U.S. patent application number 10/696013 was filed with the patent office on 2004-05-06 for data processing system for managing chemical product usage.
This patent application is currently assigned to Ecolab Inc.. Invention is credited to Gardner, James P. JR..
Application Number | 20040088076 10/696013 |
Document ID | / |
Family ID | 23700606 |
Filed Date | 2004-05-06 |
United States Patent
Application |
20040088076 |
Kind Code |
A1 |
Gardner, James P. JR. |
May 6, 2004 |
Data processing system for managing chemical product usage
Abstract
A data processing system is used to manage and track use of
chemical product in a washing machine. A detergent dispenser
distributes the chemical products (e.g., detergent, rinse agent,
and bleach) to the washing machine. The dispenser includes a
monitor that detects dispenser data based on distribution of the
chemical product by the dispenser. A database is coupled to the
dispenser and stores an account identifier and an alignment
identifier in association with the dispenser data of the dispenser.
The database further stores corporate data in association with the
dispenser data, the account identifier, and the alignment
identifier. An analysis application analyzes the dispenser data in
relation with the corporate data to characterize use of the
chemical product in the chemical application system and provide a
feedback loop. The analysis application can limit its analysis to
data associated with a given account identifier or a given
alignment identifier.
Inventors: |
Gardner, James P. JR.;
(Stillwater, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Ecolab Inc.
Mendota Heights
MN
55118
|
Family ID: |
23700606 |
Appl. No.: |
10/696013 |
Filed: |
October 28, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10696013 |
Oct 28, 2003 |
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10027116 |
Dec 19, 2001 |
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6697706 |
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10027116 |
Dec 19, 2001 |
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09428841 |
Oct 28, 1999 |
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6377868 |
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Current U.S.
Class: |
700/239 |
Current CPC
Class: |
A47L 15/0063 20130101;
D06F 95/00 20130101; G06Q 10/06 20130101; A47L 15/0055 20130101;
D06F 39/02 20130101; G06Q 10/08 20130101 |
Class at
Publication: |
700/239 |
International
Class: |
G06F 017/00 |
Claims
What is claimed is:
1. A system for monitoring operations associated with a cleaning
system at a first physical location, the cleaning system
corresponding to a first customer account identified by an account
identifier, the system comprising: a monitor module detecting
information originating at the first physical location, wherein the
detected information is associated with operation of the cleaning
system; a database communicatively connected to the monitor module
and storing the account identifier in association with the
information detected at the first physical location, the database
further storing corporate data in association with the information
detected at the first physical location and the account identifier;
and an analysis application analyzing the information detected at
the first physical location in relation with the corporate data to
characterize operations associated with the cleaning system.
2. A system as defined in claim 1, wherein the monitor module
comprises a detecting device located at the first physical
location.
3. A system as defined in claim 2, wherein the monitor module
comprises a detecting device integrated with a chemical dispenser
dispensing a chemical product to the cleaning system.
4. A system as defined in claim 1, wherein the monitor module
comprises a detecting device located at a location remote from the
first physical location.
5. A system as defined in claim 1, wherein the monitor module and
the database are communicatively connected by way of a
communications network.
6. A system as defined in claim 5, wherein the analysis application
is implemented on a client computer communicatively connected to
the database.
7. A system as defined in claim 6, wherein the client computer is
located at the first physical location.
8. A system as defined in claim 1, wherein the analysis application
further analyzes the information detected at the first physical
location and the corporate data against a target parameter
specifying a desired data characteristic associated with one or
more operations of the cleaning system, the analysis application
identifying a situation wherein the desired data characteristic is
not met.
9. A system as defined in claim 8, wherein the desired data
characteristic relates to a utility cost associated with the
cleaning system.
10. A system as defined in claim 8, wherein the desired data
characteristic relates to energy consumption associated with the
cleaning system.
