency which results in
reduced part damage and reduced packaging costs.
[0073] According to a preferred embodiment of the present
invention, a known part to be packaged is identified by, for
example, reading or entering its part identification number. Once
the part to be packaged is identified, the packaging system
retrieves a predetermined set of packaging instructions which
uniquely correspond to the identified part. The packaging
instructions preferably indicate the recommended packaging
container, generate the necessary packaging material and provide
step by step instructions to aid the operator in the packaging of
the part. Preferably, each instruction step is provided to the
operator via a computer display terminal in conjunction with a
length (or amount) of packaging material generated by the packaging
material generator. The packaging system reduces packaging costs by
dictating the proper container and the proper amounts of packaging
material. Consequently, excess, wasteful packaging voids are
eliminated. In addition, the detailed packaging instructions reduce
the need for highly experienced operators since the container,
amounts of packaging material, the sequence with which the
packaging material are generated and the manner in which the
packaging material is to be used for efficient packaging is
dictated and explained by the packaging system.
[0074] In accordance with another aspect of the present invention,
there is provided an inventory monitoring system in which the
materials consumed in the packaging of parts are monitored. For
example, for a particular part to be packaged, a predetermined
container and a predetermined amount of packaging material will be
used. While the packaging materials are being consumed during the
packaging of a part, the inventory monitoring system, for example,
decrements an internal inventory list and compares the updated list
to one or more re-order thresholds. If one or more items on the
updated inventory list (i.e., a consumption list) satisfies a
re-order criteria (e.g., falls below a minimum threshold), the
inventory monitoring system automatically generates a re-order
request to ensure that packaging inventories are not unduly
depleted. In addition to the monitoring of containers and packaging
material, the inventory monitoring system may also monitor other
packaging supplies such as product literature associated with the
identified part, warranty cards, packaging tape, etc.
[0075] According to another aspect of the present invention, a
packaging system may include a productivity monitoring system. The
productivity monitoring system is operable to time the packaging of
each part for an identified operator and monitor the time required
to complete each step within the prescribed packaging routine. The
productivity monitoring system then creates a productivity report
in which the operator's productivity is provided in an easy to
evaluate format. The productivity report preferably includes an
average time required to perform one or more packaging steps, but
may also include normalized productivity data and trending
information, as may be desired, which may be stored in a
database.
[0076] Referring now to the drawings in detail, and initially to
FIGS. 1-4, a packaging system and method according to the present
invention is shown. In FIG. 1, the packaging system 10 includes a
packaging material generator 12 for generating packaging material
to be used in packaging identified parts. According to the present
invention, the term "parts" is broadly used to include a single
part, a kit including a known arrangement of parts, and various
items requiring shipment, regardless of the nature of the part, be
it an article, product, component, piece, etc. The packaging
material generator 12 includes a controller 14 for controlling the
various operational components (not shown) within the generator 12
as will be discussed in greater detail infra. A packaging system
controller 16 is coupled to the packaging material generator 12 and
communicates to the packaging material generator 12 via the
controller 14. The packaging system controller 16 is also coupled
to an output peripheral 18 and an input peripheral 20,
respectively, and is operable to retrieve a predetermined set of
packaging instructions in response to the identification of a part
to be packaged, which is preferably identified via the input
peripheral 20.
[0077] The predetermined packaging instructions are preferably
retrieved from a memory (not shown) associated with the packaging
system controller 16 or a communication network and are selectively
sent to the controller 14 and the output peripheral 18. The
packaging instructions sent to the controller 14 preferably relate
to the generation of particular lengths (or amounts) of packaging
material in a particular sequence. In addition, as will be
described in greater detail infra, the packaging instructions may
further include post-generation packaging material manipulation
control signals for manipulating the generated packaging material
for particular packaging options such as coiling or the
implementation of a pick-and-place functionality.
[0078] The packaging instructions which are sent to the output
peripheral 18 (e.g., a computer display monitor) are preferably
detailed explanatory type instructions which aid the operator in
the efficient packaging of the identified part. The explanatory
instructions include, for example, explanatory text accompanying
graphical pictures of the part to be packaged, the packaging
material, the container, etc. Preferably, the instructions provided
via the output peripheral 18 clearly illustrate the manner in which
the packaging material engages the parts to be packaged and how the
packaging material engages the packaging container to properly and
efficiently secure the part within the container. Such instructions
may further include video type instructions including audio data,
as may be desired. The packaging instructions may also include pre
and/or post packaging information such as instructions for
selecting and erecting a particular container, inserting a liner,
taping instructions, shipping instructions, etc.
[0079] Turning now to FIG. 2, the packaging system 10 of FIG. 1
according to a preferred embodiment of the present invention is
illustrated. The packaging system 10 includes a cushioning
conversion machine 12 as the packaging material generator and a
personal computer 16 constitutes the packaging system controller of
FIG. 1. The personal computer 16 is coupled to an input peripheral
20 (not shown) such as a keyboard, a bar code reader, a mouse, etc.
for entering data or commands. The personal computer 16 is also
coupled to a display monitor 18 which corresponds to the output
peripheral 18 of FIG. 1 and may also be connected to a computer
network. The input peripheral 20 and the display monitor 18 are
used for operator interaction with the cushioning conversion
machine 12.
[0080] The cushioning conversion machine 12 preferably includes a
frame 24 upon which the various components of a conversion assembly
25 are mounted and a machine controller 14 (which is illustrated
schematically) for controlling the cushioning conversion machine 12
including the components of the conversion assembly 25. The frame
24 has mounted thereto or included therein a stock supply assembly
26 including a web separating assembly and stock support bar (not
shown) which holds a roll of stock (e.g., paper) for conversion by
the conversion assembly 25 into a cushioning material (not shown).
The illustrated conversion assembly 25 is composed of plural
conversion assemblies including a forming assembly 30, a
feeding/connecting assembly 32 powered by a feed motor 34, and a
severing or cutting assembly 36 powered by, for example, a cut
motor 38 selectively engaged with the cutting assembly 36 by a
clutch 40. Also provided is a post-cutting constraining assembly or
outlet 42 for guiding the cushioning material from the cutting
assembly.
[0081] During the conversion process, the forming assembly 30
causes the lateral edges of the stock material (not shown) to turn
inwardly to form a continuous strip having two lateral pillow-like
portions and a central band therebetween as such stock material is
advanced through the forming assembly. The feeding/connecting
assembly 32, including a pair of meshed gear-like members (gears)
in the illustrated cushioning conversion machine, performs a
feeding, e.g., pulling, function by drawing the continuous strip
through the nip of the two cooperating and opposing gears of the
feeding/connecting assembly 32 by drawing the stock material
through the forming assembly 30 for a duration which is determined
by the length of time that the feed motor 34 rotates the opposed
gears. The feeding/connecting assembly 32 additionally performs a
"connecting" function as the two opposed gears coin the central
band of the continuous strip as it passes therethrough to form a
coined strip. As the coined strip travels downstream through the
feeding/connecting assembly 32, the cutting assembly 36 cuts the
strip into sections of a desired length. These cut sections exit
from the post-cutting constraining assembly 42 and are then
available for use in the packaging of the part.
[0082] The machine controller 14 is preferably a microprocessor
based programmable controller such as that described in co-owned
U.S. patent application Ser. Nos. 08/482,015 and 08/279,149, filed
Jun. 7, 1995 and Jul. 22, 1994, respectively, both entitled
"Cushioning Conversion Machine" which are incorporated herein by
reference. The machine controller 14 controls the operation of the
various components of the cushioning conversion machine 12 (e.g.,
the feeding/connecting assembly 32, or more specifically the feed
motor 34, and the cutting assembly 36, or more specifically the cut
motor, etc.) to form one or more pads of particular lengths in
accordance with a number of control signal inputs. Such control
signal inputs may include inputs from machine sensors, such as
maybe employed to detect jams or accurately measure pad length
formation, for example, and inputs from the personal computer 16
(i.e., the packaging system controller) via a control line 44.
Specifically, when it is desired that an appropriate length of pad
be formed, the machine controller 14 causes power to be supplied to
the feed motor 34 for a duration which is sufficient for the
conversion assembly 25 to produce the desired length of pad. Power
to the feed motor 34 is then disabled and the machine controller 14
causes the cut motor clutch 40 to engage the cut motor 38 with the
cutting assembly 36 to sever the pad at the desired length.
[0083] Referring now to FIG. 3, a detailed block diagram of the
packaging system controller 16 of FIG. 1 is shown in accordance
with a preferred embodiment of the present invention. The packaging
system controller 16 preferably includes a central processing unit
(CPU) 50 which is coupled to a bus 52. The CPU or processor 50 can
be any of a plurality of processors, such as a Pentium.TM., a Power
PC.TM., Sparc.TM., or any other similar and compatible processor.
The CPU 50 functions to perform various operations described herein
as well as carries out other operations related to the packaging
system controller 16. The manner in which the CPU 50 can be
programmed to carry out the functions relating to the present
invention will be readily apparent to those having ordinary skill
in the art based on the description provided herein. The bus 52
includes a plurality of signal lines 54 for conveying addresses,
data and control between the CPU 50 and a number of system bus
components. The other system bus components include a memory 58
(including a random access memory (RAM) 60 and a read only memory
(ROM) 62) and a plurality of ports for connection to a variety of
input/output (I/0) devices which collectively comprise the output
peripheral 18 and the input peripheral 20, respectively. The memory
58 serves as data storage and may store appropriate operating code
to be executed by the CPU 50 for carrying out the functions
described herein.
[0084] The RAM 60, hard drive 78 or other type storage medium
provides program instruction storage, working memory for the CPU 50
and the predetermined packaging instructions associated with the
particular parts to be packaged. Preferably, the packaging
instructions correspond to the parts to be packaged through a
look-up table, however, other storage and retrieval techniques such
as an algorithmic search engine are contemplated as falling within
the scope of the present invention. For example, the predetermined
packaging instructions may be stored on the hard drive 78 or other
data storage medium (e.g., a CD ROM) and be accessed by the CPU 50
according to program instructions within the RAM 60.
[0085] The ROM 62 contains software instructions known as the basic
input/output system (BIOS) for performing interface operations with
the I/O devices. Also stored in the ROM 62 is a software routine
which operates to load a boot program. The boot program will
typically be executed when the packaging system controller 16 is
powered on or when initialization of the packaging system
controller 16 is needed.
[0086] The I/O devices include basic devices such as data storage
devices (e.g., floppy discs, tape drives, CD ROMs, hard discs,
etc.). Typically, the I/O devices communicate with the CPU 50 by
generating interrupts. The CPU 50 distinguishes interrupts from
among the I/O devices through individual interrupt codes assigned
thereto. Response of the CPU 50 to the I/O device interrupts
differ, among other things, on the devices generating the
interrupts. Interrupt vectors may also be provided to direct the
CPU 50 to different interrupt handling routines.
[0087] The interrupt vectors are generated during initialization
(i.e., boot up) of the packaging system controller 16 by execution
of the BIOS. Because responses of the CPU 50 to device interrupts
may need to be changed from time to time, the interrupt vectors may
need to be modified from time to time in order to direct the CPU 50
to different interrupt handling routines. To allow for the
modification of the interrupt vectors, they are stored in the RAM
60 during operation of the packaging system controller 16.
[0088] A disk control subsystem 70 bi-directionally couples one or
more disk drives 72 (e.g., floppy disk drives, CD ROM drives, etc.)
to the system bus 52. The disc drive 72 works in conjunction with a
removable storage medium such as a floppy diskette or CD ROM. A
hard drive control subsystem 76 bi-directionally couples a rotating
fixed disk or hard drive 78 to the system bus 52. The hard drive
control subsystem 76 and hard drive 78 provide mass storage for CPU
instruction data, for example.
[0089] The disk drive 72 and disk control subsystem 70 may be
utilized to download one or more pieces of data to the RAM 60 or
system hard drive 78. For each part or collection of parts, for
example, data relating to the proper container to be used for
packaging, the part identification number, the packaging material
generation control requirements (both the amount and sequencing)
and user packaging instructions (including text, graphics, digital
photos and/or video data) may be provided. Therefore as the
packaging requirements change or additional parts are required to
be packaged, the packaging system controller 16 can by dynamically
updated.
[0090] A terminal control subsystem 86 is also coupled to the bus
52 and provides output to the output peripheral 18, typically a CRT
monitor, and receives inputs from a manual input device 20 such as
a keyboard. Manual input may also be provided by a pointing device
such as a mouse or other type input peripherals such as a bar code
reader. In addition, the input device 20 may include a microphone
for receiving voice instructions and be processed by the CPU 50
according to voice recognition techniques as is well known by those
skilled in the art. Further, the input peripheral 20 may include a
touch activated display such as a capacitive touch screen. Any type
of data input device is contemplated as falling within the scope of
the present invention.
[0091] A network adapter 90 is provided for coupling the packaging
controller 16 to a network. Such a network adapter 90 is coupled to
the system bus 52 and allows for providing communication linkage to
other systems either local or remote to the packaging system 10. In
addition, other types of computer hardware may also be connected to
the bus 52. For example, a modem 91 may be provided for
transmitting, according to instructions provided by the CPU 50,
various pieces of information such as re-order requests to
inventory distributors for updating inventories in the event that
re-order thresholds are satisfied.
[0092] Turning now to FIGS. 3 and 4, a method 100 is provided in
which the packaging system 10 of FIG. 1 provides packaging material
and packaging instructions to a user. The method 100 preferably
begins with the entry of an identification number of a known part
to be packaged at step 102. The identification step 102 may be
carried out in a number of ways. For example, the part may have a
part identification number on it which may be manually input to the
packaging system controller 16 via the input peripheral 20 such as
by typing the part number into the system using a keyboard or
keypad. Alternatively, a pull-down menu illustrated on the output
peripheral 18 (e.g., the computer display) may be accessed using a
mouse as the input peripheral 20. The pull-down menu may include a
list of all the known parts which have associated sets of
predetermined packaging instructions in the packaging system 10. By
selecting the part number in the pull-down menu using the mouse,
the part to be packaging is identified.
[0093] In yet another alternative method of entering the part to be
packaged, step 102 may include reading the part identification
number from the part (or its associated packaging request
paperwork) using a pattern recognition device such as a bar code
reader or a video monitor with optical character recognition. In
still another alternative method, the input peripheral 20 may
include a microphone for receiving audio signals and the part may
be entered by reading aloud the part number into the microphone of
the packaging system 10. In such a case, the microphone receives
the acoustic sounds and transmits the data to the CPU 50 which
identifies the part using voice recognition techniques. For
example, the microphone may receive the acoustic sounds and convert
the sounds into analog signals and then transmit the data to the
CPU 50 which converts the audio data into digital data using, for
example, an A/D converter. Lastly, although a few methods of
identifying the part 102 are described above, it should be
understood that other methods exist for identifying the part and
each is contemplated as falling within the scope of the present
invention.
[0094] Once the part is entered, the CPU 50, according to the
programmed instructions within the RAM 60, retrieves a packaging
control methodology which includes a predetermined set of packaging
instructions which are associated with the identified part as step
104. The data used is retrieved from an associated memory such as
the hard drive 78 or a data recording medium in the disk drive 72
or the network drive. For example, the instructions may be stored
on the hard drive 78 or on a CD ROM in the disk drive 72. Upon
identifying the part to be packaged, the CPU 50 retrieves the
packaging instructions associated with the part at step 104.
