U.S. patent application number 10/035028 was filed with the patent office on 2002-08-08 for packaging system.
Invention is credited to Armington, Steven E., Booze, MacDonald C., Dawson, Mark C., Guth, Paul J., Ratzel, Richard O..
Application Number | 20020104293 10/035028 |
Document ID | / |
Family ID | 26791162 |
Filed Date | 2002-08-08 |
United States Patent
Application |
20020104293 |
Kind Code |
A1 |
Armington, Steven E. ; et
al. |
August 8, 2002 |
Packaging system
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 programming the
instructions using an instruction programming tool. The packaging
system also provides for pacing a packager through a set of
packaging instructions and monitoring the packager's
productivity.
Inventors: |
Armington, Steven E.;
(Concord Township, OH) ; Ratzel, Richard O.;
(Westlake, OH) ; Guth, Paul J.; (Beachwood,
OH) ; Booze, MacDonald C.; (York, ME) ;
Dawson, Mark C.; (Pepper Pike, OH) |
Correspondence
Address: |
RENNER, OTTO, BOISSELLE & SKLAR, LLP
Nineteenth Floor
1621 Euclid Avenue
Cleveland
OH
44115-2191
US
|
Family ID: |
26791162 |
Appl. No.: |
10/035028 |
Filed: |
December 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10035028 |
Dec 28, 2001 |
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PCT/US00/17956 |
Jun 29, 2000 |
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10035028 |
Dec 28, 2001 |
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09096123 |
Jun 11, 1998 |
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60141452 |
Jun 29, 1999 |
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Current U.S.
Class: |
53/472 |
Current CPC
Class: |
B65B 55/20 20130101;
B65B 57/12 20130101 |
Class at
Publication: |
53/472 |
International
Class: |
B65B 005/00 |
Claims
What is claimed is:
1. A packaging system comprising: a packaging system controller for
sequentially providing packaging instruction steps related to at
least one part to be packaged, and an output device for conveying
the packaging instruction steps to a packer for use in packing the
part, and wherein the packaging system controller automatically
advances from a first packaging instruction step to a second
packaging instruction step after a predetermined amount of time
sufficient to enable performance of the first packaging instruction
step by the packer.
2. A packaging system as set forth in claim 1, further comprising a
packaging material supply device for supplying a packaging
material; and wherein the packaging system controller instructs the
packaging material supply device to provide the packaging material
for the at least one part to be packaged in coordinated
relationship with the instruction steps conveyed to the packer.
3. The packaging system of claim 1 or claim 2, wherein the
packaging instruction steps are programmed using an instruction
programming tool, the instruction programming tool having a
database of previously stored images.
4. The packaging system of claim 1 or claim 2, wherein the
packaging instruction steps are programmed using an instruction
programming tool, the instruction programming tool being executed
by the packaging system controller.
5. The packaging system of any preceding claim, wherein the
[display] output device provides an illustration of the packing
technique of the part being packaged.
6. The packaging system of any one of claims 2-5, wherein the
packaging material supply device includes a conversion machine that
converts sheet stock material into a dunnage product.
7. A method of packaging parts, comprising the steps of: retrieving
packaging instruction steps associated with the at least one part
to be packaged; and sequentially conveying the packaging
instruction steps to a packer for use in packing the part, wherein
the packaging system controller automatically advances from a first
packaging instruction step to a second packaging instruction step
after a predetermined amount of time sufficient to enable
performance of the first packaging instruction step by the
packer.
8. The method of claim 7, further comprising the step of
programming the packaging instructions using an instruction
programming tool, the step of programming the packaging instruction
including the step of retrieving a previously stored image from an
image database.
9. The method of claim 7 or claim 8, comprising the step of
controlling a packaging material supply device to provide the
packaging material for the at least one part to be packaged in
coordinated relationship with the instruction steps conveyed to the
packer.
10. The method of claim 9, wherein sheet stock material is supplied
to the packaging material supply device for conversion into a
packaging material.
11. A method of packaging differing parts, comprising the steps of:
determining a step by step set of packaging instructions associated
with each of a plurality of parts; programming the set of packaging
instructions using an instruction programming tool; and storing the
set of packaging instructions for subsequent retrieval.
12. A packaging system comprising: a packaging system controller
for providing packaging instructions related to at least one part
to be packaged, and a display for displaying the packaging
instructions to a packer for use in packing the part, wherein the
packaging instructions are programmed using an instruction
programming tool, the instruction programming tool having a
database of previously stored images.
13. A packaging system comprising a packaging material supply
device for supplying a packaging material; and a packaging system
controller for providing packaging instructions related to at least
one part to be packaged and instructing the packaging material
supply device to provide the packaging material for the at least
one part to be packaged.
14. 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.
Description
Related Application Data
[0001] This application is a continuation of PCT application Ser.
No. PCT/US00/17956, filed Jun. 29, 2000, which claims priority of
U.S. Provisional Application No. 60/141,452 filed on Jun. 29, 1999
and is a continuation-in-part of U.S. application Ser. No.
09/096,123 filed Jun. 11, 1998, all of which are incorporated
herein by reference in their entireties.