11. A system as defined in claim 8, further comprising: a client
computer communicatively coupled to the database for requesting
retrieval of data stored therein, wherein the analysis application
is implemented on the client computer in order to provide field
service operators a user interface through which operations of the
cleaning system may be monitored from a site remote from the first
physical location.
12. A system as defined in claim 11, wherein the analysis
application provides the field service operators with an ability to
control operations of the cleaning system from the remote site.
13. A system as defined in claim 11, wherein the analysis
application directs the client computer to issue an alarm command
to the first physical facility upon detection of the desired data
characteristic not being met.
14. A system as defined in claim 1, wherein the analysis
application further analyzes the information detected at the first
physical location against a target parameter specifying a desired
data characteristic for a specific operation associated with the
cleaning system relating to the first customer account, the
analysis application identifying a situation wherein the desired
data characteristic is not met.
15. A system as defined in claim 14, wherein the analysis
application issues an alarm command to the first physical facility
upon detection of the desired data characteristic not being
met.
16. A system as defined in claim 14, wherein the desired data
characteristic relates to water temperature.
17. A system as defined in claim 14, wherein the desired data
characteristic relates to a dispensed amount of a chemical product
to the cleaning system.
18. A system as defined in claim 1, further comprising a user
terminal on which the analysis application is implemented to
provide a report related to operations associated with the cleaning
system.
19. A system as defined in claim 18, wherein the report comprises
real-time data rendered by the analysis application.
20. A system as defined in claim 18, wherein the report comprises
historical data rendered by the analysis application.
21. A system for monitoring operations associated with a cleaning
system at a first physical location, the cleaning system
corresponding to a first customer account identified by an account
identifier, the data processing system comprising: a monitor module
detecting information originating at the first physical location,
wherein the detected information is associated with operation of
the cleaning system; a database communicatively connected to the
monitor module and storing the account identifier in association
with the information detected at the first physical location, the
database further storing corporate data in association with the
information detected at the first physical location and the account
identifier; and an analysis application analyzing the information
detected at the first physical location and the corporate data
against a target parameter specifying a desired data characteristic
associated with one or more operations of the cleaning system, the
analysis application identifying a situation wherein the desired
data characteristic is not met.
22. A system as defined in claim 21, wherein the desired data
characteristic relates to a utility cost associated with the
cleaning system.
23. A system as defined in claim 21, wherein the desired data
characteristic relates to energy consumption associated with the
cleaning system.
24. A system as defined in claim 21, further comprising: a client
computer communicatively coupled to the database for requesting
retrieval of data stored therein, wherein the analysis application
is implemented on the client computer in order to provide field
service operators a user interface through which operations of the
cleaning system may be monitored from a site remote from the first
physical location.
25. A system as defined in claim 24, wherein the analysis
application provides the field service operators with an ability to
control operations of the cleaning system from the remote site.
26. A system as defined in claim 24, wherein the analysis
application directs the client computer to issue an alarm command
to the first physical facility upon detection of the desired data
characteristic not being met.
27. A system as defined in claim 21, wherein the analysis
application issues an alarm command to the first physical facility
upon detection of the desired data characteristic not being
met.
28. A system as defined in claim 21, wherein the cleaning system is
a laundry machine.
29. A system as defined in claim 21, wherein the cleaning system is
a warewash machine.
30. A method for monitoring operations associated with a cleaning
system at a first physical location, the cleaning system
corresponding to a first customer account identified by an account
identifier, the method comprising: detecting information
originating at the first physical location, wherein the detected
information is associated with operation of the cleaning system;
storing the account identifier and the information detected at the
first physical location in association with corporate data; and
analyzing the information detected at the first physical location
in relation with the corporate data to characterize operations
associated with the cleaning system.
31. A method as defined in claim 30, wherein the analyzing act
comprises: analyzing the information detected at the first physical
and the corporate data against a target parameter specifying a
desired data characteristic for a specific operation associated
with the cleaning system relating to the first customer account in
order to identify a situation wherein the desired data
characteristic is not met.