[0095] In a preferred method of the present invention, the CPU 50
uses a lookup table or an algorithmic search engine to retrieve the
predetermined packaging instructions. In such a method, each part
number is tied to an address space which contains the packaging
instructions associated with the part number. The CPU 50, using the
addresses corresponding to the address space, retrieves the
instructions and discriminates which instructions pertain to
packaging material generator control instructions and which are
directed toward operator packaging instructions. According to the
present invention the term "operator" is used to broadly mean
anyone interfacing with the packaging system and may include, for
example, a packer, a customer, a user, a supervisor, etc.
[0096] The CPU 50 sends the instructions directed to packaging
material generator control to the controller 14 of the packaging
material generator 12 to initiate the generation of the appropriate
amount of packaging material in the proper sequence. For example,
in the preferred embodiment of the present invention, the packaging
material generator 12 is a cushioning conversion machine. In such a
case, the control instructions to the controller 14 will dictate
how many cushioning pads to produce to properly package the part,
the proper length for each pad and the order or sequence in which
the pads will be produced. Therefore the retrieved packaging
instructions from the CPU 50 will provide for the control of the
packaging material generator at step 108 of FIG. 4.
[0097] The CPU 50 also sends the instructions directed to the
operator to the output peripheral 18 (preferably a computer
display) to provide step by step explanatory instructions at step
110 to ensure that the packaging material generated by the
generator 12 is properly used in packaging the part and that the
part is being packaged in the proper container. Preferably, the
instructions consist of text and graphics data which are used by
the CPU 50 to drive the output peripheral 18 and thereby provide
pictorial outputs with accompanying textual instructions. In
addition, the instructions are preferably provided in a sequence
which correspond to the order in which the packaging material is
generated. Although the preferred embodiment of the present
invention provides the packaging instructions at step 110 using
graphics and text, the packaging instructions may also further
include video and/or audio data for the packaging instructions. Any
form of packaging instructions is contemplated as failing within
the scope of the present invention.
[0098] Therefore if the identified part to be packaged requires
three pieces of cushioning pads to be generated in lengths of 12",
18" and 15", respectively, the packaging instructions which are
retrieved by the CPU 50 will result in a generation of a 12"
cushioning pad while a graphical illustration with an accompanying
textual explanation of how to use the 12" pad to properly package
the part will be provided on the display 18. Once the operator
takes the 12" pad, the cushioning conversion machine 12 detects the
condition (preferably through use of a sensor) and then
automatically generates the next pad (the 18" pad) according to the
predetermined packaging instructions, while a graphical
illustration with accompanying text is provided on the display 18
to illustrate how to properly utilize the generated pad. Lastly,
after the second pad is taken by the operator, the last pad is
produced by the cushioning conversion machine 12 with its
associated instructions on the display to illustrate how to
complete the packaging process. Consequently, the present invention
ensures that the proper packaging container and the proper amount
of packaging material is used in the packaging of an identified
part. In addition, the packaging system 10 provides the proper
amount of packaging material in the proper sequence and provides
guidance in the packaging of a part within the proper container to
ensure that the part is efficiently packaged independently of the
experienced level of the operator. Furthermore, the present
invention results in the elimination of waste packaging material,
enables packaging consistency and reduces packaging damage.
[0099] In the above example, a cushioning conversion machine was
used as the packaging material generator 12. Although a cushioning
conversion machine is used in the preferred embodiment of the
present invention, the packaging system 10 may also be used in
conjunction with other types of packaging material generators or
dispensers, such as styrofoam peanut generators and/or dispensers,
bubble-wrap generators and/or dispensers, air pad machines, void
fill generators (e.g., material shredders), etc. Any type of
packaging material generator and/or dispenser is contemplated as
falling within the scope of the present invention. In addition, in
the above example, the packaging instructions of step 110 were
limited to identifying the proper packaging container and how to
utilize the generated packaging material to pack the identified
part. The packaging instructions may, however, include additional
instructions such as specifying which type of packaging tape or
sealer to use in closing the container, how to seal the container
using the tape, whether documentation is to be included within the
container and what type of mailing label to use. In addition, the
packaging instructions may include pre-packaging instructions such
as instructions relating to the selection and erection of the
proper container, etc.
[0100] In addition to the features of FIG. 4, the method 100 may
also include a preview feature, as illustrated in FIG. 5. Once the
known part to be packaged is identified (step 102) and the CPU 50
retrieves the packaging control methodology (i.e., the packaging
instructions, step 104), the CPU 50 sends the packaging preview
data to the output peripheral 18 which allows the operator to view
the identified part and all the steps involved in the packaging
process at step 112. The preview feature allows the operator to
verify whether or not the proper part has been identified at step
114. For example, if after reviewing the display packaging preview
at step 112 the operator determines that the wrong part has been
identified (i.e., the part identification number was incorrectly
entered, etc.), the operator can return to the beginning of the
method 100 and repeat the step of identifying the part to be
packaged at step 102 (i.e., re-enter the part identification
number) prior to generating any packaging material, thereby
avoiding potential waste. If, however, the operator verifies
through use of the preview screen that the identified part is the
correct part at step 114, the method 100 continues and the CPU 50
sends the predetermined instructions to the controller 14 and
display 18 (steps 108 and 110) for the packaging of the identified
part.
[0101] The method 100 of FIG. 5 is illustrated in greater detail
according to an exemplary embodiment of the preview display feature
shown in FIGS. 6a -6c and in the flow chart of FIG. 7. FIG. 6a is
an exemplary display screen on the output peripheral 18. FIG. 6a
preferably includes a windows-type display interface 120 having a
part identification window 122, a part title box 124 and a box
number window 126 for displaying the proper packaging container
which corresponds to the identified part. The interface 120 further
includes a window 128 which allows a user to indicate how many of
the identified parts are to be packaged and a preview window 130
which illustrates a preview of the packaging process associated
with the identified part. The preview window 130 includes, for each
step in the packaging process, a step identifier 132a, a packaging
material amount identifier 132b, a window 132c which indicates the
number of pads required to complete the identified step, and a
packaging illustration box 132d. Lastly, the interface 120 includes
a preview acceptance window 134 which allows a user, after
reviewing the preview window 130, to verify that the packaging
instructions are correct ("Accept") or exit the process
("Exit").
[0102] Once the part to be packaged is entered, however, the CPU 50
retrieves the packaging instructions and inputs the various pieces
of data onto the screen as shown in FIG. 6a such as the
identification of the packaging container and the box number window
126 and the name of the part in the part title box 124. Preferably,
the number of parts to be packaged is manually input into the box
128, however, the present invention may automatically receive such
data when reading the part identification number or, alternatively,
an order, job or lot number. In addition, the preview of the
packaging methodology for the identified part is displayed by the
CPU 50 in the window 130 for verification by the user.
[0103] One manner of identifying the part to be packaged is simply
entering the part identification number into the window 122.
Alternatively, one may also use a pull-down menu using a mouse, as
illustrated in FIG. 6b, by scrolling up and down within the
pull-down menu. A user may then select the proper part from all the
known parts which are listed within the system 10. Once selected,
the CPU 50 retrieves the predetermined packaging functions
associated with the identified part from the memory (e.g., hard
drive 78 or external drive 72) and populates the windows 124, 126
and 130. The user may then verify the instructions by evaluating
the preview window 130 and selecting the proper option in the
preview acceptance window 134.
[0104] If the packer selects "Accept" in the preview acceptance
window 134, the packaging system 10 begins the packaging process by
using the retrieved packaging instructions to control the packaging
material generator 12 and provide the display instructions such as
providing pre-packaging instructions such as the selection of the
proper container, instructions regarding how to utilize the
generated packaging material, and post-packaging instructions such
as how to properly seal the container and where to send the
completed package (steps 108 and 110, respectively). One exemplary
display instruction corresponding to step 110 is illustrated in
FIG. 6c. In FIG. 6c, the output peripheral 18 displays an enlarged
packaging display window 144 having, for example, two graphical
display regions 146a and 146b and a text explanation region 146c.
The graphical regions 146a and 146b may consist of one or more
pictures and/or textual annotations which illustrate how the
packaging material which is produced by the packaging material
generator 12 is used to secure the identified part within the
selected container. The text explanation window 146c preferably
identifies which step within the packaging process is being
executed, which pad for the step is being illustrated (when
multiple pads are being used for a single step), and the length of
the pad being produced. In addition, the window 146c may include
further text instructions to further aid the operator in the
packaging of the identified part. Lastly, the packaging display
window 144 includes a stop/finish function region 148 which allows
the user to stop the process or indicate that the packaging step is
completed.
[0105] Preferably, the packaging display window 144 uses text and
graphics to communicate and explain the packaging step to the
operator. Alternatively, the packaging instructions may further
include video and/or audio data and therefore the display window
144 may include a video illustrating the packaging procedure with
accompanying audio instructions. Once the operator clicks or
otherwise activates the stop/finish region 148, the CPU 50 returns
the operator to a display window 120 similar to FIG. 6a.
[0106] A detailed flow chart illustrating the steps involved in
providing the retrieved packaging instructions (steps 108 and 110)
to the packaging material generator 12 and to the output peripheral
18 is provided in FIG. 7. The CPU 50 begins at the first part to be
packaged at step 150. In some cases, instead of simply packaging a
single part, a plurality of identical parts will need to be
packaged (see window 128 of FIG. 6a). The present invention
contemplates providing instructions for either a single or multiple
parts to be packaged, as may be desired. The CPU 50 then begins at
the first step of the packaging process (step 152) where it begins
providing the packaging instructions for the first step in the
packaging process at step 154. As illustrated in FIG. 6a, for
example, the first step may include the forming of a single pad
having a length of 60" into a coil and placing the coil in the
packaging container so that it underlies the part to be packaged
within the container. In conjunction with providing the packaging
instructions on the output peripheral 18 to the operator, the CPU
50 transmits the appropriate control signals to the controller 14
at step 156 to generate the appropriate packaging material to
complete the first step, that is, generating a pad having a length
of 60". After completing the first step, the CPU 50 determines
whether all the steps are complete at step 158. Since the packaging
process for the part in this particular example includes three
separate packaging steps, the method proceeds to step 160 where the
CPU 50 increments to the next step of the packaging process (i.e.,
step 2).
[0107] In the second step of the packaging process, the CPU 50
provides the packaging instructions for the second step at step
154. As illustrated in FIG. 6a, the second step may include the
forming of a single pad having a length of 60" into a coil and
placing the coil in the box so that it also underlies another
portion of the part to be packaged within the container. In
conjunction with sending the packaging instructions to the output
peripheral 18, the CPU 50 transmits the appropriate control signals
to the controller 14 in step 156 in accordance with the packaging
instructions to generate the appropriate packaging material to
complete the second step. After completing the second step, the CPU
50 again determines whether all the steps are completed at step
158. Since the packaging process is still not complete, the method
continues to step 160 and again provides packaging instructions at
steps 154 and 156, respectively.
[0108] After the completion of all three steps, the CPU 50
determines that the steps are completed at step 158 and then the
packaging process for that particular part is completed and the
method continues to step 162, wherein the CPU 50 queries whether
all the parts that need to be packaged are complete. If additional
parts still remain to be packaged, the method continues to step 164
and the CPU 50 increments to the next part and again begins the
packaging process step at step 152. If all the parts to be packaged
are completed at step 162, the CPU 50 continues to step 166 and the
packaging process is completed.
[0109] As stated above, the CPU 50 retrieves packaging instructions
which constitute a packaging control methodology which is
associated with the identified part to be packaged. The packaging
instructions which are retrieved by the CPU 50 in response to the
identification of the part to be packaged include both control
instructions to control the operation of the packaging material
generator 12 and operator instructions to help the operator
properly use the generated packing material so as to efficiently
package the part within the specified container.
[0110] In addition to the above packaging instructions, the
packaging instructions may further include packaging material
manipulation instructions which provide control functions in
addition to the generation of the packaging material. For example,
the packaging material manipulation instructions may include
instructions to activate a coiler to take a cushioning pad which
has been produced by the packaging material generator 12 and form a
coil with the pad for use in packaging the part within the
packaging container.
[0111] Alternatively, the manipulation instructions may activate a
pick-and-place apparatus to effectuate an automated system to take
a generated pad and place it into a packaging container without the
need of an operator. In yet another alternative arrangement, an
automated packing mechanism such as a pick-and-place apparatus, a
robot or a pad insertion system may be used in conjunction with an
operator to improve the productivity of the packing station.
Although a coiling operation and a pick-and-place control
functionality are provided as two examples for the packaging
material manipulation instructions, additional packaging material
manipulation instructions may also be included and are contemplated
as falling within the scope of the present invention. Like the
packaging instructions, the packaging material manipulation
instructions are predetermined and are associated with the
particular part to be packaged and therefore are retrieved by the
CPU 50 after the part has been properly entered.
[0112] Turning now to FIG. 8, a flow chart is disclosed which
illustrates an exemplary flow diagram by which the CPU 50 retrieves
the packaging instructions which include the packaging material
manipulation instructions and how the packaging material
manipulation instructions are utilized by the system in providing
additional control functionality. FIG. 8 illustrates a method 170
by which additional control functionality is provided using the
retrieved packaging instructions from the CPU 50. As discussed, the
CPU 50 retrieves the packaging instructions which correspond to the
part to be packaged and sends the control instructions to the
packaging material generator 12 at step 108. The packaging
instructions also include the packaging material manipulation
instructions. At step 172, the CPU 50 queries whether the material
which is being generated by the packaging material generator 12 is
to be coiled. If the packaging instructions indicate that the
packaging material is to be coiled (YES), a coiler, which is
functionally coupled to the packaging material generator 12, is
activated at step 174 and the generated packaging material, having
a length in accordance with the packaging instructions, is coiled
at step 176 using the coiler apparatus which is functionally
coupled to the packaging material generator. After being coiled at
step 176, two options exist, which depend upon the control
instructions. In one case, the coiled packaging material is simply
made available to the operator to manually take and utilize the
coil in the packaging of the part at step 178. In another case, the
packaging instructions further include control instructions which
initiate a pick-and-place control apparatus, for example, at step
180. The control instructions dictate a control routine which
allows the pick-and-place apparatus to take the coiled packaging
material and automatically place it within the packaging
container.
[0113] Alternatively, if at step 172 the packaging instructions do
not contain any control signals requiring the generated packaging
material to be coiled (NO), the generated packaging material may
simply be made available to the operator for use in packaging the
identified part at step 182. Alternatively, however, the packaging
instructions may include control instructions for the initiation of
a pick-and-place apparatus for use in an automated packaging
routine at step 184. An exemplary coiler and pick-and-place
apparatus are illustrated and described in greater detail
below.