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 programming of the
packaging information, and further to provide for packaging
production productivity enhancements. 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; 4,968,291; 4,884,999; 5,607,383
and 5,836,538. (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.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the invention, a packaging system
comprises a packaging material supply device for supplying a
packaging material; and a packaging system controller for providing
packaging instructions related to at least one part to be packaged
and instructing the packaging material supply device to provide the
packaging material for the at least one part to be packaged. In a
preferred embodiment there is provided an output peripheral for
providing packaging instructions; and the packaging controller
instructs the packaging material supply device to provide packaging
instructions via the output peripheral.
[0009] According to another aspect of the invention, a method of
packaging parts comprises 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.
[0010] According to a further aspect of the invention, a method of
packaging differing parts, comprises the steps of determining a
step by step set of packaging instructions associated with each of
a plurality of parts; programming the set of packaging instructions
using an instruction programming tool; and storing the set of
packaging instructions for subsequent retrieval.
[0011] According to yet another aspect of the invention, a
packaging system comprises a packaging system controller for
providing packaging instructions related to at least one part to be
packaged, and a display for displaying the packaging instructions
to a packer for use in packing the part, wherein the packaging
instructions are programmed using an instruction programming tool,
the instruction programming tool having a database of previously
stored images.
[0012] According to a still further aspect of the invention, a
packaging system and method are characterized by a packaging system
controller for sequentially providing packaging instruction steps
related to at least one part to be packaged, and an output device
for conveying the packaging instruction step to a packer for use in
packing the part, and wherein the packaging system controller
automatically advances from a first packaging instruction step to a
second packaging instruction step after a predetermined amount of
time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram illustrating a packaging system
according to the present invention;
[0014] FIG. 2 is an illustration of a packaging system according to
the present invention including a cushioning conversion machine and
a packaging system controller;
[0015] FIG. 3 is a block diagram illustrating a portion of the
packaging system controller according to the present invention;
[0016] FIG. 4 is a flow chart illustrating an operational flow
diagram of the packaging system according to the present
invention;
[0017] 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;
[0018] 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;
[0019] 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;
[0020] 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;
[0021] 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;
[0022] 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;
[0023] FIG. 9 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;
[0024] FIG. 10 is a block diagram illustrating a programming
terminal according to the present invention;
[0025] FIG. 11 is a flow chart illustrating an operation flow
diagram of an instruction programming tool according to the present
invention;
[0026] FIG. 12 is an output peripheral display and user interface
which highlights a method of identifying instruction steps for a
part to be packaged according to one aspect of the invention;
[0027] FIG. 13 is an output peripheral display and user interface
which highlights a method of programming an instruction step for a
part to be packaged;
[0028] FIG. 14 is an output peripheral display and user interface
which highlights a method of accessing previously stored
images;
[0029] FIG. 15 is a flow chart illustrating a method for monitoring
operator packaging productivity and providing a productivity report
according to the present invention;
[0030] FIG. 16 is a flow chart illustrating in greater detail an
exemplary method of monitoring productivity and generating the
productivity report of FIG. 13;
[0031] FIGS. 17A-17D are flow charts illustrating in detail the
operation of the packaging system of FIG. 2 according to one
embodiment of the present invention;
[0032] FIG. 18 is a flow chart illustrating a method of pacing a
packager and monitoring the packager's performance according to one
aspect of the present invention;
[0033] FIG. 19 is a first output peripheral display and user
interface which highlights the method of pacing the packager and
monitoring the packager's performance; and
[0034] FIG. 20 is a second output peripheral display and user
interface which highlights the method of pacing the packager and
monitoring the packager's performance.
DETAILED DESCRIPTION OF THE INVENTION
[0035] 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.
[0036] 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.
[0037] 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.
[0038] The predetermined packaging instructions are preferably
retrieved from a memory (not shown) associated with the packaging
system controller 16 or a communication network having a network
database 21 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] The machine controller 14 is preferably a microprocessor
based programmable controller such as that described in co-owned
U.S. Pat. No. 5,897,478 issued Apr. 27, 1999, 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.
[0044] 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/O) 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.
[0045] 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.
[0046] 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.
[0047] The I/O devices include basic devices such as data storage
devices (e.g., floppy discs, tape drives, CD-ROMs, DVD-ROM, CD-RW,
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.
[0048] 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.
[0049] A disk control subsystem 70 bi-directionally couples one or
more disk drives 72 (e.g., floppy disk drives, CD-ROM drives,
DVD-ROM drives, CD-RW 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.
[0050] 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.
[0051] A terminal control subsystem 86 is also coupled to the bus
52 and provides output to the output peripheral 18, typically a CRT
or LCD monitor, but could also include a printer, 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, scanner or
digital camera. 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.
[0052] 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. The modem 91 may establish
direct data connections or exchange data messages and signals over
a network such as a WAN, LAN or the Internet.
[0053] 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.
[0054] 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.
[0055] 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, or
obtained from a remote storage device or memory via the modem 91 or
network adapter 90. Upon identifying the part to be packaged, the
CPU 50 retrieves the packaging instructions associated with the
part at step 104.
[0056] In a preferred method of the present invention, the CPU 50
uses a look-up 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.
[0057] 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.
[0058] 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 falling within
the scope of the present invention.
[0059] 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.
[0060] 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 (i.e., any packaging
material supply device) 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.
[0061] 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 (ie., 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.
[0062] 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").
[0063] 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.
[0064] 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
pulldown 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.
[0065] 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.
[0066] 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.
[0067] 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).