32. A method as defined in claim 31, further comprising: sending a
notification to the first physical facility that the desired data
characteristic is not met.
33. A method as defined in claim 32, wherein the desired data
characteristic relates to a utility cost associated with the
cleaning system.
34. A method as defined in claim 32, wherein the desired data
characteristic relates to energy consumption associated with the
cleaning system.
35. A method as defined in claim 31, further comprising: generating
a report related to operations associated with the cleaning
system.
36. A method as defined in claim 33, wherein the report comprises
real-time data rendered by the analyzing act.
37. A method as defined in claim 36, wherein the report comprises
historical data rendered by the analyzing act.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/027,116, entitled DATA PROCESSING SYSTEM
FOR MANAGING CHEMICAL PRODUCT USAGE, filed Dec. 19, 2001, which is
a continuation of U.S. patent application Ser. No. 09/428,841,
filed Oct. 28, 1999 and issued as U.S. Pat. No. 6,377,868. These
prior (parent) applications are hereby incorporated herein by
reference by their entirety.
TECHNICAL FIELD
[0002] The invention relates generally to storage and processing of
data related to chemical product usage, and more particularly, to
collecting, communicating, and analyzing chemical product usage
data based on distribution of the product by a product
dispenser.
BACKGROUND OF THE INVENTION
[0003] Institutional laundry facilities, such as those employed in
many large hotels, nursing homes, and hospitals, typically employ
washing machines with separate automated detergent dispensers.
Generally, these institutional washing machines are larger and wash
greater volumes of laundry over time than standard consumer washing
machines used in homes. Typically, a separate, automated cleaning
product dispenser is connected to one or two industrial washing
machines to automatically deliver cleaning products, such as
detergent, bleach, rinse agent, etc., according to logic designed
or programmed into the dispenser.
[0004] In a broader sense, automated chemical product ("chemistry")
dispensers are useful in many different chemical application
systems, including cleaning systems relating to laundry operations,
warewashing operations (e.g., a dishwasher), water treatment
operations, and pool and spa maintenance, as well as other systems,
such as food and beverage operations and agricultural operations.
For example, chemical products used in a warewashing operation may
include detergent, de-ionized water, sanitizers, stain removers,
etc. Chemistry used in agriculture may include without limitation
pesticides, herbicides, hydration agents, and fertilizers. Other
applications of the present invention may be used in, without
limitation, dairies and dairy farms, (e.g., in teat dips);
breweries; packing plants; pools spas, and other recreational water
facilities; water treatment facilities, and cruise lines. Other
chemical products may include without limitation glass cleaning
chemicals, hard surface cleaners, antimicrobials, germicides,
lubricants, water treatment chemicals, rust inhibitors,
[0005] Automated chemical product dispensers can reduce labor and
chemistry costs by automatically delivering predetermined amounts
of chemicals in a proper sequence. Furthermore, some chemical
products can be hazardous in concentrated form; therefore,
automated chemical product dispensers reduce the risks of exposure
to operators, who would otherwise measure and deliver the chemical
products manually.
[0006] In a laundry operation, to coordinate the proper delivery of
cleaning product for each washing machine cycle, both the washing
machine and the dispenser are preferably programmed to run a given
"formula" for a particular type of item being washed. For example,
if the laundry operator is washing bed sheets, he or she selects a
washing machine selection corresponding to a set of cycles (i.e., a
formula) for "sheets" and selects a separate dispenser setting
corresponding to a "sheets" formula of chemical products (e.g.,
including possibly detergent, bleach, sanitizer, and rinse agent).
Therefore, the dispenser supplies the proper cleaning product (or
provides no cleaning product) for appropriate washer cycles, in
accordance with the selected formulas. In this manner, for example,
detergent is supplied to the washing machine during the wash cycle
and not during the rinse cycle.