[0114] FIG. 9a illustrates an exemplary coiling apparatus 250
according to the present invention. The coiler 250 may be
physically attached to the cushioning conversion machine 12 near
its outlet 42, as illustrated in FIG. 9b. The coiler 250 includes a
U-shaped frame 252 securely attached to the cushioning conversion
machine 12 via a bolt assembly 253. Preferably, the coiler 250 is
pivotally mounted to the cushioning conversion machine 12, as
illustrated in FIG. 9b, to allow the coiler 250 to be moved into an
out of the outlet pad flow path as maybe desired. A rotating
mechanism 254 is rotatably mounted to the frame 252 in the outlet
pad feed path in a first position, and when the frame 252 is moved
from this operating position, the rotating mechanism 254 is no
longer aligned with the outlet 42, and the cushioning conversion
machine 12 may be used without the coiler 250.
[0115] The rotating mechanism 254 is rotatably mounted to the frame
252 and includes a rotating shaft which forms the center of
rotation for the coiler 250. A capture device 260 is attached to
and rotates with the shaft, and a power source 268 is provided for
rotating the shaft. The rotating shaft extends through an opening
in a support panel and projects in a direction which is transverse
to the outlet pad feed path.
[0116] The capture device 260 is fixably attached to the projecting
ends of the shaft 214, whereby it is aligned with the outlet 42 of
the cushioning conversion machine 12. The capture device 260 is
designed to capture the leading end of the strip of cushioning when
the coiler 250 is in a ready-to-coil condition. The illustrated
capture device 260 includes a connecting hub and at least two
capture members 262 projecting therefrom. The hub is an elongated
rod or bar attached to, and rotatably driven by, the shaft. The
capture members 262 are symmetrically positioned to extend from the
hub into the outlet pad feed path. The capture members 262 are
sized and spaced so that they have a length which is approximately
as wide as the strip of cushioning product (i.e., the pad produced
by the cushioning conversion machine). When the coiler 250 is in a
ready-to-coil condition, the capture members 262 of the capture
device 260 are aligned in a plane which is perpendicular to a
travel path of the strip of cushioning material as it is emitted
from the cushioning conversion machine 12 so that the leading end
of the strip of cushioning product will pass between the capture
members 262. When the shaft, and thus the capture members 262, are
rotated, the capture members 262 will capture the end of the strip
so that the remaining portions of the strip may be coiled
therearound.
[0117] The power source 268 for driving or rotating the shaft is
mounted on the support panel on the side facing away from the
outlet 42 of the cushioning conversion machine 12. The power source
268 is preferably a motor, more preferably an electric motor, and
even more preferably a low speed DC torque motor. The power source
268 having an adjustable current limit is preferable because the
motor torque is proportional to motor current, whereby the current
limit is actually an adjustable torque setting to control the
tightness of the spiral/coil. Note that the adjustable torque
setting may also be placed under control of the packaging system
controller 16 and thus may produce spiral/coil configurations with
different cushioning characteristics in accordance with the
packaging instructions. Alternatively, a fluid-power source with a
pressure regulator for torque adjustment may also be utilized.
Another option is to incorporate a slip clutch into the drive to
maintain a constant coiling tension on the strip of the cushioning
product.
[0118] The coiler 250 may additionally include a taping device (not
shown) for supplying tape to secure the trailing end of the strip
of cushioning product to the coil. The taping device may be
designed for manual dispensing of the tape and manual placement of
the tape on the coil, however, an automatic taping device is
possible with, and is contemplated by, the present invention.
[0119] When the coil of cushioning product has been completely
formed and possibly taped, it may be removed from the coiler 250 by
pulling the coil in a transverse direction away from the support
panel. This pulling is easily accomplished, especially if the
capture members 262 of the capture device 260 are in the
ready-to-coil position where they are aligned in a plane
perpendicular to the travel path of the strip of cushioning
material as it is emitted from the cushioning conversion machine.
Alternatively, an automatic ejection system (controlled, for
example, by the controller 14) is possible with and is contemplated
by the present invention.
[0120] As previously discussed, the cushioning conversion machine
12 includes a controller 14 which controls the operation of the
cushioning conversion machine 12. In addition, the controller 14
also controls the coiler 250 based on the packaging instructions
provided by the packaging system controller 16 of FIG. 1. In one
aspect of the present invention, the controller 14 operates in
conjunction with a strip-production indicator which preferably
includes a strip sensing mechanism which senses whether a strip of
cushioning product is being emitted from the outlet 42 of the
cushioning conversion machine 12. In this embodiment, the strip
product indicator includes a upstream strip sensor (not shown) on
the cushioning conversion machine which senses whether the strip is
present at an upstream location at the outlet 42 and a downstream
strip sensor 274 which senses whether the strip is present at a
downstream location. The upstream strip sensor is mounted at an
upstream portion of the support panel or on the cushioning
conversion machine 12 itself. The downstream strip sensor 274 is
preferably mounted on the coiler frame 252 and in this manner, the
downstream location is positioned to ensure that the leading end of
the strip of the cushioning product is correctly positioned
relative to the capture device 260.
[0121] The controller 14 activates the coiler 250 (i.e., energizes
the motor 268 of the rotating mechanism 254) when both the sensors
(the upstream and downstream sensors) sense that the strip of
cushioning product is present at both the upstream location and the
downstream location. This ensures that the leading end of the strip
of the cushioning product is correctly positioned relative to the
capture device 260 and that the strip of cushioning product is long
enough to coil. The controller 14 deactivates the coiler 250 when
the upstream sensor senses that the strip of the cushioning product
is no longer present (i.e., its trailing end has passed the
upstream location) after a period of time corresponding to a time
period necessary to ensure that the trailing end portion of the
strip of cushioning product is coiled and a capture device is
properly aligned.
[0122] In this manner, the coiling apparatus 250 may operate in
conjunction with the cushioning conversion machine 12 to provide
additional manipulation control to the packaging material in
accordance with the retrieved packaging instructions by the CPU 50.
The operation of a coiling apparatus is also described in U.S.
patent application Ser. No. 60/071,164 entitled "Cushioning
Conversion System and Method for Making a Coil of Cushioning
Product", which is incorporated by reference herein in its
entirety.
[0123] As discussed supra, an alternative packaging material
manipulation apparatus may include a packaging material
pick-and-place system 300, as illustrated in FIG. 10a. The
pick-and-place system 300, according to one exemplary embodiment,
includes the cushioning conversion machine 12 of FIG. 2 and a
pick-and-place assembly 302 having an outfeed drive unit 304 which
feeds a generated cushioning pad to an indexing conveyor system
306. The outfeed drive unit 304 contacts a produced pad at the
outlet 42 and pulls the pad away from the machine outlet 42 and
onto the conveyor system 306.
[0124] The conveyor system 306 preferably includes a supporting
frame 306a and a conveyor belt 306b which receives a produced pad
from the outfeed drive unit 304 and transfers the pad along the
conveyor belt 306b to a loading station 307 where a pick-and-place
unit 308 is located, as illustrated in FIG. 10b. The pick-and-place
unit 308 has an arm 308a which grabs the produced pad in a first
position 309a as (illustrated in FIG. 10b) and rotates the arm 308a
180.degree. to a second position 309b (as illustrated in FIG. 10c)
and releases the pad, thus placing the pad in a container (not
shown). In addition, the conveyor belt 306b preferably includes a
chain belt with 306c which create a pocket to align and hold the
cushioning pads on the belt 306b during transport to the
pick-and-place staging area 307. The conveyor belt 306b also allows
multiple cushioning pads to accumulate between the machine 12 and
the staging area 307.
[0125] Alternatively, the pick-and-place system 300 may include a
pick-and-place unit 308 directly at the machine outlet 42. In such
a case, the pick-and-place unit 307 grabs the produced pad at the
machine outlet 42 and rotates the pad 90.degree. and places the pad
into an appropriate packaging container. The pick-and-place system
300 is controlled by the packaging instructions which are retrieved
by the CPU 50 of the packaging system controller 16 and transmitted
to the controller 14 of the cushioning conversion machine 12. The
controller 14 also controls the motor 304b of the outfeed drive
unit 304, the conveyor belt 306b of the conveyor system 306 and the
pick-and-place unit 308, respectively. Other types of pick and
place type systems are also contemplated by the present invention
such as the one described in U.S. Pat. No. 5,749,821 entitled
"Cushioning Conversion System for Converting Paper Stock into
Cushioning Material with a Staging Area and a Pick and Place
Assembly", which is incorporated by reference herein in its
entirety.
[0126] The packaging material manipulation control feature of the
present invention has been discussed in conjunction with the
coilers 200 and 250 and the pick-and-place control system 300 of
FIGS. 9a-9c and FIGS. 10a-10c, respectively. These packaging
material manipulation control features, however, are merely
exemplary and this feature extends to other manipulation control
functions such as robotic control functionality for automated
packaging. Other types of dunnage manipulators and manipulation
techniques include the pad discharge and insertion apparatus shown
and described in U.S. patent application No. 60/059,290 filed on
Sep. 18, 1997, which is hereby incorporated herein by reference in
its entirety. In addition, although the discussion of the packaging
material manipulation control feature was disclosed in conjunction
with the cushioning conversion machine 12 of FIG. 2, this feature
extends to other types of packaging material generators and/or
dispensers which are contemplated as falling within the scope of
the present invention.
[0127] The packaging system 10 of FIG. 1 may also be utilized to
provide an inventory control feature which tracks the consumption
of various packaging items or materials in conjunction with its
automated generation and supply of packaging material. One
exemplary method 350 of providing such inventory control (which may
alternatively be considered a monitoring of consumption) is
illustrated in FIG. 11a. As discussed previously in conjunction
with FIG. 4, the packaging system 10 identifies the part to be
packaged at step 102 and the CPU 50 retrieves the packaging control
methodology consisting of packaging instructions at step 104. Using
the packaging instructions, the packaging material generator is
controlled at step 108 while an operator is concurrently receiving
graphical and textual packaging instructions on an output
peripheral 18, such as a CRT display, at step 110.
[0128] As each part is packaged, various items associated with the
packaging process are consumed. For example, each part is packaged
within a particular packaging container or box and each part uses a
specified amount of packaging material. In addition, the packaging
of the part also includes the use of a specified amount of
packaging tape depending on the specified container size as well as
other materials such as the insertion of warranty cards,
manufacturer's documentation, etc. into the packaging container. As
these various packaging materials are consumed during the packaging
process, inventories of these items are depleted. The present
invention monitors the consumption of these packaging items and
automatically generates re-order requests when the inventory
control level of the packaging material has dropped below a pre-set
value, thus ensuring that inventories are not fully depleted at
inopportune times.
[0129] The method 350 monitors the amount of packaging materials
consumed by the packaging material generator 12 at step 352,
wherein, for example, the packaging system controller 16 keeps
track of the number of each type of packaging container used at
step 354, calculates the amount of packaging material used by the
machine 12 at step 356, and keeps track of the other various
packaging items at step 358, respectively.
[0130] In one example of the present invention, step 354 is
performed when the packaging instructions have been retrieved by
the CPU 50 and confirmed by the operator. Since the packaging
instructions preferably identify the appropriate packaging
container, the CPU 50 updates a list within a memory such as an
inventory database to indicate that one of the identified
containers has been used. Similarly, since the packaging
instructions will dictate the amount of packaging material to be
generated and used for the packaging of the identified part (e.g.,
three pads each having a length of 60" in FIG. 6a) the CPU 50
calculates the total amount of packaging material that will be used
and updates the list within the memory. Lastly, for each identified
part, the packaging instructions will preferably dictate the amount
of packaging tape to be used as well as which additional items such
as warranty cards and documentation are to be packaged within the
container. The CPU 50, using the retrieved packaging instructions,
then updates a list within the memory. As the list within the
memory is continuously updated, the CPU 50 takes each item within
the list and compares them with predetermined re-order thresholds
either continuously or periodically, as may be desired. If an item
in the updated list satisfies its associated re-order criteria or
threshold, the CPU 50 generates a re-order request at step 360
(FIG. 11). In addition, the CPU 50 may generate a consumption
report using the updated list at step 362 for review as may be
desired. Preferably, the re-order thresholds may be adjusted as may
be desired. Therefore if, for example, procurement procedures
change so that reordering may be made at lower inventory levels,
the re-order threshold may be adjusted, thereby making the
packaging system dynamic.
[0131] The re-order thresholds may also be dynamic in the sense
that the threshold is a function of the packaging rate. For
example, if the packaging system controller 16 via the CPU 50
identifies that the rate of consumption of the various packaging
materials is above a certain rate, the packaging system controller
16 may increase one or more thresholds to ensure that a re-order
request is generated soon enough to ensure that inventories are not
unduly depleted. Likewise, if a consumption rate falls below a
predetermined rate, the packaging system controller 16 may decrease
one or more thresholds to ensure that a re-order request be
generated at a later time since the time required to consume the
remaining inventory will be greater and thus prevent excess
inventories from being generated.
[0132] According to the present invention, the method 350 may
provide a reorder request in various ways. For example, when the
CPU 50 determines that a packaging item such as packaging tape must
be re-ordered (e.g., the amount of remaining packaging tape falls
below the associated re-order threshold), the CPU 50 may send the
re-order message requesting that packaging tape be ordered to the
output peripheral 18 (e.g., the display) so that the operator can
communicate the re-order request to personnel in an inventory
control department. Alternatively, the CPU 50 may, using the
network adaptor 90 of FIG. 3 transmit the re-order request directly
to inventory control or the purchasing department over a local
network. In yet another alternative aspect of the present
invention, the CPU 50 may, using a modem, for example, transmit the
re-order request directly to the appropriate inventory distributor
or to a packaging materials manufacturer for production planning
purposes. In any event, the present invention provides an automated
inventory control system and method to continuously monitor the
consumption of one or more packaging materials and re-order the
materials prior to their complete depletion.
[0133] Preferably, the CPU 50 updates the packaging materials at
various times instead of continuously. For example, instead of the
CPU 50 decrementing an amount paper each time a cushioning
conversion machine produces a length of dunnage, the CPU 50 may
alternatively, decrement the amount of paper each time a roll of
paper is completely consumed and is being replaced by a new roll.
Such a function can be effectuated by a sensor which identifies the
end of a roll. Similarly, the CPU 50 can update the packaging
materials list each time a roll of tape is completely consumed,
etc.
[0134] In yet another aspect of the present invention, the method
350 of FIG. 11 may operate in conjunction with multiple packaging
material generators 12. In such a case, the memory containing the
updated list is shared over a computer network linking the
packaging system controllers 16 of each packaging system 10. As
each packaging system 10 consumes various packaging items, the
global list is then continuously updated.
[0135] An exemplary method for monitoring the packaging materials
(step 352 of FIG. 1) and implementing re-order control is
illustrated in FIG. 12a. According to this method, the packaging
system 10 via the CPU 50 stores a value representing an initial
amount of inventory for various packaging materials in memory,
representing the amount of materials available. As the various
packaging materials are consumed, the CPU 50 updates a consumption
list by decrementing the number associated with the item in memory.
For example, if fifty (50) type-1 packaging containers are in
inventory ("50" stored in a memory location associated with type-1
containers) and the packaging system 10 dictates that one of the
type-1 packaging containers be utilized, the CPU 50 decrements the
inventory number of type-1 packaging containers in memory to
forty-nine (49). The CPU 50, then either constantly or periodically
checks to see whether the updated inventory list satisfies a
re-order criteria (e.g., falls below a predetermined re-order
threshold) and generates a re-order request if appropriate.