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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 168 (FIG. 1) 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.
[0072] Alternatively, the manipulation instructions may activate a
pick-and-place apparatus 169 (FIG. 1) 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 the
pick-and-place apparatus 169, 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.
[0073] 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), the coiler 168, 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 168 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
the pick-and-place apparatus 169, for example, at step 180. The
control instructions dictate a control routine which allows the
pick-and-place apparatus 169 to take the coiled packaging material
and automatically place it within the packaging container.
[0074] 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
the pick-and-place apparatus 169 for use in an automated packaging
routine at step 184.
[0075] 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 168 based on the packaging instructions
provided by the packaging system controller 16 of FIG. 1. In this
manner, the coiling apparatus 168 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 the coiler 168 is also described in U.S. patent application Ser.
No. 09/551,094 filed Apr. 18, 2000 entitled "Cushioning Conversion
System and Method for Making a Coil of Cushioning Product" and No.
60/172,060 filed Dec. 23, 1999 entitled "Cushioning Conversion
System, Handheld Coiler and Method for Producing Coiled Cushioning
Product, each incorporated by reference herein in their
entirety.
[0076] As discussed supra, an alternative packaging material
manipulation apparatus may include the packaging material
pick-and-place system 169 (FIG. 1), Example pick and place type
systems 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.
[0077] The packaging material manipulation control feature of the
present invention has been discussed in conjunction with the coiler
168 and the pick-and-place system 169, however, these devices 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 Ser. No.
09/156,109 filed on Sep. 18, 1998 entitled Dunnage Pad Production
and Packaging System, 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.
[0078] 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. 9. 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.
[0079] 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.
[0080] 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.
[0081] 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. 9). 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 re-ordering may be made at lower inventory levels, the
re-order threshold may be adjusted, thereby making the packaging
system dynamic.
[0082] 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.
[0083] According to the present invention, the method 350 may
provide a re-order 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.
[0084] 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.
[0085] In yet another aspect of the present invention, the method
350 of FIG. 9 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.
[0086] Referring now to FIGS. 1 and 10, a programming terminal 1000
is illustrated. The programming terminal 1000 is used to program
the packaging control methodology described above and provide the
methodology, including the control signals for the packaging
material generator 12 (step 108 of FIG. 5) and the packaging
instructions to be displayed on the output peripheral display 18
(step 110 in FIG. 5), to the packaging system 10. The programming
terminal 1000 is a computing device very similar to the packaging
system controller 16 illustrated in FIG. 3. The programming
terminal 1000 can be connected directly to the packaging system 10
or located remotely and communicate with the packaging system 10
via a network interface. Alternatively, the programming terminal
1000 can generate packaging control methodology sets, or
instruction sets, saved on machine-readable medium or on the
network database 21 to be read by the packaging system controller
16. One skilled in the art will appreciate that the operational
logic of the programming terminal 1000 described below can be
executed on the packaging system controller 16, thus alleviating
the need for a programming terminal 1000 separate from the
packaging system controller 16.
[0087] The programming terminal 1000 includes a computer system
1002. The computer system 1002 has a processor 1004 for executing
instructions, usually in the form of computer code (i.e.,
software), to carry out a specified logic routine and a memory 1006
for storing data, software, logic routine instructions, computer
programs, files, operating system instructions, and the like. The
memory 1006 can comprise several devices and includes, for example,
volatile and non-volatile memory components. Volatile components
typically do not retain data values upon a loss of power.
Non-volatile retain data upon the loss of power. Thus, the memory
1006 can be, for example, random access memory (RAM), read only
memory (ROM), hard disk, floppy disk, compact disk (including, but
not limited to, CD-ROM, DVD-ROM, and CD-RW), tapes, and or other
memory components, including drives and players for these memory
types.
[0088] The processor 1004 and the memory 1006 are coupled to a
local interface 1008. The local interface 1008 can be, for example,
a data bus with accompanying control bus, or a network between a
processor and/or processors and a memory or memories. The computer
system 1002 also has a video interface 1010, a number of input
interfaces 1012, a modem and/or network adapter 1014, a number of
output interfaces 1016, each being coupled to the local interface
1008.
[0089] The programming terminal 1000 also has a display 1018
coupled to the local interface 1008 via the video interface 1010.
Although shown as a cathode ray tube (CRT), the display device may
alternatively be, for example, a liquid crystal display (LCD), a
plasma display, an electro-luminescent display, indicator lights,
or light emitting diodes. In addition, the programming terminal
1000 has several input devices, including, but not limited to, a
keyboard 1020, a mouse 1022, a microphone 1024, a scanner 1026 and
a camera 1028, each being coupled to the local interface 1008 via
the input interfaces 1012. It is noted that the camera 1028 can be,
for example, a digital still picture camera or a video camera. The
modem or network adapter 1014 is coupled to an external network or
some other computing device 1030, allowing the exchange of data
signals, voice signals, video signals and the like via the external
network 1030, as is well known in the art. The external network
1030 may be, for example, the Internet, a wide area network (WAN),
a local area network (LAN), direct data link or other similar
network. It is noted that the programming terminal 1000 can be
accessed and used by a remote user via the external network 1030
and modem 1014. The programming terminal 1000 can also include
output devices coupled to the local interface 1008 via the output
interfaces 1016, such as audio speakers 1032, a printer 1034, and
the like.