[0007] Unfortunately, operator error (i.e., improper formula
selections on one or both of the washing machine and the dispenser)
can result in the cleaning products being supplied to the washing
machine during the wrong cycle or not at all. Such errors can
result in improperly washed or potentially damaged laundry items.
Other costly inefficiencies can include washing items without
filling the wash basin to capacity, which wastes water, energy, and
cleaning product and increases labor and maintenance costs.
[0008] In addition, individual institutional laundry accounts tend
to be geographically dispersed, requiring many individual field
service managers to physically visit individual laundry operations
or accounts periodically, to monitor product usage on a periodic
basis at those operations, and to provide the corrective
instructions to the corresponding laundry operators. Typically,
this manual method fails to provide the rapid feedback or the
cross-account analysis that can be helpful to laundry operators in
managing their operations.
[0009] Accordingly, it is desirable to maintain and analyze
automatically a real-time or historical log of operational data
detectable or storable by a dispenser or a dispenser-related
device, preferably in relation to corporate information, such as
work shifts, facility location, hotel occupancy rates, energy
costs, etc., so as to facilitate rapid corrective action. Existing
approaches, however, fail to provide the capability or capacity of
automatically detecting large amounts of dispenser data,
communicating and recording dispenser data and corporate data to a
central database, and analyzing the data to provide feedback to the
laundry operation and/or the dispenser, particularly across an
aggregation of multiple accounts within the same corporation.
SUMMARY OF THE INVENTION
[0010] A communications network coupling one or more chemical
dispenser sites to a server computer and a database is useful to a
corporation in managing its chemical product usage, as well as
other costs. For example, a given hotel corporation operates
multiple hotels throughout the nation. Each hotel, preferably
corresponding to an account, includes one or more laundry
operations (e.g., a dispenser site having a dispenser and one or
more washing machines). The dispenser or detergent vendor operates
a server computer and database to which dispenser data for one or
more laundry operations within the corporation are stored.
Exemplary dispenser data includes without limitation one or more of
the following data types: dispensed detergent amounts; dispensing
times, dates, and sequences; water temperature; water flow volumes;
chemical product type; machine identifiers; washing machine
signals; empty capsule indications; start/end of formula
indications, formulas, and other information originating at the
detector site, whether detected by a dispenser or by an associated
device (such as a remote temperature probe). Corporate data
relating to the laundry operation, such as account information,
alignment information, utility costs, employee shift information,
labor costs, and additional information relating to other aspects
of the corporation or laundry operation, can be also be stored and
analyzed alone or in combination with dispenser information.
[0011] By collecting and analyzing the dispenser and corporate data
in the database, a dispenser vendor can analyze this data to
generate performance information (such as product usage data) and
provide feedback to the customer. For example, a calculation of the
number of pounds of laundry washed per occupied room ("LbsOCR)" can
be made from a combination of dispenser data (e.g., the number of
loads, which corresponds to the number of completed formulas) and
corporate data (e.g., the number of occupied rooms). Furthermore, a
target can be set (statically or dynamically) for the LbsOCR
result, so that LbsOCR results that are above the target are
flagged as "out-of-spec." "Out-of-spec" results, which may indicate
inflated detergent, labor, and utility expenses, for example, can
be fed back to the customer to allow the customer to improve its
laundry procedures.
[0012] Furthermore, the analysis may be performed across multiple
accounts, such as multiple accounts within a single corporation or
organizational region, to compare, for example, one account in a
corporation with others accounts with the same corporation. An
alignment identifier is used to relationally group multiple
accounts. In this manner, for example, the LbsOCR of one account in
a corporation can be compared against the LbsOCR of other accounts
in the corporation to determine its relative performance. The
customer can then use this information to improve the laundry
procedures at poorer performing accounts.