[0136] At step 361, the CPU 50 determines whether it is time to
analyze whether a re-order criteria is satisfied. As stated
earlier, the analysis time may be constant (i.e., each time one or
more packaging materials are consumed) or may be periodic (e.g.,
each hour, each shift, each day, etc.). If the CPU 50 determines
according to programmed instructions in the memory, that it is time
to analyze the inventory, the CPU 50 checks one or more inventory
levels in the inventory list against a re-order point (i.e., a
re-order threshold) at step 362. If none of the items on the
inventory list meet or fall below their associated reorder
threshold, the CPU 50 does not take any action. If, however, one or
more of the re-order criteria are met, the CPU 50 makes a list of
items to be reordered which may include specified re-order
quantities at step 363 and transmits the re-order list at step 364
via, for example, the modem 91, the Internet, facsimile, etc. The
re-order request may be sent directly to the operator, to inventory
personnel, to a packaging materials distributor or to the packaging
materials manufacturer for production planning purposes.
[0137] According to a preferred embodiment of the present
invention, the CPU 50 allows for the operator to manually adjust
one or more parameters within the inventory list in the event, for
example, that one of the materials is inadvertently destroyed and
cannot be utilized in the packaging process. In addition, the CPU
50 decrements the inventory list each time one or more packaging
materials are consumed, however, the inventory monitoring may be
provided in a variety of different ways that are each contemplated
as falling within the scope of the present invention.
[0138] Another alternative, exemplary method for monitoring the
packaging materials (step 352 of FIG. 11) is illustrated in greater
detail in FIG. 12b. At step 370, the CPU 50 initializes the list to
be updated within the memory to zero so that the number of
containers as well as the various associated supplies indicate that
none of the supplies have yet been consumed. Likewise, the CPU 50
at step 372 initializes the length of packaging material (e.g.,
cushioning conversion products such as Padpak.RTM. dunnage
material) so that the updated list within the memory indicates that
no packaging material has yet been consumed. At step 374, a
packaging step is performed in accordance with the retrieved
packaging instructions by the CPU 50. As has already been
previously discussed, the packaging step includes the consumption
of a particular amount of packaging material. At step 376, the CPU
50 updates the amount of packaging material consumed by taking the
present amount within the memory (at this particular time equal to
0) and adds to that amount the amount of packaging material used in
the packaging step. For example, if the packaging step involves the
consumption of a 60" piece of cushioning conversion product, the
length within the updated list would be updated to 60" at step 376.
Once the length is updated at step 376, the CPU 50 compares the
amount of material consumed to a re-order threshold at step 370. If
the re-order threshold is met or exceeded, a re-order message is
generated at step 380. Alternatively, the comparison function can
be performed periodically, as may be desired.
[0139] Once the packaging step is completed, the CPU 50 at step 382
queries whether the packaging process is complete. If the packaging
process is not complete (NO), the CPU 50 goes to the next packaging
step at step 384 and again updates the list within the memory in
accordance with the amount of packaging material used in the next
packaging step. Steps 376, 378, 382 and 384 are repeated until all
the packaging steps are completed. The method 352 then continues to
step 385 in which the CPU 50 increments each of the supplies which
were utilized in the packaging in the previous part. For example,
the specified packaging container for packaging the part to be
packaged is incremented so that the updated list indicates that one
of the selected containers has been consumed. Likewise, the various
packaging supplies such as packaging tape, warranty cards, etc.
utilized in the packaging of the identified part are also updated
in the list at step 385. Each time the supplies are incremented at
step 385, the CPU 50, at step 386, performs a compare function in
which the various supplies in the updated list within the memory
are compared to predetermined re-order thresholds. If the various
updated supplies do not meet or exceed the re-order thresholds, the
CPU 50 does not take any additional action, and the method
precedes. If, however, one or more supplies in the updated list
meet or exceed an associated re-order threshold, the CPU 50
generates a re-order request message at step 380.
[0140] In addition to incrementing the supplies (step 385) after
the completion of all the steps at step 382 (YES), the CPU 50 also
queries at step 388 whether all the parts to be packaged have been
packaged. If all the parts have been packaged (YES), the method 352
ends at step 390. If, however, it is determined by the CPU 50 that
additional parts remain to be packaged (NO), the CPU 50 begins the
packaging of a new part via step 394. Therefore the packaging steps
for the next part to be packaging are performed and the monitoring
function continues as was previously discussed. In this manner the
method 352 provides an inventory monitoring and automatic
re-ordering function.
[0141] According to yet another aspect of the present invention, a
packaging productivity monitoring system may also be incorporated
in the packaging system of FIG. 1. A method 400 for providing such
a productivity monitoring capability as illustrated in FIG. 13. As
discussed previously, the packaging system 10 of the present
invention identifies a part to be packaged at step 102 and
retrieves a packaging control methodology via a predetermined set
of packaging instructions associated with the identified part at
step 104. The CPU 50 then transmits the retrieved packaging
instructions to the controller 14 to provide appropriate control of
the packaging material generator at step 108. As may be
appreciated, the time required to package and the part consists of
the time required to complete each of the necessary packaging
steps. The present invention provides a timing mechanism for
determining the time required to package each identified part and
the time taken to execute each of the steps in the packaging
process. According to the present invention, each piece of
collected time data is saved in a memory associated with the CPU 50
and used to generate a productivity report for productivity
analysis purposes.
[0142] In FIG. 13, when the packaging system 10 identifies a part
to be packaged, the method 400 initiates, via the CPU 50, a global
packaging timer at step 402, which is used to determine the amount
of time required to package each part. In one embodiment of the
present invention, a timer 50a associated with the CPU 50 is
utilized. In addition, once the packaging instructions initiate
control of the packaging material generator (step 108), the method
400 initiates via the CPU 50 one or more timers for determining the
amount of time required to complete each of the steps of the
predetermined packaging process for the identified part at step
404.
[0143] Once the packaging of the identified part is complete at
step 406, the global timer is stopped at step 408. The global timer
thus indicates the amount of time required to package a single
part. After the packaging of each part is completed, the CPU 50
takes the time data for each packaging part and saves it in a
memory such as the hard drive 78 of FIG. 3. In addition to the time
data, the CPU 50 also records other pertinent information such as
the packaging material generator identification number, an operator
identifier, and a code which indicates which predetermined set of
packaging instructions are associated with the time data. The CPU
50 may then utilize the saved data in generating the productivity
report at step 410. Alternatively, the CPU 50 may be programmed to
time-stamp and date stamp each step and further programmed to
process the various time-stamps to determine the time data.
[0144] The productivity report generated at step 410 may appear as
a report 412 as illustrated in FIG. 13. In generating such a report
412, the CPU 50 performs mathematical operations on some of the
data in accordance with programmed instructions to generate
additional productivity characteristics which are helpful in
evaluating greater productivity. For example, for the packaging of
a plurality of identical parts, an average global time may be
calculated according to known techniques to gauge the average time
it takes for a given operator to complete the packaging of a
particular part. In addition, an average time for each step of the
packaging process may be calculated. Therefore the report 412
allows one to analyze which packaging steps need to be addressed to
best improve the packaging productivity. Lastly, the productivity
data may be used for the documentation of various processes and
procedures such as ISO 9001 certification, etc.
[0145] In addition, the collected time can be normalized in several
ways. For example, the time data may be normalized with respect to
the particular packaging process uniquely associated with the
identified part to allow for productivity comparisons across
various packaging processes. Using such data one can focus on the
particular packaging processes that need the most improvement.
Also, the time data may be normalized across all the various
operators to allow for direct comparisons between various operators
who perform different packaging processes. In such a normalization,
for example, a 1.0 would indicate an average packaging productivity
while numbers greater than 1.0 would indicate a productivity less
than average and numbers less than 1.0 would indicate a
productivity greater than average.
[0146] Lastly, the collected time data may be dated and used to
generate productivity trending information to monitor changes in
packaging productivity over time. Although the above example
discussed various steps within the process which may be measured
with regard to time, the present invention also contemplates
measuring various other characteristics which may be associated
with productivity. Each such characteristic is contemplated as
falling within the scope of the present invention. In addition,
while several exemplary mathematical operations are disclosed (and
performed by the CPU 50) to generate productivity characteristics,
it is understood that other types of statistical techniques and
mathematical operations may also be employed to provide other types
of productivity measurement criteria. Each such form of
productivity measurement and data manipulation are contemplated as
falling within the scope of the present invention.
[0147] An exemplary method by which the packaging system 10 may
monitor the time required to execute each step for each part of the
packaging process (step 404 of FIG. 13) is illustrated in greater
detail in FIG. 14. Once the CPU 50 has retrieved the packaging
instructions associated with the identified part at step 104 of
FIG. 13, the CPU 50 initializes two counting variables ("i" which
represents the number of parts which need to be packaged and "j"
which represents the number of steps required to package each part)
at step 420. At step 422, the CPU 50 transmits the retrieved
packaging instructions to the controller 14 of the packaging
material generator 12 which begins generating the packaging
material for the first part (i=1) using the first step in that
packaging process (j=1). As the first step is initiated, the CPU 50
initiates a timer at step 424 for part i=1 and step j=1. The CPU 50
then monitors whether the first step (step j=1) is complete at step
426.
[0148] When it is indicated that the first step (step j=1) is
complete, (YES) the CPU 50 stops the timer which is measuring the
time duration of the first step (step j=1) at step 428 and store
the time value in memory. The controller 14 of the packaging
material generator 12 then continues to the next packaging step at
step 430 (j=j+1; j=2). The CPU 50 then inquires at step 432 whether
all the steps of the packaging process are complete by comparing
the incremented variable j (in this case, j=2) to a threshold value
which when met indicates the maximum number of steps in the
particular packaging process has been exceeded. If all the steps
are not complete, the variable j will not be equal to the threshold
value, and the method 404 will return to step 422 and the
controller will generate packaging material for the second step
(j=2) of the first part (i=1). Likewise, steps 424, 426, 428, 430
and 432 will continue until all the steps in the packaging of the
first part are completed (YES at step 432), at which point the CPU
50 stops the timer which measures the total time required to
package the part at step 434. The data regarding the amount of time
required to package the first part is then stored in the
appropriate memory for later analysis. The controller 14 then
continues to the packaging of the next part at step 436 (i=i+1;
i=2) and the CPU 50 inquires at step 438 whether all the parts to
be packaged have been completed (i.e., whether i is equal to a
threshold). If all the parts to be packaged are not completed (NO)
the method 404 continues to step 440, wherein the CPU 50 resets the
step counter variable j back to j=1 and begins the timing process
for a second part at step 422, wherein i=2 and j=1.
[0149] The timing of the various steps for the second part (i=2)
then continues with steps 424-432. After the times are measured for
the various steps of part i=2, steps 434 through 438 are again
repeated until all of the parts to be packaged are complete (i=the
threshold value at step 438) and the method 404 ends at step 442.
The CPU 50 then takes all the data which has been saved for each
step j and each part i and saves the data in the appropriate memory
for use in generating the productivity report at step 410 which may
have a display output similar to the report 412 of FIG. 13.
[0150] As discussed above in conjunction with FIGS. 1-14, the
packaging system 10 of the present invention provides for the
efficient, optimized packaging of various parts by identifying a
part to be packaged, retrieving predetermined packaging
instructions associated with the identified package and using the
retrieved packaging instructions to provide control of the
packaging material generator and provide graphical/textual
packaging instructions to the operator via a display.
[0151] Yet another embodiment in which such functionality may be
provided is discussed below in conjunction with FIGS. 15a-15d. The
operation of the packaging system 10 generally, and specifically
the functions executed by the packaging system controller 16, is
described below in detail with reference to the flow charts
illustrated in the FIGS. 15a-15d.
[0152] Initially, during execution of the programmed instructions
within the packaging system controller 16, a display is provided on
the output peripheral 18 such as a CRT monitor in step 500,
prompting the operator to identify the part to be packaged, such as
by providing a part number as well as a number of such parts to be
packaged. (As used herein, solid lines in the flow chart represent
generally the flow of the program steps and dashed lines indicate
the flow of data or messages. Moreover, while the program flow is
represented as linear or serial for the purposes of description
simplicity, it is recognized that the program is preferably
executed in an event driven manner with steps being executed in a
time-slice fashion.)
[0153] Upon initialization of program operation, a database 501 of
the part and the corresponding packaging information is made
accessible at step 502, part information is provided to the program
in an accessible format 504 and initialization of flags, pointers,
counters and/or other program control variables is performed in
step 506. The operator can then indicate to the packaging system 10
the part number of the part or parts to be packaged and the number
of parts to be packaged at step 508. Based on the identification of
the part to be packaged, the program will retrieve from the
information for a packaging process from the database 501 and
provide to the operator, as a confirmation, a description of the
part which the operator identified for packaging at step 510. A
description may be in the form of the name of the part or
preferably an image of the part to be packaged. The operator then
confirms that the program has identified the correct part to be
packaged at step 512 and the program begins the process of
producing pads (in the case where the packaging material generator
is a cushioning conversion machine) and instructing the operator in
the proper or recommended packaging the part.
[0154] First, a monitor flag is set to one (1) to indicate that the
display on the monitor 18 has not been then updated to reflect the
beginning of the packaging sequence at step 514. The program then
checks, as shown in FIG. 15b, that the required number of parts
have not yet been packaged at step 516. Assuming that the required
number of parts have not yet been packaged, and, as in this
example, this is the first time through the program, the program
will initialize the current step counter equal to one at step 518,
meaning that the correct number of pads of the correct lengths are
to be produced for the first step in the process of packaging the
identified part. The number of steps having been executed in the
packaging process is then examined at step 520 and if the current
step is less than 4 (for a part packaging process having three
packaging steps) and the quantity of pads to be produced is greater
than 0 at step 522, a wake-up code is provided to the machine
controller 14 at step 524.
[0155] The purpose of the wake-up code is to inform the machine
controller 14 to begin looking for the appropriate instructions
from the packaging system controller 16. Previous to receiving the
wake-up code, the machine controller 14 will ignore any codes, such
as those randomly generated by noise in the input port of the
machine controller 14 so as not to take any unintended action in
the event that noise on the line would match one of the
instructional codes to the machine controller at step 524. Once the
wake-up code has been sent to the machine controller at step 524, a
timed handshake function is implemented through steps 526 to 532
which ensures that the packaging system controller 16 and the
machine controller 14 are communicating correctly.
[0156] The handshake function includes starting a timer at step
526, waiting to receive a message at step 530 from the machine
controller 14 and checking any received message to determine
whether the received message is the intended message, for example,
the word "Ranpak" at step 532. In the event the message is not
received from the machine controller 14 within the appropriate
time, the timer will time out at step 528, an error code will be
displayed at step 534 and the packaging controller 16 will inquire
to the operator whether it should try to reestablish communication
with the machine controller 14 at steps 536 and 538. If the
operator does not reestablish control of the machine controller 14,
the program is terminated, otherwise the program will cycle again
starting with step 520.