[0090] The computer system 1002 is programmed to display and
execute an instruction programming tool in graphical user interface
(GUI) format. Alternatively, the computer system 1002 has logic
stored in the memory 1006 capable of being executed to display and
function as the instruction programming tool. As is known in the
art, the GUI includes a menu bar disposed across the top of the
display 1018, having a series of pull down menus from which a
programming terminal 1000 administrator, or user, can access
various features of the instruction programming tool. As is
appropriate, the GUI will also have pop-up menus to illustrate
selection choices when a certain feature is selected, scroll bars
allowing the user to navigate through a displayed window, drop-down
menus which drop down from the menu bar or other selected area, and
content sensitive menus for highlighting options available or
unavailable to the user depending upon the context of the selected
content sensitive menu.
[0091] With additional reference to FIG. 11, an instruction
programming tool logic routine 1050 is illustrated. Upon activating
the logic routine 1050, the user of the programming terminal 1000
is requested to log in using a password scheme or digital signature
verification scheme in step 1052. The log in step 1052 provides a
measure of access control to the instruction programming tool. Once
logged in, the instruction programming tool will display GUI
windows relating to various aspects of the instruction programming
tool on the display 1018.
[0092] With additional reference to FIG. 12, an example window 1054
is illustrated. The window 1054 has a menu bar 1056 having drop
down menus including, for example, a file menu, an edit menu, and a
report menu. The file menu contains links and commands that are
generally well known in the art and include file manipulation
commands such as new, open, close, save, save as, print and
exit.
[0093] The edit menu contains selectable links to features which
are specific to the instruction programming tool and include, for
example, settings, new/add part, edit part, new/add supplies, edit
supplies, new/add vendors, and edit vendors. Using a mouse pointer
1058, as is well known in the art, the user can select the various
commands appearing under the edit menu. Programming of the
packaging system controller 16 generally begins in step 1060 by
programming basic operating parameters of the packaging system
controller 16. This is accomplished by choosing the settings menu
item from the edit menu. Upon selecting the settings menu item, the
instruction programming tool will generate a settings window (not
shown) and display the settings window on the display 1018. The
settings window contains various selection menus and fields to be
populated by the user. These menus and fields include a machine
type field for specifying the type of packaging material generator
12 to be controlled, a location of the packaging material generator
12 (such as the United States or Europe), a measurement unit field
(such as English inch measurements or metric centimeter
measurements), access control information used by the logic routine
1050 in step 1052, communication port and network settings, a
shipping address field, a billing address field, a return address
field and a contact person field(s). The address and contact person
information is used on supply reorder forms and reports generated
by the packaging system controller 16, as discussed in more detail
herein.
[0094] Once basic operating parameters are programmed in step 1060,
the user can define a part to be packaged in step 1062 by selecting
the new/add part menu item from the edit menu. Upon selecting the
new/add part menu, the programming terminal 1000 will display a
new/add part window (not shown) on the display 1018. Using the
new/add part window, the user defines the new part by inputting a
part number, a description and/or picture of the part. In addition,
the user may define other characteristic of the part, such as a bar
code value associated with the part. The bar code value can later
be used by the packaging system controller 16 to verify that the
packager has selected to the correct part for packaging or to
automatically retrieve the instruction set for the part.
[0095] Once the part has been defined with the part number and
associated description, an instruction set programming window 1064
(FIG. 12) will be displayed on the display 1018. The instruction
set programming window 1064 has a header 1066 which contains the
part number and/or the description of the part. The instruction set
programming window 1064 also has an instruction summary region
1068. The instruction summary region 1068 is initially blank, but
once the user programs instruction steps for packing the part
identified in the header 1066, summaries of the instruction steps
will appear in the instruction summary region 1068 in the order the
instruction steps are to be carried out.
[0096] The instruction set programming window 1064 has a plurality
of function buttons 1070. An add instruction button 1072 allows the
user to add an instruction step to the instruction set for the
specified part. More specifically, the add instruction button 1072
directs the instruction programming tool to display an instruction
step template window 1074 as illustrated in FIG. 13. Briefly, the
instruction step template window 1074 is used to program and enter
information relevant to the packaging methodology steps used to
generate the graphical displays 146 and packaging material
generator 12 commands. In the illustrated example, the instruction
step template window 1074 displays a template populated with
information to carry out an intermediate packaging step of the
instruction set for packaging the specified part.
[0097] The instruction step template window 1074 has an image
region 1076 where graphics associated with the packaging step are
shown. The number of images and their layout can be specified using
various image layout menus 1077. Images can be illustrated directly
on the instruction template window 1074 or imported using an import
button 1078. The import button will link the user to an import
picture window (not shown) allowing the user to browse existing
files containing desired images that have previously been generated
by a drawing program, a CAD program, a digital camera and/or
associated photo editing software tool, a video camera and/or video
editing software tool or the scanner 1026 and associated
scanning/editing software. The pre-existing image files can be
saved in standardized formats, such as JPEG, MPEG, TIFF, PICT, and
the like. Alternatively, the import image window can allow the user
to directly capture a scanned image using the scanner 1026 or an
image taken with the camera 1028.