[0013] In accordance with the present invention, the above and
other problems are solved by providing a monitor at a chemical
product dispenser to automatically detect and communicate dispenser
data. Real-time or historical dispenser data is communicated to be
stored in a central database in combination with an account
identifier and corporate data (e.g., an alignment identifier) to
facilitate analysis within and across accounts associated with a
laundry operator. Furthermore, all data associated with a
particular alignment identifier (e.g., a corporate identifier, a
regional identifier, etc.) may be consolidated for analysis,
providing, for example, a corporate customer with a broad view of
problem trends and overall corporate performance of laundry
operations in its multiple accounts. Furthermore, performance
targets, including dynamic performance targets, may be employed to
detect performance data that does not satisfy acceptable
criteria.
[0014] A data processing system for managing use of chemical
product in a chemical application system is provided. A chemical
product dispenser distributes the chemical product to the chemical
application system. A monitor module detects dispenser data based
on distribution of the chemical product by the chemical product
dispenser or some other detection mechanism associated with the
dispenser or dispenser site. A database is coupled to the chemical
product dispenser and stores the account identifier in association
with the dispenser data of the chemical product dispenser. The
database further stores corporate data in association with the
dispenser data and the account identifier. An analysis application
analyzes the dispenser data in relation with the corporate data to
characterize use of the chemical product in the chemical
application system.
[0015] A method and computer program product for managing use of
chemical product in a chemical application system corresponding to
a first customer account identified by an account identifier are
provided. The chemical product is distributed to the chemical
application system via a first chemical product dispenser. The
first dispenser data is recorded based on distribution of the
chemical product by the chemical product dispenser. The account
identifier is recorded in association with the dispenser data of
the first chemical product dispenser. Second dispenser data is
monitored from a second chemical product dispenser corresponding to
a second customer account. The first dispenser data of the first
chemical product dispenser is analyzed relative to the second
dispenser data of the second chemical product dispenser to
characterize the use of the chemical product in the chemical
application system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts a general purpose computer that implements
the logical operations of an embodiment of the present
invention.
[0017] FIG. 2A illustrates an exemplary communications network
including detergent dispensers coupled to a server computer in an
embodiment of the present invention.
[0018] FIG. 2B illustrates an exemplary topology of dispensers,
accounts, and alignments relative to a server computer in an
embodiment of the present invention.
[0019] FIG. 3 illustrates an exemplary database schema in an
embodiment of the present invention.
[0020] FIG. 4A illustrates a second portion of an exemplary
database schema in an embodiment of the present invention.
[0021] FIG. 4B illustrates a third portion of an exemplary database
schema in an embodiment of the present invention.
[0022] FIG. 5 illustrates an exemplary corporate summary report for
a fictional laundry operator in an embodiment of the present
invention.
[0023] FIG. 6 illustrates an exemplary unit summary report for a
fictional laundry operator in an embodiment of the present
invention.
[0024] FIG. 7 illustrates exemplary shift productivity and cost
reports for a fictional laundry operator in an embodiment of the
present invention.
[0025] FIG. 8 illustrates exemplary general productivity and cost
basis reports for a fictional laundry operator in an embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] In the following description of the exemplary embodiment,
reference is made to the accompanying drawings that form a part
hereof, and in which is shown by way of illustration the specific
embodiment in which the invention may be practiced. It is to be
understood that other embodiments may be utilized as structural
changes may be made without departing from the scope of the present
invention.
[0027] FIG. 1 depicts a general purpose computer capable of
executing a program product embodiment of the present invention.
One operating environment in which the present invention is
potentially useful encompasses the general purpose computer. In
such a system, data and program files may be input to the computer,
which reads the files and executes the programs therein. Some of
the elements of a general purpose computer are shown in FIG. 1
wherein a processor 101 is shown having an input/output (I/O)
section 102, a Central Processing Unit (CPU) 103, and a memory
section 104. The present invention is optionally implemented in
software devices loaded in memory 104 and/or stored on a configured
CD-ROM 108 or storage unit 109 thereby transforming the computer
system in FIG. 1 to a special purpose machine for implementing the
present invention.