[0157] Assuming that a message was received from the machine
controller 14 at steps 530 and 532 before the timer timed out and
the message was the appropriate message, the packaging system
controller 16 will instruct the machine controller 14 as to the
number of pads to be produced and their order of generation (step
540 of FIG. 15c). Alternatively, instead of providing the pad
length and the number of pads to be produced to the machine
controller 14 in one step, the section of program code can be
executed through a loop in which the machine controller 14 is
instructed to produce one pad of the appropriate length as many
times as needed to produce the correct number of pads.
Communication between the packaging system controller 16 and the
machine controller 14 is again coordinated through a timed
handshake function through steps 542 through 548, similar to the
handshake function described above relative to steps 524 through
532 to confirm that the machine controller 14 received the length
and the number of pads to be produced.
[0158] Accordingly, after the machine controller 14 has been
instructed to produce a pad of the appropriate length at step 540,
a timer is started at step 542 and the program will monitor whether
a message is received at step 546 before the timer times out at
step 544. If a message is received, the message will be checked to
determine whether it was the intended message. In this case, the
intended message may be a carriage return 548, for example. If the
timer timed out before a message was received or the incorrect
message was received, an error code will be displayed at step 534
of FIG. 15b and the operator will be prompted as to whether the
packaging system controller 16 should attempt to re-establish
communication with the machine controller 14 at step 536.
[0159] Assuming the appropriate message was received from the
machine controller 14, and the packaging system controller 16 is
executing the first packaging step for the part to be packaged at
step 550, the appropriate display will be presented on the monitor
18 at step 552 and a picture of the part being packaged according
to the first step will be displayed at step 554. If this is not the
first time in the program for this part to be packaged (NO at step
550), a five second delay is instituted at step 556 before the
picture of the part being packaged in accordance with the next step
in the packaging process is displayed at step 554. The purpose of
this five second delay is so that the operator has time to examine
the display of the first step in packaging the part before the
display is replaced by the display corresponding to the second step
of packaging the part.
[0160] Concurrently with displaying the picture of the part being
packaged, the packaging system controller 16 will begin requesting
the machine controller 14 at a set time interval to provide it with
the status of producing the requested pad or pads (steps 558, 560)
and again begin the timed handshake function (steps 570-76), as
discussed above. If the message has been received from the machine
controller 14, the message is examined to determine if an error has
occurred in producing the pad at steps 578 and 580 of FIG. 15d. If
no error has occurred, the message will either indicate that the
cushioning conversion machine is still in the process of producing
a pad or pads (steps 578 and 580), and the packaging system
controller 16 will again inquire as to the status of the pad
production (steps 558-576) until it has been determined that the
required pads have been produced. The timer is then disabled at
step 582 and the packaging system controller 16 will continue to
the next step in the packaging process by incrementing the
packaging step counter at step 584 and setting the display flag to
indicate that a picture of the part being packaged is currently
being displayed at step 586. The machine controller 14 will then
begin the process of producing the pads for the next packaging step
in providing the packaging recommendation to the operator (steps
520-586).
[0161] If the three packaging steps have been completed for the
identified part, as indicated by the step counter being equal to 4
at step 520 of FIG. 15b, the part quantity counter is decremented
at step 588 and the packaging system controller 16 will determine
whether all of the same parts have been packaged or not (step 516).
If not, the machine controller 14 will again produce the necessary
pads and instruct the operator with recommendations. If all like
parts have been packaged, the display on the output peripheral 18
is returned to the display prompting the operator for an indication
of the next part type to be packaged (step 590, FIG. 15a) and the
process is repeated for the next part.
[0162] In the first embodiment of the present invention, the
packaging system is utilized in conjunction with one or more known
parts. A predetermined set of packaging instructions is associated
with each of the part numbers or identifiers and is retrieved from
a memory in response to the notification of the part to be
packaged. In another embodiment of the present invention, a
packaging system is disclosed in which the part to be packaged is
unknown. In this context, an unknown part means that the part,
along with predetermined packaging instructions associated with the
part, do not reside within an associated memory. Instead, the
packaging system, according to the alternative embodiment of the
present invention, identifies one or more characteristics of the
part to be packaged and uses the identified characteristics to
determine (rather than retrieve) an optimized packaging methodology
for packaging the part. According to the alternative embodiment of
the present invention, an operator who does not possess packaging
experience can employ an optimized packaging of the part which
insures the prevention of packaging damage while simultaneously
avoiding the use of excess packaging material, thus minimizing the
packaging costs for a given part.
[0163] In accordance with another aspect of the present invention,
once the optimized packaging methodology is determined, a packaging
preview is provided on an output peripheral such as a display. The
packaging preview allows the operator (i.e., a user or customer) to
view the determined packaging process to verify that the determined
packaging methodology is appropriate. In addition, once the
optimized packaging methodology is determined, the packaging system
displays the costs associated with both the packaging and the
shipping of the part and allows the operator to accept the
packaging and shipping costs or alternatively discontinue the
process.
[0164] In yet another aspect of the present invention, the
packaging system provides packaging instructions associated with
the determined optimized packaging methodology to both the
packaging material generator and the operator via an output
peripheral. The packaging instructions are used to generate an
appropriate amount of packaging material in a specified sequence
for use in packaging the part. Concurrently, the packaging
instructions are used to provide step by step explanatory
instructions to the operator, preferably via a display, in a
graphical and textual format. The explanatory instructions
illustrate how to properly utilize the generated packaging material
in securing the part in the properly identified container, thereby
insuring that the part is properly packaged in accordance with the
determined optimized packaging process.
[0165] According to one aspect of the present invention, the
packaging system controller which determines an optimized packaging
methodology includes an expert system. The expert system includes a
knowledge base which consists of a plurality of rules and data
related to packaging which are applied to data supplied by the
operator which relate to the part to be packaged to form a
conclusion (i.e., the optimized packaging methodology). Preferably,
the rules consist of "if-then" rules, although alternative rule
schemes such as the use of "frames" may be used instead of, or in
conjunction with, the "if-then" rules to generate conclusions using
both internal data and the one or more characteristics associated
with the part. Such characteristics may include, but are not
limited to, the following: the size, shape, weight and fragility of
the part, the method of shipping and a preference of whether the
packaging methodology is to be optimized with respect to packaging
or cost.
[0166] According to still another aspect of the present invention,
the packaging system includes an inventory monitoring system which
maintains a list of packaging materials. As various packaging
materials are utilized in accordance with the determined packaging
methodology for various parts, the inventory monitoring system
updates the inventory list and compares the updated amounts to one
or more re-order thresholds. If any of the re-order threshold
conditions are satisfied (e.g., equal to less than a threshold or
alternatively greater than or equal to a threshold), the packaging
system automatically generates a re-order request to prevent the
packaging material inventory from becoming unduly depleted.
[0167] A packaging system 590 according to the alternative
embodiment of the present invention is illustrated in FIG. 16a. The
packaging system 590 includes a packaging system controller 592
which is coupled to the packaging material generator 12, which in
the preferred embodiment of the present invention is a cushioning
conversion machine, as illustrated in FIG. 2. An output peripheral
18 is coupled to the packaging system controller 592. The output
peripheral 18 may include one or more components and preferably
includes a freight cost or postage meter 18a for generating the
proper shipping cost or postage in response to the identified
shipping destination and the weight of the shipment (including the
part, the packaging container and the packaging material). In
addition, the output peripheral 18 preferably includes a printer
18b for printing a mailing label in accordance with instructions
provided by the operator. Lastly, the input peripheral also
preferably includes a display 18c such as a CRT for providing step
by step graphical and textual instructions in parallel is with the
generation of the packaging material to aid in the proper packaging
of the part.
[0168] The packaging system 590 of FIG. 16a also includes an input
peripheral 20 which is coupled to the packaging system controller
592. The input peripheral 20 may include one or more components and
preferably includes a scale 20a for measuring the weight of the
article or part to be packaged. In addition, a dimension
measurement apparatus 20b is preferably included to identify the
size and shape of the part to be packaged. The dimension
measurement apparatus 20b may be a simple device such as a ruler
which measures the part's height, length and width, respectively.
Since many parts, however, have more detailed three-dimensional
shapes than a cube, a more complex dimension measurement apparatus
20b may be utilized. For example, the apparatus 20b may include one
or more robotic arms which contact a plurality of parts about the
part and record the locations of the various contact parts in
three-dimensional space (x, y, z). The apparatus 20b, in
conjunction with the CPU 50 of the packaging system controller 592
(or using its own processor) identifies the shape and size of the
part. In yet another alternative, the dimension measurement
apparatus 20b may include a Cubiscan.TM. measuring system provided
by Quantronix, P.O. Box 929, Farmington, Utah 84025, U.S.A.
[0169] The input peripheral 20 may also include a keyboard/mouse
type input device 20c or touch screen type display, as is commonly
used with personal computers or a microphone. The keyboard and
mouse may be used to input various characteristics of the part to
be packaged and/or may be used to access various pull-down menus to
identify the part or indicate items within a database which are
similar to the part. In addition, the keyboard/mouse 20c may be
used to identify the shipping destination, method of shipment
(e.g., truck, ship, air or rail) and other types of shipping and/or
packaging preferences. Collectively, the scale 20a, the dimension
measurement apparatus 20b and the keyboard/mouse 20c collect
various pieces of data which serve to characterize the part; the
pieces of data including, for example, the weight, size, shape and
fragility.
[0170] FIG. 16b is an idealized side view of the packaging system
590 of FIG. 16a. the packaging system 590 includes a Windows
personal computer as the packaging system controller 592 which
underlies a desktop work area 593 for packaging. Also under the
work area 593 is the printer 18b and the cushioning conversion
machine 12. On top of the work area 593 is the scale 20a, the
dimension measurement apparatus 20b, the display 18c and the
keyboard/mouse 20c. Also on the work areas 593 are a series of
labeled bins 594 for housing a variety of packaging containers or
boxes (not shown). At one end 595 of the work areas 593, is an exit
chute 596 for the cushioning pads which are produced by the
cushioning conversion machine 12.
[0171] A method 600 for packaging an unknown part using, for
example, the packaging system 590 of FIGS. 16a and 16b is
illustrated in the flow chart diagram of FIG. 17. The method 600
begins with the step of identifying a part to be packaged at step
602. Although the word "identifying" is used to describe step 602,
it should be understood that the method 600 contemplates a broad
function of ascertaining one or more characteristics that
characterize the part to be packaged while not necessarily
identifying the part itself. Therefore, although the step 602 may
in some instances be able to gather enough data to fully identify
the part to be packaged, in many instances a full identification of
the part will not be made, and instead the packaging methodology
will be determined based on the several pieces of data which
characterize the part such as the weight, size, shape and
fragility.
[0172] Once the part is identified at step 602, the method 600
proceeds to step 604, wherein the packaging system controller 592
takes the data collected at step 602 and uses it to determine an
optimized packaging methodology. As will be discussed in greater
detail infra, the packaging system controller 592 preferably
determines the optimized packaging methodology using an expert
system. Alternatively, however, fuzzy logic, binary decision trees
and neural networks may be utilized in the packaging determination
process, and each are contemplated as falling within the scope of
the present invention.
[0173] After the packaging methodology is determined at step 604,
the packaging methodology is displayed along with its associated
packaging and shipping costs at step 606. Step 606 is similar to
steps 112 and 114 in FIG. 5 (see also FIG. 6a) since the packaging
methodology may be previewed by the operator. Although the
determination process of step 604 is preferably performed using an
expert system, such processes are limited in that rules may not
exist for every situation which may cause an incorrect conclusion.
In addition, if some of the data is provided via the input
peripheral 20 incorrectly, the packaging system 590 may base its
conclusion on the wrong data. The packaging methodology display
step 606 therefore allows the operator to provide a "sanity check"
to insure that the packaging method which has been determined is
correct prior to the generation of any packaging material.
[0174] In addition, the packaging system controller 592, upon
determining the packaging method at step 604, calculates the
packaging costs by adding together the cost of the selected
container, the cost of generating the appropriate amount of
packaging material and the cost of various other supplies such as
packaging tape. The packaging system controller 592 also utilizes
the shipping destination, the combined weight of the part and the
shipping materials, and the method of shipment to calculate the
shipping costs. Upon a display of the packaging costs and the
shipping costs on the display 18c, the operator has the opportunity
to proceed at 608 if the operator determines the costs to be
acceptable. Alternatively, the operator may choose to end the
process or begin again at step 608.
[0175] If the operator chooses to proceed with the packaging of the
part in accordance with the determined optimized packaging
methodology at step 608, the packaging system controller 592 (via
the CPU 50) then sends packaging instructions which are associated
with the determined packaging methodology to the cushioning
conversion machine 12 at step 610 and to the output peripheral 18
at step 612. The packaging instructions sent to the cushioning
conversion machine 12 at step 610 are control signals which dictate
the number of cushioning pads to produce, their respective lengths
and their order of manufacture, similar to the description provided
earlier in conjunction with FIG. 7. Likewise, the packaging
instructions sent by the packaging system controller 592 via the
CPU 50 to the output peripheral 18 are control signals that
automatically generate the proper amount of postage via the postage
meter 18a, generate a shipping label with the appropriate address
via the printer 18b and provide step by step packaging instructions
on the display 18c. The packaging instructions on the display 18c
preferably include graphical representations which illustrate how
to utilize the generated packaging material to properly secure the
part within the specified container. In addition, textual
explanations are also preferably included to further aid in the
proper packaging of the part. Lastly, the packaging system
controller 16 via the CPU 50 may notify a shipper via a
communications link (e.g., the modem 91 or the network interface
90) to pick up the packaged item.
[0176] The step of identifying the part to be packaged (step 602)
is illustrated in greater detail according to an exemplary
embodiment of the present invention in FIG. 18. Step 602 begins
with either weighing the part to be packaged at step 650 using, for
example, the scale 20a or prompting the user to input the weight
via an input peripheral. The weight value is then saved in the
memory associated with the CPU 50 of the packaging system
controller 592, such as the RAM 60 (see FIG. 3). Next, the
dimensions (i.e., the size and shape) of the part are measured
and/or provided at step 652 or the operator is asked for the
dimensions. This step itself may include one or more steps. For
example, the packaging system 590 may automatically measure the
cubic dimensions of the part using the dimension measurement
apparatus 20b and then query the operator on the general shape of
the object (e.g., is it a cube, a pyramid, a sphere, etc.).
Alternatively, as described earlier, a robotic apparatus may be
used to map the outer contour of the object. In yet another
alternative, a pen-type apparatus or a mouse may be utilized to
sketch the general shape of the object at step 652. Any method and
apparatus to measure or ascertain the size and shape of the part is
contemplated as failing within the scope of the present
invention.
[0177] The next step in identifying the part is determining the
fragility of the part at step 654. This step may be accomplished in
a variety of ways, as illustrated in FIGS. 19a-19c. In FIG. 19a,
the fragility of the part is identified using a plurality of
pull-down menus. A first pull-down menu 662 includes a listing of
general categories 664 within which the part may belong. By
highlighting one of the categories 664a (e.g., household items),
using, for example, the mouse 20c, a second listing of
sub-categories 666 is displayed, wherein each of the sub-categories
666 are related to the earlier selected category 664a (e.g.,
furniture and kitchenware are both considered household items). The
operator may then select one of the sub-categories 666a (i.e.
kitchenware) using the mouse 20c or alternatively the touch display
to reveal another more detailed list of items 668 (e.g. pots and
pans, dishes, etc.). This process may be further continued until
the user selects the actual part or a part which is similar to the
part to be packaged in terms of fragility. Each final object which
is displayed in the pull-down menus on the display 18c have a
fragility rating associated with the part which is stored within a
memory associated with the packaging system controller 592 (e.g.,
the hard drive 78) which is subsequently utilized in determining
the proper packaging methodology.