[0098] From the instruction step template windows 1074 the user can
also select an image from a pre-defined library database containing
various images by selecting a library button 1080. The library
button 1080 will link the user to a library window 1081 (FIG. 14)
allowing the user to browse through previously saved drawings, clip
art, stenciled images, photographs and the like. The library window
1081 can be provided with a preview feature so that the image can
be reviewed by the user before selecting the image and associating
it with the instruction step being defined in the instruction step
template window 1074.
[0099] The library database, in addition to having a database of
pictures, drawings, illustrations and video clips, can have
databases of textual instructions and packaging material generator
12 control commands. Additionally, multiple items of stenciled
images can be combined to form more complex drawings. For example,
a drawing of a cushioning pad can be superimposed on a drawing of a
box to show the orientation of the pad with respect to the box.
[0100] With continued reference to FIG. 14, the library window 1081
has a file selection browser 1082 for finding a desired image from
previously saved images on a computer readable medium. The library
window 1081 also has an image preview area 1083 to display a
graphic representation of an image selected using the browser 1082.
The library window 1081 may also be provided with a selection menu
1084 to allow the user to specify how a selected image should be
displayed on the graphical display 146. In the illustrated
exemplary layout selection menu 1084, the graphical display 146
being programmed may have no pictures, one picture or two pictures.
By selecting one of the layout choices from the layout selection
menu 1084, the user can specify where on the graphical display 146
the image is to appear. It is noted that the layout selection menu
1077 can be the same as, similar to or different from the layout
selection menu 1084 of FIG. 14. In the illustrated example, the
layout selection menu 1077 is intended to have expanded
functionality and a greater image capacity than the layout
selection menu 1084. Once the user has found an image and specified
the image's layout, the user may return to the instruction step
template window 1074 by selecting an okay button 1085. Upon
returning to the instruction step template window 1074, the
selected image will appear in the image region 1076. Alternatively,
the user may elect to forgo displaying an image and return to the
instruction step template window 1074 by selecting a cancel button
1086.
[0101] The instruction template window 1074 also has a text
instruction region 1088 in which the user can enter textual
instructions for the packer to follow, via typing or copying from
previously saved text. Additionally, the user can specify a name
for the instruction step in a step name menu 1090. A default set of
names, including previously used names, can be placed in a pull
down menu for fast retrieval. Alternatively, a unique name can be
typed.
[0102] The user can specify various control operations for the
packaging material generator 12 to carry out during the execution
of the instruction step. For example, the user can specify a
quantity of pads for the packaging material generator 12 to
generate and the length of those pads using a number of pads menu
1092 and a pad length menu 1094 respectively. Other materials to be
used during the instruction step can also be programmed in
additional supply menus (not shown) such as tape, glue, staples,
warranty cards, and the like. The instruction step can be
supplemented with additional information regarding these supplies,
as well as boxes. The additional information can include bar code
values for use by the packaging system controller 16 to verify that
the user has selected the correct item.
[0103] The user can specify whether the present instruction step
requires a box using a box menu 1096. Usually, only the first
instruction step in an instruction set will instruct the user to
obtain and set-up a box. However, if a box is needed for the
instruction step, the user can specify the box by a serial number,
the box's dimensions, or other identifying characteristics of the
box using the box menu 1096.
[0104] The instruction template window 1074 also has a first time
only check box 1098 which will allow the user to specify to the
packaging system controller 16 whether the instruction step should
only be displayed to the packer during the first pass through the
instruction set, if more than one of the same part is to be
packaged. The check box 1098 is useful, for example, when certain
steps are directed to the set-up of a packaging work station.
[0105] Using a delay time menu 1100, the user can set an amount of
time that the packaging system controller 16 will display the
instruction step before automatically proceeding to the next
instruction. As will be discussed in more detail below, the entered
delay time establishes a time during which the packer should
complete the instruction step. The delay time is therefore also
used to pace the packager, and enhance and monitor the packager's
productivity. The delay time can be set in seconds, from zero
seconds to hundreds of seconds, as is needed for the packaging
step.
[0106] Alternatively, a manual action to be completed by the
packager can be specified in a manual action menu 1101. In order
for the packaging system controller 16 to proceed to the next
instruction step, the manual action must be completed. Manual
actions can include pressing a keyboard key, a mouse button, or a
touch screen. Other manual actions include manipulating an object,
such as removing a cushioning pad from the packing material
generator 12 or scanning a bar code disposed on a box to confirm
that the packer has selected the correct box. Even if a manual
action is specified in the manual action menu 1101, a delay time
can be entered in the delay time menu 1100. As will be described in
more detail below, the delay time is used to pace the packager.
[0107] It is noted that certain information entered into the
instruction step template window 1074, such as the number of pads
and pad length, is used by the packaging system controller 16 to
generate machine instructions to the packaging material generator
12 and, more specifically, the controller 14, to invoke a response
by the packaging material generator 12 to perform the specified
action. In addition, the instruction step template window 1074 has
a control functions button 1102 to link the user to a control
functions window (not shown). The control functions window has
menus for specifying additional instructions for the packaging
material generator 12 such as commands for the coiler 168, commands
for the pick and place system 169, and so forth.
[0108] The instruction template window 1074 has navigation buttons
1104, including a previous instruction button to display the
instruction step template window 1074 associated with the preceding
instruction step in the instruction set and a next instruction
button for displaying the instruction step template window 1074
associated with the next instruction step in the instruction set.