[0028] The I/O section 102 is connected to keyboard 105, display
unit 106, disk storage unit 109, and disk drive unit 107.
Generally, in contemporary systems, the disk drive unit 107 is a
CD-ROM driver unit capable of reading the CD-ROM medium 108, which
typically contains programs 110 and data. Computer program products
containing mechanisms to effectuate the systems and methods in
accordance with the present invention may reside in the memory
section 104, on a disk storage unit 109, or on the CD-ROM medium
108 of such a system. Alternatively, disk drive unit 107 may be
replaced or supplemented by a floppy drive unit, a tape drive unit,
or other storage medium drive unit. The network adapter 111 is
capable of connecting the computer system to a network via the
network link 112. Examples of such systems include SPARC systems
offered by Sun Microsystems, Inc., personal computers offered by
IBM Corporation and by other manufacturers of IBM-compatible
personal computers, and other systems running a UNIX-based or other
operating system. In accordance with the present invention,
software instructions such as those directed toward communicating
data between a client and a server; detecting product usage data,
analyzing data, and generating reports may be executed by CPU 103,
and data such products usage data, corporate data, and supplemental
data generated from product usage data or input from other sources
may be stored in memory section 104, or on disk storage unit 109,
disk drive unit 107 or other storage medium units coupled to the
system.
[0029] FIG. 2A illustrates an exemplary communications network
including detergent dispensers 208 and 209 coupled to a server
computer 226 in an embodiment of the present invention. An
installation 200 includes washing machines 206 and 207, a detergent
dispenser 208, a control/monitor module 210, and a communication
device 212 located at a laundry operation associated with a
customer account identifier. An installation 202 illustrates a
second laundry operation in accordance with the present
invention.
[0030] Generally, FIG. 2A is intended to represent one or more
laundry operations coupled to the network 204. In an alternative
embodiment, an installation may include multiple dispensers coupled
to one or more washing machines each. Furthermore, although FIG. 2A
shows individual control monitors in communication devices for each
dispenser, in other embodiments, multiple dispensers may be coupled
to a single control/monitor module, and a single communications
device may be used to communicate data to and from multiple
dispensers. It should also be understood that I or more dispensers
may be associated with a single account, and one or more accounts
may be associated with a single alignment ID (e.g.,
corporation).
[0031] The detergent dispenser 208 is coupled via hose 234 to the
washing machine 206 and via hose 235 to washing machine 207.
Washing machine 202, for example, is coupled to the dispenser 208
via a communications link 224. It should be understood that a
dispenser can accommodate many different types of washing machines.
Some installations, for example, include modern dispensers coupled
to older washing machines via an analog interface.
[0032] Other detecting devices may be integrated with or used in
association with the dispenser at the dispenser site within the
scope of the present invention. For example, a flow meter for
detecting water flow volume through input hose 234 may be used to
generate detected dispenser data for storage in the database. Other
examples may include a remote or integrated water temperature
detector, a detector for determining the actual weight of laundry
items in a wash basin, and other detection operations to provide
detected dispenser data at the dispenser site.
[0033] In an embodiment of the present invention, the dispenser 208
supplies detergent and other cleaning products to the washing
machine 206. Preferably, the detergent dispenser 208 receives
containers of solid cleaning products into receptacles 214, 216 and
218. In an alternative embodiment of the present invention, four
receptacles are provided by a dispenser. Accordingly, a dispenser
having one or more receptacles for receiving liquid or solid
chemical products is contemplated within the scope of the present
invention.