[0178] According to a preferred embodiment of the present
invention, the fragility of a product is measured in terms of "G's"
which is a measure of the maximum acceleration (i.e., the rate of
change in velocity over a measured period of time) the part can
withstand without incurring damage (G is calculated as the ratio of
acceleration of the packaged item to the acceleration of gravity,
G=a/g). Therefore, the lower the G factor, the more delicate is the
part. In one exemplary manner, the G factor for various parts is
determined by subjecting the various products to a series of
gradually more severe decelerations (i.e., shocks) in order to
determine the lowest value at which damage occurs.
[0179] Another method of determining a part's fragility is
illustrated in FIG. 19b. FIG. 19b provides a categorization of
fragility from the most delicate (i.e., extremely fragile) to the
least delicate (i.e., rugged), using six fragility categories 669a.
An operator, by selecting one of the categories 669a will see a
variety of exemplary items 669b which fall within the selected
fragility category 669a. By analogizing to the exemplary items
within each category, the operator can approximate the part's
fragility. Once selected, the CPU 50 saves the G factor associated
with the part in the memory such as the RAM 60. As illustrated in
FIG. 19b, the six fragility categories may be categorized as
follows: (I) extremely fragile (about 15-25 G's); (II) very
delicate (about 25-40 G's); (III) delicate (about 40-60 G's); (IV)
moderately delicate (about 60-85 G's); (V) moderately rugged (about
85-115 G's); and (VI) rugged (about 115 G's and up). Note that the
categories 669a provided in FIG. 19b are merely exemplary, and
fewer or greater categories may be provided as necessary. It is
preferable, however, that the number of categories be sufficient to
avoid excessive "educated guesses" of fragility, since an estimate
G factor which is too low results in a package being over designed,
and thus unnecessarily increases the packaging costs. Likewise, if
a fragility G factor is estimated too high, the product packaging
will be under designed, and damage to the product during shipping
may result.
[0180] Yet another way to determine the fragility (step 654) of the
product is illustrated in FIG. 19c, wherein automated techniques
are utilized. The step 654 begins by viewing the object using a
viewing apparatus such as a digital camera at step 670. The data
which comprises the image of the part is then subjected to various
forms of image processing using, for example, an image processor to
identify attributes of the part which provide indications of
fragility at step 672. Such image processing may include, for
example, segmentation and filtration, as well as the passing of the
entire image or image segments through trained classifiers as is
well known by those skilled in the art of image analysis. Such
classification, for example, may include pattern recognition (step
672a), use of an expert system (step 672b) or application of the
image to one or more neural networks (step 672c). Other
alternatives may include, for example, binary decision trees and
use of fuzzy logic. In addition to step 672, the packaging system
controller 592 may query the operator or user (not shown) for
additional data to fill in the gaps in the classification/inference
process. Such queries may include, for example, "Is the object
solid?", "Is the object hollow?", "How thick is a piece of the
object?", "Is the object made of plaster, ceramic or glass?", etc.
The packaging system controller 592 then utilizes the information
provided to conclude the fragility of the part. Note that the
actual fragility cannot be determined without destroying the part
to be packaged which is obviously undesirable. Therefore the
present invention uses the above exemplary method to infer the
fragility of the item. If, after the querying for additional
information, the controller 592 determines that the gaps existing
within the data prevent a conclusion to be drawn within a specified
degree of certainty, the packaging system controller 592 sends a
message to the operator via the display 18c that a conclusion
regarding the fragility of the product can not be drawn and which
requests the operator to contact a service representative for
additional consultation.
[0181] Returning now to FIG. 18, once the fragility of the part is
determined at step 654, the packaging system controller 592 queries
the operator regarding the package destination at step 656. In many
instances, the operator has the shipping destination information at
hand and can manually input the data using, for example, the
keyboard/mouse 20c or touch type display. Alternatively, if the
operator does not have the shipping destination information, the
user may access an address database residing in a memory such as,
for example, the hard drive 78 or a CD ROM residing in the disk
drive 72 (see FIG. 3). Once the appropriate destination information
is established at step 656, the CPU 50 saves the data in the
working memory such as the RAM 60.
[0182] Preferably, the packaging system 590 also queries the
operator regarding the desired method of shipment by prompting the
operator to select, for example, one of air, trucking, shipping and
rail at step 658. The selection may be generic or may be further
tailored to be more specific, for example, by identifying the
particular freight or shipping company. The CPU 50 then saves the
data in the working memory such as the RAM 60 for use in the
determining of the optimum packaging methodology. The data
collected at step 658 may subsequently be utilized to determine the
height from which the product may be dropped during shipping as
well as the vibration effects, which will be discussed in greater
detail infra. Such information may then be utilized in determining
the proper packaging methodology.
[0183] Lastly, the packaging system 590 allows the operator to
select an optimization option at step 660. For example, as will be
discussed in greater detail later, in some cases several packaging
options may be available. In such cases, by selecting a packaging
optimization preference or a cost optimization preference, the
packaging system will select a different packaging method. For
example, a selection of the cost optimization preference may allow
the system to utilize a lower certainty threshold in determining
the product's fragility. Alternatively, when applying a cushioning
curve residing in the memory of data to a set of rules for
determining the proper amount of packaging, etc., a selection of
one preference may dictate a different point on the cushioning
curve, as will be discussed in greater detail infra.
[0184] In still another embodiment of the present invention, the
packaging system 590 may determine two packaging methodologies,
wherein one is optimized to insure a high degree of certainty in
preventing shipping damage while the other is optimized to provide
a reasonable degree of certainty in preventing shipping damage
while seeking to minimize the packaging costs. The packaging system
controller 592 then displays both options on the display 18c along
with their associated packaging and shipping costs to allow the
user to compare and thus select one of the packaging methods. The
present invention thus allows the operator substantial flexibility
in selecting an optimization preference at step 660.
[0185] In addition, the packaging system 10 may also include a
variable, user defined (or alternatively fixed) safety margin which
takes the determined fragility and increases the amount by a
predetermined amount (e.g., 20%). With this feature, a safety
margin may be achieved for package insurance purposes, for example.
This safety margin may be fixed by the packaging system owner or
alternatively by the user through an interactive type menu, as may
be desired.
[0186] Once the various characteristics of the part and the
shipping information is ascertained and saved in the memory
associated with the CPU 50 at step 602 of FIG. 18, the CPU 50
(alternatively a specialized processor (not shown) which operates
in conjunction with the CPU 50) determines the optimized packaging
methodology at step 604 of FIG. 17. According to a preferred
embodiment of the present invention, the optimized packaging
methodology is determined using an expert system.
[0187] An expert system is an information system that supports or
automates decision making in well-defined situations requiring
expert knowledge. Thus, an expert system supports or automates
decision making in an area where recognized experts do better than
nonexperts. Consequently, expert systems are well-suited to
packaging design since an optimized packaging design requires a
substantial amount of technical expertise and experience. For
example, in designing an appropriate packaging methodology, one
does not merely find a box which is large enough to contain the
part, and then wrap or surround the part with an arbitrary amount
of packaging material and subsequently fill in any remaining voids.
Instead, an efficient packaging design takes into account the
fragility of the part to be packaged as well as its size, shape and
weight and tailors the packaging method to ensure that expected
shocks are sufficiently absorbed by the packaging material (e.g.,
the cushioning pads). In addition, a packaging design may take
additional factors into consideration such as the compressive creep
of the packaging material, the impact of expected temperature
conditions on the cushioning ability of the packaging material, the
possibility of buckling and vibration effects. The present
invention takes the expert knowledge and data provided by
experienced packaging designers and distills the information into a
set of rules with accompanying data in conjunction with the data
provided by the operator in step 602 of FIG. 17 (which characterize
the part to be packaged) to determine the optimized packaging
methodology.
[0188] The expert system of the present invention produces
conclusions which dictate a packaging methodology based on the data
it receives from the operator. The conclusions follow from the
application of the set of rules and accompanying data provided
within the expert system (which is often called the knowledge base)
to the data or information provided by the operator. Thus,
knowledge in the expert system is a combination of instincts,
ideas, rules and procedures that guide actions and decisions.
According to one aspect of the present invention, the knowledge
base may be constructed within an expert system shell which is
commercial software product that allows for the efficient creation
of an expert system. The expert system shell provides preprogrammed
modules for entering rules and data as well as modules for
performing calculations and presenting various pieces of
information to the user or operator.
[0189] The expert system may represent knowledge in a variety of
ways. Preferably the knowledge is represented in the form of
"if-then" rules. If-then rules are stated in the form: IF one or
more particular conditions are true, THEN certain conclusions
should be drawn. An exemplary rule of the expert system of the
present invention may be illustrated as follows:
[0190] IF the part occupies a volume V,
[0191] THEN no packaging containers having a volume less than V
should be considered.
[0192] The above rule is used in determining the appropriate
packaging container for the part to be packaged. In the present
example, all the data needed to draw the conclusion is provided by
the operator at step 652 of FIG. 18. In many cases, however, the
expert system of the present invention will use several approaches
for determining whether a given condition is true. As shown above,
the data may be already provided by the operator and therefore
reside in a database. Alternatively, the system might ascertain
whether the condition is true by using data within the database
plus other rules. Lastly, the expert system may actively seek
additional data by asking the operator questions and/or use other
rules to draw a conclusion.
[0193] Preferably, the expert system of the present invention is
like a human expert working on a problem. The expert system uses
the knowledge within the knowledge base to draw interim conclusions
based on whatever information is currently available, even if the
information is incomplete. When a conclusion cannot be reached, it
uses the knowledge in the knowledge base to figure out questions to
ask or determines what data to retrieve in order to make more
progress in reaching a packaging conclusion.
[0194] As stated above, if-then rules may be used to represent
knowledge in the knowledge base. Not only may if-then rules take on
the form provided above (i.e., naming conditions and conclusions)
the rule may contain a certainty factor (e.g., 0.75) which
indicates that a conclusion has a particular likelihood, but
nevertheless is uncertain. The certainty factor may then be used as
another fact and may be applied in additional rules to arrive at a
conclusion and thus mimic the uncertainty which is oftentimes
inherent in much of the work that experts do.
[0195] Another type of knowledge representation may also be used to
construct a knowledge base for determining an optimized packaging
methodology. This type of knowledge representation is often called
"frames" which organizes information to make sense of the
information and identify any unexpected features that are present.
Frames provide a way to organize data about specific situations.
For example, when you enter a room your mind processes the visual
data and compares it to what your mind expects. Further, your
expectations are different in different types of rooms. For
example, when you walk into a kitchen you expect to see a
refrigerator, stove, sink and cabinets. You do not, however, expect
to see a computer or filing cabinet in the kitchen although either
might exist in some limited circumstances.
[0196] A frame is therefore a data structure which represents an
entity such as a concept, item or class. The frame consists of
fields which identify the attributes for that kind of entity. Each
field has an entry or value for each attribute which is being
considered. Frames can be used in determining the fragility of an
unknown part by finding a frame which most closely approximates the
part. That is, a fragility value may be assigned to an unknown part
if a substantial number of attributes are similar to a part having
a known fragility value. Similarly, frames which comprise
pre-designed packaging methodologies for parts having specified
attributes may be utilized as a starting point for designing an
optimized packaging methodology. Although if-then rules and frames
have been described as exemplary rules and structures for
representing knowledge within a knowledge base, it is understood
that other structures or methods for representing expert knowledge
may also be utilized and such structures and methods are
contemplated as falling within the scope of the present
invention.
[0197] An exemplary structure for the expert system 700 of the
present invention is illustrated in FIG. 20. As briefly discussed
earlier, the expert system 700 may reside within the CPU 50 of FIG.
3 or may exist as a separate processing component within the
packaging system controller 592 of FIG. 16. The expert system 700
may include a knowledge base 702, a database 704, an inference
engine 706, an interface 708 and an explanation module 710.
Although FIG. 20 suggests that the components are physically
separate components, it is not required. Instead, the components of
the expert system 700 may be considered as functional components
within a processor. In still another alternative embodiment, the
expert system may be remote and be accessed via the network
interface 90 or other communication means of FIG. 3, thus making
the input/output peripheral a dummy-type terminal.
[0198] The knowledge base 702 is a section of memory containing one
or more sets of data relating to the packaging material such as the
cushioning pads and a plurality of rules and/or frames which are
supplied by an expert. The database 704 is another section of
memory used to store facts and/or characteristics of the part to be
packaged provided by the operator via any one of the input
peripherals 20a-20c. In accordance with the present invention, the
database 704 may contain the various pieces of data collected at
step 602 of FIG. 18, as illustrated in FIG. 21. The various pieces
of data within the database 704 include, but are not limited to,
package weight data 712, package dimension data (size and shape)
714, fragility information 716, package handling information 718,
package transportation information 720, and other miscellaneous
packaging data 722 such as compressive creep data, temperature
effects (thermal coefficient) data, buckling data and vibration
information. In addition, the data characterizing the part to be
packaged may include a cost/packaging optimization preference 724
and dynamic cushioning curve data 726 for one or more types of
packaging material and packaging material configurations.
[0199] The inference engine 706 applies the rules and data within
the knowledge base 702 to whatever facts are provided in the
database 704 to decide what question to ask next, either to the
operator or back to the database 704 and the knowledge base 702.
Which questions are asked next by the inference engine 706 depend
upon the current goal of the inference engine 706. For example, if
the inference engine 706 has identified five different facts that
all must be true in order to confirm a current working hypothesis,
the inference engine 706 may ask those five questions in turn. If
any one of the responses is negative, the inference engine 706 may
then abandon the current line of reasoning for another.
[0200] The interface 708 may consist of the display 18c and the
keyboard mouse 20c and represents functionally the way in which the
expert system 700 interacts with the operator, if such action is
necessary. The interface 708 may operate as a set of text questions
and answers or may be graphical (or a combination) as may desired.
The explanation module 710 is optional and is not included in the
preferred embodiment of the present invention. The explanation
module 710 is made available to the operator via the display 18c as
a way for the operator to know how a particular conclusion or fact
was inferred or why a particular question is being asked in order
to explain the sequence of inferences that produced a resulting
conclusion.
[0201] FIG. 22 is an exemplary expert system determination flow
diagram 800 which illustrates one method in which the expert system
700 of the present invention determines an optimized packaging
methodology using packaging material generated by the cushioning
conversion machine 12 of FIG. 2 (cushioning pads) for an unknown
part. As discussed previously in connection with FIGS. 16-21, the
packaging system 590 identifies the part to be packaged (step 602)
by obtaining a variety of pieces of information relating to the
part to be packaged (see FIG. 21). Using the data of FIG. 21 (i.e.,
the database 704), the expert system 700 applies the data to
various rules within the knowledge base 702 as illustrated in FIGS.
20 and 22.