The navigation buttons 1104 also include an okay button which will
store the information entered by the user in the memory 1006 and
return the user to the instruction set programming window 1064. The
navigation buttons also include a cancel button to return the user
to the instruction set programming window 1064 without storing any
new or changed information entered in the instruction step template
window 1074.
[0109] Referring back now to FIG. 12, the instruction set
programming window 1064 has a delete instruction button 1106. After
selecting one of the instructions displayed in the instruction
summary region 1068 with the mouse pointer 1058, the user can
select the delete instruction button 1106 to remove the
instruction, if desired.
[0110] The instruction set programming window 1064 has a copy
instruction button 1108 for linking the user to an instruction
library window (not shown) similar to the library window 1081 of
FIG. 14. The instruction window allows the user to browse through
previously defined and stored instruction steps, select an
appropriate instruction step and add a copy of that instruction
step to the instruction set being assembled. Alternatively, the
user can select an instruction displayed in the instruction summary
region 1068 with the mouse pointer 1058 and press the copy
instruction button 1108 to copy the selected instruction. To
replicate the selected instructions, the user will then press a
paste instruction button 1110. If the user would like to reposition
an instruction step in the instruction set, the user will select a
move instruction button 1112 which has functionality to move a
selected instruction to a new position in the instruction set. The
user may modify an existing instruction by selecting the
instruction step in the instruction summary region 1068 and then
selecting an edit instruction button 1114 which will link the user
to the instruction step template window 1074 associated with that
instruction step. Once the associated instruction step template
window 1074 has been displayed the user can make any appropriate
modifications and store those modifications by selecting the okay
navigation button 1104.
[0111] The instruction set programming window 1064 also has a link
instruction to preview button 1116 to logically associate a
selected instruction step or instruction steps with the preview
function discussed in more detail above. Using the link instruction
to preview button 1116, the user can specify which instruction
step(s) from the instruction set are to be displayed in the preview
window 130 (FIG. 6A) for the specified part.
[0112] Once the user has programmed and/or edited the instruction
steps for a part's instructions set, the user can store the
instruction set in the memory 1006 by selecting an okay button 1118
or can exit the instruction set programming window 1064 without
saving any additions or changes by selecting a cancel button
1120.
[0113] Using the edit menu from the menu bar 1056, the user can
select an edit part menu which will prompt the user for a part
number. Once the part number has been entered, or selected from a
menu of existing part numbers, the instruction programming tool
will link the user to the instruction set programming window 1064
associated with the part. Once linked to the instruction set
programming window 1064 the user can modify the instruction set as
needed by following the procedures discussed above.
[0114] The instruction programming tool also allows the user to
set-up and maintain a database of supplies and supply vendors in
step 1122 of the logic routine 1050 (FIG. 11) Using the edit menu
from the menu bar 1056, the user can add suppliers or edit
suppliers for various consumable items such as boxes, tapes,
warranty cards, packaging dunnage, glue, staples, and the like. The
supplier information will be used to generate re-order forms for
ordering these supplies once the re-order threshold has been
reached. In addition, the user can select an add supply or an edit
supply menu from the edit menu on the menu bar 1056 to create and
maintain a database of supplies. The database of supplies contains
information related to the supply (e.g., a box having a specified
description and dimensions), the typical cost of that supply, the
supplier associated with the supply, inventory information such as
quantity of the supply on hand, the re-order threshold, and how
many of the supply should be re-ordered upon reaching the re-order
threshold.
[0115] Once the operating parameters, parts, instructions and
database of supplies and supply vendors has been entered and stored
using the instruction programming tool, this collection of
information can be stored in a memory directly associated with the
packaging system controller 16 or on a computer readable medium
accessible by the packaging system controller 16. Alternatively,
the information can be stored on a network database 21 accessible
by the packaging system controller 16 or retrieved by the packaging
system controller 16 from the programming terminal 1000 via a
network interface. One skilled in the art will appreciate that
these steps of making the collection of information available to
the packaging system controller 16 will be modified appropriately
in the embodiment where the instruction programming tool is
executed directly on the packaging system controller 16.
[0116] In FIG. 15, 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 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.
[0117] 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.
[0118] The productivity report generated at step 410 may appear as
a report 412 as illustrated in FIG. 15. 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.
[0119] 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.
[0120] 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
failing within the scope of the present invention.
[0121] 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. 15) is illustrated in greater
detail in FIG. 16. Once the CPU 50 has retrieved the packaging
instructions associated with the identified part at step 104 of
FIG. 15, 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.
[0122] 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.
[0123] 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. 15.
[0124] As discussed above in conjunction with FIGS. 1-16, 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.
[0125] Yet another embodiment in which such functionality may be
provided is discussed below in conjunction with FIGS. 17a-17d. 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. 17a-17d.
[0126] 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.)
[0127] 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.
[0128] 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. 17b, 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.
[0129] 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.
[0130] 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.
[0131] 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. 17c). 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.
[0132] 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. 17b 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.
[0133] 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.
[0134] 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. 17d. 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).
[0135] 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. 17b, 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. 17a) and the
process is repeated for the next part.
[0136] Referring now to FIG. 18, a packager pacing logic routine
1200 is illustrated. In its most basic embodiment, the packager
pacing logic routine 1200 is executed by the packaging system
controller 16 and controls the pace with which the packaging
material generator 12 produces packaging material and the pace with
which the graphical instruction sets are displayed on the display
18. In general, the these rates are based on values entered in the
delay time menu 1100, as discussed more fully above with respect to
FIG. 13.