[0202] Initially, the inference engine 706 eliminates one or more
packaging containers 802 from further consideration using the size
and shape data 714 within the database 704. For example, if the
part is 24" long, 12" wide and 12" deep, then any packaging
container having a volume (V) less than 24".times.12".times.12"
(3,456 cubic inches) could not contain the part and thus is
eliminated from further consideration. In addition, given the
desired method of shipment and the shipping destination data 720,
the inference engine 706 searches the knowledge base 702 for any
shipping regulation data 804 which may either preclude or require
certain classes of shipping containers, thus further reducing the
remaining available containers. The inference engine 706 then moves
on to another analysis since additional information is needed in
order to make further progress in the selecting the proper
packaging container. The above step 802 is merely exemplary and may
include additional rules, as may be desired.
[0203] Next, the expert system 700 determines the drop height that
the part may encounter during shipping 806 so that substantive
analysis may proceed regarding what amounts, styles, etc. of
cushioning pads will be needed to properly protect the part. The
drop height is calculated by the inference engine 706 using the
weight information 712 within the database 704 and the package
handling information 718. Using the packaging handling information
718, the inference engine 706 can determine whether one or more
individuals will be carrying or throwing the package and, in
conjunction with the weight information 712, can identify the
probable drop height the packaged part would experience if the part
were inadvertently dropped during shipping. For example, if one
person is carrying the package and the package is light (e.g.,
about 10-20 pounds) the height at which the package may
inadvertently be dropped is high (e.g., about 36"). However, if two
individuals are carrying the package and it is more heavy (e.g.,
about 50-100 pounds) the height in which the package may be
inadvertently dropped is less (e.g., about 24"). In the above
manner, the inference engine 706 using data within the knowledge
base 702 and the data provided by the user in the database 704
determines the potential drop height the part may experience in
shipping. The drop height data may then be used by the inference
engine 706 in selecting the proper dynamic cushioning curve data
726 in the knowledge base 702 when determining the functional
cushioning requirements data weight at step 808.
[0204] The determination of which class and configuration of
cushioning materials will functionally be appropriate (step 808) is
preferably performed by the inference engine 706 using a variety of
pieces of information. According to an exemplary embodiment of the
present invention, a plurality of cushioning curves (shown
graphically as FIGS. 23a-23n with the reference numeral 810)
consist of data 726 residing in the knowledge base 702. The
cushioning curves 810 are evaluated and if any of the curves
contain drop heights that do not match the determined drop height
of step 806, they are removed from further consideration by the
inference engine 706. A plurality of exemplary dynamic cushioning
curves 810 are provided in FIGS. 23a-23n. Typically, many more
cushioning curves 810 will exist, however, in this example the
determined drop height is 30" and therefore only the cushioning
curves 810 having data at drop heights of 30" are considered in the
subsequent analysis undertaken by the inference engine 706.
[0205] A dynamic cushioning curve 810 illustrates how a packaging
material (for a particular packaging material configuration)
behaves at different impact levels. The curves of FIGS. 23a-23n
were generated by dropping a series of known weights onto a
cushioning pad configuration sample (not shown) and measuring the
amount of shock the sample allowed to be transferred (i.e.,
transferred to the part to be packaged). In other words, the drop
tests simulate the part being dropped from its expected drop height
(step 806). Each point in the curve represents how much loading a
part of known weight will apply to the cushioning pad
configuration, and how much shock the cushion will allow to be
transferred to the product. The inference engine 706 utilizes the
fragility data 716 and calculates the static loading data 816 using
the packaged dimension data 714 in the database 704 to evaluate
what cushioning pad configuration is sufficient for each
orientation part (since each side of the part may provide a
different static loading value).
[0206] The cushioning curves of FIGS. 23a-23n were developed in the
following exemplary manner. A 10" by 10" by 4" weighted plywood box
was utilized to simulate the part to be packaged and was packed
inside a 12" by 12" by 12" corrugated container. Various cushioning
pad configurations were placed in the bottom of the corrugated
container and the weighted product was then placed on top of the
configured cushioning pad. Such exemplary cushioning pad
configuration include a spiral/coil configuration which is a length
of cushioning material which is coiled into a spiral shape, a cross
configuration which includes two lengths of cushioning material
crossing each other and a star configuration which includes a
plurality of lengths of cushioning material crossing each other. In
addition, other type configurations and individual pad lengths are
also anticipated as falling within the scope of the present
invention and dynamic cushioning curves may be generated for each
of those configurations. Further still, the cushioning conversion
material itself can be modified by using, for example, differing
types of paper weight. For example, a three ply paper stock
30/50/30 consists of outside sheets consisting of 30 weight paper
and a inner sheet consisting of 50 weight paper, respectively. The
product box was then weighted to simulate the products from one
pound (0.01 pounds per square inch (PSI)) to 30 pounds (0.30 PSI),
thus providing data at different static loading values. An
accelerometer was attached to the product box to record the
acceleration levels (in G's) for each drop. The corrugated
container was then dropped five times from a height of 30" (the
drop height) for each simulated product weight. A minimum of five
different product weights (static loading) were used to generate
each curve (using known curve fitting techniques) and the results
of the last four drops for each product weight were recorded and
averaged. The peak accelerations (G's) versus the static loadings
(PSI) were then plotted to generate the dynamic cushioning curves
810.
[0207] Using the fragility data 716 within the database 704, each
of the cushioning curves 810 are evaluated to see if the cushioning
pad configuration provides sufficient cushioning to absorb the
potential shock for an identified fragility. One exemplary manner
of making such an evaluation is illustrated in FIG. 24 which
illustrates a spiral/coil cushioning pad configuration for a 30"
drop height. The fragility data 716 within the database 704
indicates, for example, that the part can only withstand up to 35
G's without incurring damage. Thus, a horizontal line 812 is drawn
at 35 G's across the cushioning curve 810. If the curve 810 passes
through or below the horizontal line 812, then it is confirmed that
the cushioning product (the spiral configuration) may not transfer
more shock to the part than the product can withstand under certain
static loading conditions. Then, one or more vertical lines 813 are
drawn from the point or points 814 where the horizontal fragility
threshold 812 intersects the cushioning curve 810. The vertical
lines 813 establish the highest and the lowest static loading
values at which the cushion pad configuration will provide adequate
protection. In the example of FIG. 24, the static loading values
are 0.03 and 0.24, respectively. Note that the static loading is
defined as the force exerted by the part to be packaged on the
cushioning pad configuration and is determined by dividing the
weight of the part by the surface of the side of the part which is
engaging the packaging material. Note that since products often
have different surface areas depending upon their orientation,
their static loadings may also differ depending upon their
orientation. Using the calculated static loading data from the
weight and data 712 and the size/shape data 714, the inference
engine 706 eliminates from further consideration any cushioning pad
configurations that cannot provide adequate protection for the
determined static loading 816.
[0208] The inference engine 706 then uses the data collected from
the cushioning conversion curve 810 to calculate the cushion
bearing area which is the weight of the part divided by the static
loading (which in this case is some value between 0.03 and 0.24).
To optimize costs, the inference engine 706 will select
configurations which exhibit greater static loading (and thus the
lowest cushion bearing area) because less cushioning product will
be adequate for protection and thus reduce the packaging costs.
However, since the present invention allows for a cost/packaging
optimization preference to be selected, a higher cushion bearing
area may be selected using a lower static loading value which
increases the packaging protection. Note that in FIG. 24, the least
amount of shock is transferred to the part at a static loading of
about 0.1; therefore an orientation of the part on the spiral
configuration which produces such a static loading value may be
selected by the inference engine 706 if a packaging optimization
preference has been selected.
[0209] The task of determining the functional cushioning
requirements (step 808) further includes considering the impact of
compressive creep of the packaging material using the compressive
creep data 722. Compressive creep is defined as the loss of
thickness of the cushioning pad under a constant loading over a
period of time. If the amount of creep is too large (in this
exemplary embodiment taken to be about 10 percent) the ability to
properly cushion the part is impaired. The compressive creep data
is uniquely associated with the packaging material and is
maintained in the knowledge base 702. The inference engine 706
compares the compressive creep of the cushioning material to a
predefined limit 818 and if the compressive creep data 722 exceeds
the limit 818, the packaging option using the maximum static
loading 816 (and thus the least amount of packaging material) is
eliminated and the cushioning curves using a lower static loading
816 are maintained.
[0210] The packaging system 590 via the expert system 700, and more
particularly the inference engine 706, also takes into account the
temperature effects in determining the functional cushioning
requirements. The inference engine 706 uses temperature effects
data 722 which is a function of the packaging material used (in
this particular example, the cushioning pads are made of paper
stock). The knowledge base 702 provides thermal coefficients which
characterize the dependence of the pad's cushioning properties over
temperature. If the inference engine 706 determines that the
thermal coefficient is too large (positive or negative), then the
inference engine 706 evaluates the package transportation
information 720 provided by the operator which resides in the
database 704. The package transportation information 720 includes,
for example, the shipping destination and the shipping method
(e.g., rail or truck). The inference engine 706 then uses the
package transportation information 720 to eliminate any cushioning
curves that will not provide adequate protection.
[0211] For example, if the packaging location is in Arizona and the
destination location is Alaska, and the packaging material has a
strong thermal coefficient such that the material loses its
cushioning capability as the temperature drops and the method of
shipment is by truck without any thermal controls, the inference
engine 706 will eliminate cushioning options that are near the
maximum static load limits and require adjustments to the amount of
cushioning material to optimize the packaging design.
[0212] The expert system 700 also considers buckling using the
buckling data 722 within the database 704 of FIG. 21. Buckling is
defined as the non-uniform compression of the cushioning material.
When buckling occurs, the energy or shock of an impact is not
distributed evenly throughout the cushioning pad, thus resulting in
the potential for a greater amount of shock being transferred to
the part. Buckling occurs most often when the shape of the cushions
or cushion configuration is too tall and thin. The inference engine
706 analyzes whether buckling is an issue by evaluating the
buckling coefficient 820 of each remaining cushioning pad
configuration with respect to the expected static loading exhibited
by the product. The buckling coefficient 820 is a ratio of the area
822 of the cushioning product configuration and its thickness 824.
The inference engine 706 uses the graph data of FIG. 25 which
resides in the knowledge base 702. Since the inference engine 706
knows the static loading, the engine 706 determines the buckling
coefficient 820 graphically and then multiples the coefficient by
the thickness 824 of the cushioning product configuration (which is
known) to determine how wide and how long the pad must be to avoid
the undesired buckling. The inference engine 706 then further
removes any remaining packaging configurations that pose a
significant risk of buckling (i.e., those configurations which fail
to provide the minimum desired pad width).
[0213] The expert system 700 may further evaluate the impact of
vibration using the vibration data 722 within the database 704
using data such as that shown in FIGS. 26a and 26b.
[0214] As illustrated in FIGS. 20 and 22, the inference engine 706
uses the data within the database 704 along with rules and data
within the knowledge base 702 to draw conclusions regarding which
packaging methodologies are acceptable and which are not. After
determining the functional cushioning requirements at step 808, a
variety of packaging options will most likely still exist and the
inference engine 706 will need to apply additional rules to further
focus upon a single solution. For example, the number of available
containers at step 802 may be further reduced by determining
whether each of the remaining containers available could facilitate
the remaining packaging options.
[0215] In addition, the inference engines 706 uses the optimization
preference data 724 of FIG. 21 to select a smaller subset of
packaging methods that either provide optimized packaging security
(i.e., a minimal amount of damage uncertainty) or optimized cost
(i.e., the methods using the least amount of packaging materials
while providing an acceptable amount of damage uncertainty). If an
optimization preference is not provided, the expert system 700 of
the present invention selects an optimized cost preference as a
default. In addition, other rules may also be used to select the
best remaining packaging solution. For example, the inference
engine 706 may select the packaging methodology that will result in
the least amount of wear on the cushioning conversion machine
(e.g., which results in the fewest number of packaging material
generation steps) or the method that requires the least amount of
effort by the operator in executing the packaging method. Other
rules may also be utilized and are contemplated as falling within
the scope of the present invention.
[0216] Although the preferred embodiment of the present invention
utilizes an expert system 700, other types of intelligent systems
may alternatively be utilized and are contemplated as falling
within the scope of the present invention. For example, the expert
system 700 may be replaced with a neural network type intelligent
system. A neural network is an information system that recognizes
objects or patterns based on examples that have been used to train
the neural network. Each training example is described in terms of
a number of characteristics, each of which are input into a
separate neuron or "node". The neural network then combines these
inputs in a way that distinguishes between different objects
included in the training examples. The neural network performs
identification and discriminates between various available
packaging methodologies by assigning numerical weights to many
characteristics. Thus, neural networks may operate well even when
some information is missing.
[0217] Thus according to the alternative embodiment, the neural
network is trained, wherein an expert packer designs optimum
packaging methodologies while internally applying many of the
expert rules discussed above in conjunction with the expert system
700. The expert packer therefore communicates a number of system
inputs to the neural network which represent the characteristics of
the part to be packaged and provides the neural network the proper
output (the resulting optimized packaging methodology) for the
given inputs. The neural network then successively updates its
numerical weights at its various nodes to more closely approximate
the proper output for the provided input. After a significant
amount of training, the neural network provides a function of
determining the appropriate packaging instructions, but in a manner
which is different than the expert system. The neural network
system does not use defined rules (e.g., if-then rules) to generate
conclusions, but the neural network blindly acts on the provided
inputs to generate ("determine") an optimized packaging
methodology.
[0218] In addition, an inventory monitoring system may be included
with the packaging system 590 of FIG. 16a. The inventory monitoring
system may operate in a manner similar to the inventory monitoring
system of FIG. 12, for example. As each operator provides a part to
be packaged and proceeds with packaging, the inventory monitoring
system accounts for the consumption of the various packaging
materials utilized in the packaging process by updating a packaging
materials list. The inventory monitoring system then compares the
packaging materials list with one or more appropriate re-order
thresholds and automatically generates a re-order request using the
CPU 50 to replenish the depleted inventories in a timely
manner.
[0219] As discussed above, the packaging system 590 of FIG. 16a
determines an optimized packaging methodology for a part to be
packaged. The optimized packaging methodology includes a set of
packaging instructions which serve as control signals to the
cushioning conversion machine 12 and explanation instructions to
the operator via the display 18c. In addition to the control
signals to control the operation of the cushioning conversion
machine 12, the determining packaging methodology may also include
cushioning material manipulation control instructions similar to
those discussed earlier in conjunction with FIGS. 8-10c. The
manipulation control signals may be used to activate and control
either a coiler 250 or an automated insertion device such as a
pick-and-place system 302 as may be dictated by the determined
optimized packaging methodology.
[0220] In the description of the above preferred embodiment of the
present invention, a cushioning conversion machine 12 was
disclosed. The packaging system 590 of the present invention,
however, may also be utilized in conjunction with other types of
packaging material generators such as loose fill packaging material
generators and dispensers, bubble wrap, air pillow generators and
dispensers, shredded material generators, and pulp molded
generators and dispensers. It is understood that any form of
packaging material generator may be incorporated into the packaging
system and is contemplated as falling within the scope of the
present invention.