[0137] Starting in step 1202, a part to be packaged is identified
and the packaging system controller 16 retrieves the packaging
control methodology for the part, as discussed in greater detail
above. The part to be packaged may be identified by a number of
methods, including, for example, the packer entering a part
identification number into the packaging system controller 16 or
scanning a bar code associated with the part. Alternatively, a
facility management computer used to control the flow of parts
through a facility having the packaging system 10, can be used to
dictate (i.e., send an electronic message) to the packager system
10 the next part to be packaged.
[0138] Once the part has been identified and the packaging control
methodology has be retrieved, the packaging system controller 16
controls the packaging material generator 12 via the controller 14,
and displays instructions for the packager in step 1204. It is
noted that step 1204 of FIG. 18 generally corresponds to steps 108
and 110 of FIG. 4. An example first instruction step is illustrated
in FIG. 19. In the illustrated example, three identical parts have
been identified for packaging meaning that the packaging pacing
logic routine 1200 will repeat itself three times.
[0139] It is noted that the packager is provided with various
control buttons 1208 located on the display 18. The control buttons
1208 include a back button 1210, a forward button 1212, a pause
button 1214 and a break button 1216. The back button 1210 allows
the user to backtrack to the previously displayed instruction.
However, when the first instruction of an instruction set is being
displayed the back button 1210 can be turned off and made
unavailable to the packager since no prior steps are available for
viewing. The forward button 1212 allows the packager to proceed to
the next step when the instruction step has been completed.
However, in instances where a manual action is required, the
forward button may be turned off and made unavailable to the
packager in favor of sensing the specified manual action.
[0140] As the graphical display 146 for the instruction step is
displayed, the packaging system controller 16 will start a step
timer in step 1206. The step timer is used to track how long it
takes the packager to complete the currently displayed instruction
step. The pause button 1214 allows the user to pause the display of
instructions and the generation of packaging material by the
packaging material generator 12, but will not stop the step timer
1206. As will become more apparent below, the pause button 1214 is
used to provide the operator more time to complete the displayed
step. The break button 1216 allows the user to both pause the
display of new instructions, the generation of packaging material,
and stop the step timer. The break button 1216 allows the packager
to take a lunch break or direct his or her attention to other
matters. If desired, the packaging system controller 16 can be
programmed to limit the packager's use of the break button 1216 by
allowing only a certain number of breaks per shift, allowing only a
certain amount of time per break and/or allowing only a certain
total of break time per shift, before restarting the step timer
1206.
[0141] To assist the packager, the displayed instruction can have
one or more icons, such as the stop sign illustrated in FIG. 19.
The icon(s) are intended to directly or indirectly represent the
manual action needed to complete the instruction step or to
illustrate the time remaining before the packaging system
controller 16 will proceed to the next step automatically (i.e.,
expiration of the delay time). In addition to an icon for manual
actions, a countdown timer can be displayed on the graphical
display 146 to illustrate how much time the packager has to
complete the step without falling behind the time programmed in the
delay time menu.
[0142] As mentioned above, a step may be completed by performing a
manual action. If a manual action has been programmed, the
packaging system controller 16 will not proceed to the next step
until the manual action is completed by the packager. For example,
as illustrated in FIG. 19, the first step instructs the packager to
assemble a particular box and then scan a bar code located on the
box in order to proceed to the next step.
[0143] FIG. 20 illustrates a second step for packaging the part
where no manual action has been programmed to complete the step.
Rather, at the expiration of the delay time, the packaging system
controller 16 will proceed to the next instruction step
automatically. If the packager is not ready for the next step, the
packager may press the pause button 1214, go on break using the
break button 1216 or return to the prior step by pressing the back
button 1210. If the packager is ready for the next step before the
expiration of the delay time, the packager may proceed to the next
step using the forward button 1212. To continue advancing through
the packaging instruction steps after using the pause button 1214
or break button 1216, the packager can select the forward button
1212. To assist the packager, the time remaining before the
expiration of the delay time may be displayed in a timer icon
1218.
[0144] Returning to FIG. 18, the packager pacing logic routine 1200
will detect the completion of the instruction step and stop the
step timer in step 1220. If the step has a manual action, the
completion of the step is based on the performance of the manual
action. The end value of the step timer for an instruction step
having a manual action will be the time from the starting of the
step timer in step 1206 to the completion of the manual action.
[0145] If the instruction step does not have a manual action, the
completion of the instruction step is detected when the first of
the following two conditions occurs. The first condition is when
the packager presses the forward button 1212 before the expiration
of the programmed delay time. If the first condition is met first,
the end value of the step timer will be the time from the starting
of the step timer to the pressing of the forward button 1212. The
second condition is when the packaging system controller 16
proceeds to the next step at or after the expiration of the
programmed delay time. It is noted that proceeding to the next step
could occur at the natural expiration of the programmed delay time
or sometime thereafter if the packager has used the back button
1210 or the pause button 1214. If the second condition is met
first, the end value of the step timer will be the time from the
starting of the step timer to the time when the packaging system
controller 16 progresses to the next instruction step. One skilled
in the art will appreciate that the end value of the step timer is,
generically, the time the packager takes to complete the displayed
instruction step.
[0146] Next, the packaging system controller 16 will subtract the
delay time from the end timer value to derive a .DELTA.t value for
the instruction step in step 1222. Next, the packaging system
controller 16 will add the .DELTA.t value to a log to provide a
record of packager performance in step 1224. The log can simply be
an aggregate record of how fast the packager operates in relation
to the aggregate of the delay times for the steps completed or can
keep track of more sophisticated packager performance, such as
tracking packager performance for each step, each part or each
shift. It is noted that if the operator completes the step before
the expiration of the delay time, .DELTA.t will be a negative value
thereby indicating that the operator is working faster than the
programmed delay times. However, a positive .DELTA.t indicates that
the packager is working slower than the programmed delay times.
[0147] After adding .DELTA.t to the log, the packaging system
controller 16 will proceed to step 1226 where the packaging system
controller 16 will determine whether the last instruction step in
the instruction set has been completed. If the last step has not
been completed, the packager pacing logic routine 1200 will return
to step 1204 and display the next instruction step and send
commands to the packaging material generator 12 as programmed. If
the last step has been completed, the packaging system controller
16 will monitor and log the time between the completion of the last
instruction step and the start of packaging the next part in step
1228. The monitored time between parts can be compared against an
expected time value for the time interval between parts.
Alternatively, the packaging system controller 16 can be programmed
to automatically display the first instruction step for packaging
the next part, thereby commencing the step timer and the tracking
of the packager's performance as described in more detail
above.
[0148] 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.
[0149] Returning now to FIGS. 10 and 12, the programming terminal
can be used to specify and format various types of reports
generated by the packaging system controller 16. For example, the
format of the foregoing productivity reports and packager log can
be specified. Reports are formatted by selecting the reports menu
from the menu bar 1056 and completing GUI display screens. Other
reports include a purchase order form, an inventory report to list
quantities of supplies on hand, and a packaging instruction report
allowing the user to print out the information normally displayed
on the graphical display 146 (FIGS. 6c, 19, 20) or the instruction
step template 1074. The packaging instruction reports can be used
to consolidated multiple instruction steps on a single page to
provide the reader of the report consolidated information about the
packaging instructions for a particular part. Another report is a
packaging activity report which tracks the parts the packaged using
the packaging system 10 to provide a consolidated report on overall
packaging facility performance. The packaging activity report
preferably includes each part number packed, the associated
description of those parts, the quantity of each part packaged, the
average time taken to package each part, the quantity of supplies
used to package the parts and any other information the user is
interested in.
[0150] Although the logic routines 1050 and 1200 (FIGS. 11 and 18)
of the present invention are embodied in software as discussed
above, this logic may alternatively be embodied in hardware or a
combination of software and hardware. If embodied in hardware, the
foregoing logic can be implemented as a circuit or state machine
that employs any one of or a combination of a number of
technologies. These technologies may include, but are not limited
to, discrete logic circuits having logic gates for implementing
various logic functions upon an application of one or more data
signals, application specific integrated circuits having
appropriate logic gates, programmable gate arrays (PGA), field
programmable gate arrays (FPGA), or other components, etc. Such
technologies are generally well known by those skilled in the art
and, consequently, are not described in detail herein.
[0151] The diagrams described herein show the architecture,
functionality, and operation of an implementation of the foregoing
logic. If embodied in software, each block may represent a module,
segment, or portion of code that contains one or more executable
instructions to implement the specified logical function(s). If
embodied in hardware, each block may represent a circuit or a
number of interconnected circuits to implement the specified
logical function(s). Although the block diagrams and flow charts
show a specific order of execution, it is understood that the order
of execution may differ from that which is depicted. For example,
the order of execution of two or more blocks may be altered
relative to the order shown. Also, two or more blocks shown in
succession in may be executed concurrently or with partial
concurrence. In addition, various blocks may be omitted. It is
understood that all such variations are within the scope of the
present invention.
[0152] Also, the logic can be embodied in any computer-readable
medium for use by or in connection with an instruction execution
system such as a computer/processor based system or other system
that can fetch or obtain the logic from the computer-readable
medium and execute the instructions contained therein. In the
context of this document, a "computer-readable medium" can be any
medium that can contain, store, or maintain logic and/or data for
use by or in connection with the instruction execution system. The
computer readable medium can be any one of many physical media such
as, for example, electronic, magnetic, optical, electromagnetic,
infrared, or semiconductor media. More specific examples of a
suitable computer-readable medium would include, but are not
limited to, a portable magnetic computer diskette such as floppy
disk, a hard disk, a random access memory (RAM), a read-only memory
(ROM), an erasable programmable read-only memory, or a compact
disc.
[0153] Although the invention has been shown and described with
respect to certain preferred embodiments, equivalent alterations
and modifications will occur to others skilled in the art upon
reading and understanding this specification and the annexed
drawings. In particular regard to the various functions performed
by the above described integers (components, assemblies, devices,
compositions, etc.), the terms (including a reference to a "means")
used to describe such integers are intended to correspond, unless
otherwise indicated, to any integer which performs the specified
function of the described integer (i.e., that is functionally
equivalent), even though not structurally equivalent to the
disclosed structure which performs the function in the herein
illustrated exemplary embodiment or embodiments of the invention.
In addition, while a particular feature of the invention may have
been described above with respect to only one of several
illustrated 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.
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