[0221] In addition, in the preferred embodiment of the present
invention, the determined packaging instructions are utilized to
provide automated control of the packaging material generator 12.
Alternatively, the present invention may transmit the determined
packaging instructions solely to the user or operator who then uses
the instructions to manually control the packaging material
generator 12.
[0222] In the previous embodiments of the present invention
highlighted above, the packaging systems primarily addressed the
packaging of a single part. For example, for a single known part to
be packaged, the packaging system retrieves a pre-determined set of
packaging instructions associated with the part which is used to
generate appropriate amounts of packaging material. In addition,
for an unknown part to be packaged, the packaging system identifies
one or more characteristics which characterize the part. Using the
characteristics and an expert system having a knowledge base, the
packaging system determines the packaging instructions and uses the
determined instructions to control the packaging material
generator.
[0223] According to another alternative embodiment of the present
invention, a packaging system is used to package together a
plurality of known parts. The packaging system identifies the parts
to be packaged and retrieves data associated with the parts from a
database. Using the data and an expert system having a knowledge
base, the packaging system determines the packaging instructions
which represent an optimized packaging methodology for packaging
the plurality of parts.
[0224] According to the alternative embodiment of the present
invention, the packaging system is utilized, for example, in
conjunction with a mail-order company or a warehouse distribution
facility. A shipping order is created by a customer requesting a
plurality of items (i.e., parts). A warehouse management system
arranges the shipping order to facilitate an efficient retrieval of
the various items. When the retrieved items arrive at a packaging
station, the packer implements a pick list verification in which a
check occurs to ensure that all the retrieved items match with
items on the shipping order. Preferably, a tote in which the items
are retrieved contains a bar code which reflects the shipping
order. The packer, using a bar code reader, reads the tote bar code
and a bar code on each of the retrieved items to verify that each
item on the shipping order has been properly retrieved.
[0225] Once the pick list verification step is complete, the
packaging system uses the shipping order to retrieve data
associated with each of the items in the shipping order, such as
the weight, size, shape and fragility of each of the items. The
shipping order itself also contains additional data which may be
used by the packaging system such as the shipping destination and
the method of shipment. The packaging system then applies the
retrieved data to a set of rules and packaging material data in an
expert system knowledge base to determine packaging instructions
which represent an optimized or preferred packaging methodology for
the plurality of parts.
[0226] Note that the expert system of the present invention may use
the data such as the parts' size, shape, weight and fragility in
determining the optimized or preferred packaging methodology. In
addition, the expert system may use additional information such as
the cushioning properties of the various parts to determine the
appropriate orientation of the various parts with respect to one
another within the packaging container. Thus, according to the
present invention the expert system uses or considers the
cushioning properties of the parts themselves along with the
cushioning properties of the packaging material in determining the
packaging methodology.
[0227] The packaging system then uses the determined packaging
instructions to control the packaging material generator (e.g., the
cushioning conversion machine) and thereby produce appropriate
lengths of packaging material in the proper sequence to effectuate
the optimized packaging methodology. The packaging system also uses
the packaging instructions to provide graphical and/or textual
guidance to the packer via a display to aid in the proper packaging
of the various items. For example, the display will illustrate the
order of packaging of the various items and their proper
orientation in the specified container along with the way the
generated packaging material is to be used, thus making the
packaging process simple and clear.
[0228] Once packaging of the items into the proper container is
complete, the container is weighed and compared to an expected
weight which includes the expected weight of the parts, the
container and the packaging material. If the measured weight is
outside a pre-selected tolerance, a warning message is provided to
the packer which allows the packer to evaluate the situation and
make a judgement as to whether an error in the packaging process
has occurred. If acceptable, the container is sealed using, for
example, packaging tape and the packaging system prints out a
mailing label in accordance with the destination data supplied on
the shipping order and prints out a bill-of-lading which contains
information which identifies, for example, the shipper, the ship to
address, the number of containers in the shipping order, and the
total weight of the shipment. The packaging system also sends the
bill-of-lading data to a manifest system.
[0229] According to an alternative embodiment of the present
invention, the parts to be packaged are placed directly into the
container selected by the packaging system. In the alternative
embodiment, the determined packaging methodology determines the
order of the pick list and the packaging material generator
generates (in advance) all the packaging material needed to package
the parts. The packer then takes the generated packaging material
and the selected container along the pick route (using, for
example, a cart) and, after selecting a part according to the pick
list, packages the part in the container using one or more of the
pieces of generated packaging material. In the above manner, the
packaging process is made more efficient by eliminating the step of
placing the parts into the tote and subsequently removing the items
from the tote and packaging them in the selected container.
[0230] According to yet another embodiment of the present
invention, the packaging system is portable (e.g., on wheels or on
a portable cart). The packaging system determines the packaging
methodology and thus dictates the order of the pick list. The
packaging system produces the appropriate amount of packaging
material at the location for the picking of the appropriate part
along the pick list route. The packer then uses the packaging
instructions provided by the output peripheral to then package the
part in the selected container. In the above manner, the packaging
material is provided when needed and the part is selected and
immediately packaged without being placed into an intermediate
tote.
[0231] The packaging system includes an inventory management system
which accounts for the receipt of material into inventory and
accounts for inventory consumption by updating a packaging
materials list. The inventory management system compares the
updated packaging materials list to one or more re-order
thresholds. If any of the re-order thresholds are satisfied, the
packaging system generates a re-order request directed toward the
depleted item to ensure that inventories are replenished in a
timely manner. Alternatively, the system may periodically check the
inventory and re-order at predetermined times.
[0232] The packaging system of the present invention also includes
a productivity monitoring system which collects and summarizes
various productivity statistics. For example, the productivity
monitoring system collects data for various productivity criteria
such as, but not limited to, the number of orders packed, the
number of items packed, the total weight packed, the average time
per order and the average amount of packaging material generated
per order. In addition, various time frames of data may be
collected and additional processing may be employed to normalize
various productivity criteria, provide trending analysis, etc.
[0233] Turning now to FIG. 27, an operational flow diagram of the
packaging system 900 according to the present invention is
illustrated. The system 900 includes a packaging system controller
901 operationally coupled (preferably via an electronic data link)
to a warehouse management system 902. The packaging system
controller 901 transmits a tote bar code number 903 (or RF tag
reader) which represents a shipping order to the warehouse
management system 902 when a packer 904 receives a retrieved number
of items to be packaged. The license plate is read from the tote
and the shipping order is determined from the license plate using a
look up table, for example. The tote contains the retrieved items
and the license plate is read with a bar code scanner or reader
906, however, any type of reading device is contemplated by the
present invention. The warehouse management system 902, in response
to receiving the tote bar code 903, provides the packaging system
controller 901 with order information 907 which includes a list of
the parts in the shipping order and information relating to each
item such as the weight, size, shape and fragility of the item.
Using the information 907 provided by the warehouse management
system 902, the packaging system controller 901 determines
packaging instructions 908 which represent an optimized packaging
methodology.
[0234] The packaging instructions determined by the packaging
system controller 901 have several components. Some of the
packaging instructions 908a are provided to the packer 904 as
graphical/textual instructions which illustrate how to use the
generated packaging material to properly package the various items.
The packaging instructions 908 also include instructions 908b
identifying the size and quantity of the specified packaging
containers and are transmitted to a carton erector 909 for
construction of the specified containers. The packaging
instructions 908 are also communicated to the packaging material
generator 12 (e.g., the cushioning and conversion machine) as
control signals 908c which dictate the number and length of
cushioning pads to produce as well as their sequence of generation.
The instructions 908 also include the specification of the
necessary tape length 908d to a tape sealer 910, instructions 908e
for generation of a shipping label to the label printer 18b, and
instructions 908f for generation of a bill-of-lading to the printer
18b. Lastly, the packaging system controller 901 sends the
bill-of-lading data to a manifest system 912 and monitors inventory
consumption. If any inventories drop below a predetermined
threshold, the packaging system controller 901 transmits a reorder
request 913 to a distributor via a communication link 914 such as
an EDI value added network.
[0235] According to one embodiment of the present invention, the
manifest system 912 may be used to keep track of the destination of
the packaged parts for tax or other purposes. For example, in
certain European countries some tax provisions exist which relate
to taxes on waste materials. The manifest system 912 records the
destination of the package (container) and the amount of packaging
material used in packaging the parts so that such information may
be efficiently used, for example, for compliance with the
appropriate tax provisions.
[0236] A block diagram of the packaging system 900 is illustrated
in FIG. 28. The packaging system 900 includes the packaging system
controller 901 coupled to the warehouse management system 902 and
the packaging material generator 12. In addition, an output
peripheral 18 is coupled to the controller 901 and may include one
or more of a postage meter 18a, a printer 18b and a display 18c and
an input peripheral 20 may include a keyboard/mouse 20c and a bar
code reader 20d. Other input/output peripherals may be included and
are contemplated by the present invention.
[0237] A method 1000 of packaging a plurality of items in one or
more containers according to the present invention is illustrated
in FIG. 29. When a tote containing a plurality of items to be
packaged is received at the packaging station, the packer reads an
order number associated with the items at step 1002 using, for
example, the bar code reader 20b. The packaging system controller
901 of FIG. 28 then uses the order number at step 1004 to access
the warehouse management system which contains a database
containing all the items in the warehouse as well as various pieces
of data associated with the items such as the number of items in
inventory 1006, the size, shape and weight of the item 1008 and the
item's fragility 1010.
[0238] The packaging system controller 901 then uses the data
(e.g., data 1008 and 1010) along with, for example, shipping
destination data from the shipping order to determine packaging
instructions which result in an optimized packaging control
methodology at step 1012. Once the packaging instructions have been
determined, the packaging system controller 901 uses the packaging
instructions to control the packaging material generator 12 at step
1014 and provides instructions to the packer 904 via the display
18c at step 1016.
[0239] The step of reading the order number (step 1002 of FIG. 29)
is illustrated in greater detail in FIG. 30. The process begins at
step 1020 when the warehouse facility receives an order for a
variety of items and the warehouse management system 902 assigns an
order number to the order. The order is then arranged at step 1022
by the warehouse management system 902 to optimize the retrieval of
the various items in the shipping order. A large warehouse has many
items located in various, diverse areas in the warehouse. To
minimize the amount of backtracking, etc., the warehouse management
system 902 contains location data for each of the items and uses
the data to arrange the items on the shipping form to generate and
optimize a pick list which minimizes the time required to retrieve
the various items. The various items corresponding to the arranged
pick list are then retrieved at step 1024 and brought to the
packaging station at step 1026.
[0240] The pick list generated by the warehouse management system
902 is then verified in the following exemplary manner at step
1028. A bar code reader 20d reads the order number (or license
plate number) from the bar code 903 on the tote which contains the
retrieved items. The packer then reads the bar code of each of the
retrieved item and matches them with the items on the shipping
order using the CPU 50 of the packaging system controller 901. If a
match is not found, or if an item is missing, the CPU 50 or
warehouse management system 902 generates a warning message which
is provided to the packer on the display 18c. Once the pick list is
verified at step 1028, the packaging system controller 901 sends
the order number back to the warehouse management system 902 at
step 1030 with a request to retrieve all the data residing in the
warehouse management system database that relates to the parts on
the shipping order. Such data includes, but is not limited to, the
weight, size, shape and fragility of the items.
[0241] The step of determining the packaging instructions (step
1012 of FIG. 29) is preferably provided in the same manner to the
steps illustrated in FIGS. 20-26b, wherein an expert system uses a
knowledge base and data relating to the packaging material and the
parts to be packaged to determined an s15 optimized packaging
solution. In addition, alternative intelligent type systems may be
utilized, such as binary decision trees, fuzzy logic and a trained
neural network.
[0242] The packaging system 900 of FIG. 28 of the present invention
may alternatively, or in addition to the use of if-then rules,
incorporate cubing rules in the knowledge base. Generally, using
the cubing concept, the packaging system controller 901 ascertains
the cubic volume of each item will occupy when properly packaged.
The expert system then utilizes the various cubic volumes to
determine their location and orientation within a selected
packaging container to maximize the packaging efficiency and thus
reduce the need for void fill and extra boxes. One exemplary method
for implementing such an optimized cubing concept is taught in U.S.
Pat. No. 5,430,831 entitled "Method of Packing Rectangular Objects
in a Rectangular Area or Space by Determination of Free Subareas or
Subspaces", which is hereby incorporated by reference. The manner
in which various cubes (i.e., parallelepiped volumes) are arranged
in different ways to maximize the packaging efficiency is
illustrated in FIGS. 31a-31d. In addition, cubing optimization
products are commercially available such as OPTIPAK.TM. by Advanced
Logistics Systems, Inc., Roche Harbor Wash. 98250. Such a cubing
product may be incorporated into the packaging system controller
901. Therefore in the above manner the packaging system utilizes
the parts data from the warehouse management system 902 and
determines the packaging instructions that represent an optimized
packaging methodology.
[0243] FIG. 32 is a functional block diagram illustrating
additional packaging system functions. After using the determined
instructions to control the packaging material generator (step 1014
of FIG. 29), the packaging system controller 901, using data from
the shipping order prints a shipping label at step 1100 using the
printer 18b of FIG. 28. Likewise, the packaging system controller
901 uses the shipping order data to print out a bill-of-lading at
step 1102 using the printer 18b. Using the shipping destination and
the expected weight as dictated by the determined packaging
instructions, the packaging system controller 901 also generates
the proper postage using the postage meter 18a of FIG. 28 at step
1104. The packaging system controller 901 also generates production
statistics and performs inventory control at steps 1106 and 1108,
respectively.
[0244] The inventory control of step 1108 is similar to the
inventory control of FIGS. 11 and 12 and may be performed for each
packaging station individually or centrally for all the packaging
stations through communication of inventory consumption data from
each packaging system controller 901 to the warehouse management
system 902. Similarly, the packaging system 900 may provide
productivity monitoring as illustrated previously in FIG. 13 and
which is briefly summarized in FIG. 33. The generation of
production statistics (step 1106) includes the counting of the
number of order packed per unit time at step 1120 and the counting
of the items packed per unit time at step 1122. In addition, the
packaging system controller 901 also monitors the total weight of
items packed at step 1124 and calculates the average time required
to complete an order and the average amount of packaging material
consumed per order at steps 1126 and 1128, respectively.
[0245] The present invention provides for the effective and
efficient packaging of parts. Since the packaging system provides
packaging instructions for one or more parts, an inexperienced
packer may efficiently package the one or more parts without
wasting packaging materials, thus providing cost savings of about
25-50%.
[0246] Although the invention has been shown and described with
respect to certain preferred embodiments, it is obvious that
equivalent alterations and modifications will occur to others
skilled in the art upon the reading and understanding of this
specification and the annexed drawings. In particular regard to the
various functions performed by the above described components, the
terms (including a reference to a "means") used to describe such
components are intended to correspond, unless otherwise indicated,
to any component which performs the specified function of the
described component (i.e., that is functionally equivalent), even
though not structurally equivalent to the disclosed structure which
performs the function in the herein illustrated exemplary
embodiments of the invention. In addition, while a particular
feature of the invention may have been disclosed with respect to
only one of the several embodiments, such feature may be combined
with one or more other features of the other embodiments as may be
desired and advantageous for any given or particular
application.
* * * * *