[0034] An input hose 220 receives hot water from the facility's hot
water system (not shown). Preferably, the water temperature is
120.degree. F. or greater. The hot water mixes with the solid
cleaning product mounted in the detergent dispenser 208 by flowing
through the solid cleaning product until a required amount of the
cleaning product is mixed with or dissolved into the hot water. The
amount of cleaning product is measured directly using a technique
detailed in U.S. patent application No. 4,845,965, entitled "METHOD
AND APPARATUS FOR DISPENSING SOLUTIONS"; U.S. patent application
No. 4,858,449, entitled "CHEMICAL SOLUTION DISPENSER APPARATUS AND
METHOD OF USING"; and U.S. patent application No. 4,964,185,
entitled "CHEMICAL SOLUTION DISPENSER APPARATUS AND METHOD OF
USING", all assigned to the assignee of the present invention.
[0035] After a specified amount of cleaning product is supplied to
the washing machine 206 (i.e., an example of a chemical application
system), the dispenser 208 cuts off the cleaning product supply to
the washing machine 206. The washing machine 206 receives the water
and cleaning product mixture via hose 234, which continues its
cycle with the supplied cleaning product in its basin. The
dispenser is then flushed with fresh water from intake hose 220.
The fresh water flows from the dispenser 208 through the hose 234
into the washing machine 206. The water and chemistry in the wash
basin is applied to the laundry items during the washing machine
cycle. After the cycle completes, the wastewater and chemistry are
dumped from the basin into the facility's sewage line via hose
222.
[0036] Thereafter, the next washer cycle is signaled to the
dispenser 208 from the washing machine 206 via link 224, which
preferably consists of thirteen wires, although other
communications links are contemplated within the scope of the
present invention. In an embodiment of the present invention, the
digital signal informs the dispenser 208 to transition to the next
state in the cleaning product formula. In an embodiment having a
washing machine providing analog cycle signals, the analog signals
are preferably converted to digital signals before transmission to
the dispenser.
[0037] Although a washing machine is an example of a chemical
application system, other chemical application systems are
contemplated within the scope of the present invention. Other
examples include, without limitation, chemical dispensers used in
dishwashers; chemical application systems for "clean in place"
systems; water sanitizing systems such as, but not limited to, bath
and spa systems; and herbicide dispensers in agricultural
settings.
[0038] In an embodiment of the present invention shown in
installation 200, the control/monitor module 210 is a processor
driven control and monitoring circuit that preferably (1) controls
the dispensing of cleaning product in accordance with selections
made by a laundry operator, and/or (2) detects the amount and
sequence of dispensed cleaning product, the signals received from
the washing machine over communications link 224, the temperature
of hot water flowing through the dispenser 208, and other
parameters including time, date, and duration of each wash/dispense
cycle. In an alternative embodiment of the present invention, the
operation of the control/monitor module 210 may be limited to
detecting data for communication to the database. Preferably, the
control/monitor module 210 also includes a storage medium, such as
a semiconductor memory device or a magnetic or optical storage
device, for temporarily storing the dispenser data locally and for
storing dispenser system data, such as formulas, dispenser numbers,
account numbers, etc. However, the storage medium may be omitted in
an alternative embodiment, particularly if generally continuous
communication of dispenser data is made to a remote database or
storage medium.
[0039] The communications device 212 is coupled to the
control/monitor module 210 (1) to receive commands from the
communications network 204 and (2) to access data detected and
stored by the control/monitor module 210, including historical
detected data and dispenser system data stored on the local storage
medium. The communications device 212 may be programmed to access
the communications network 204, preferably by a LAN (local area
network), WAN (wide area network), a dial-up connection, or another
well-known network connection.
[0040] In an embodiment of the present invention, the
communications device 212 periodically accesses a server computer
226 to provide data for storage in the database 228. As such, the
communications device 212 preferably accesses real-time data
detected by the control/monitor module 210 and any historical data
stored on a local storage medium for transfer to the database 228.
In an alternative embodiment, the communications device 212
maintains communications with the server computer 226 over the
communications network 204 continually; therefore, the local
storage medium is unnecessary for storing detected data. Instead,
the communications device 212 continually transmits real-time
product usage data to the server computer 226. In this embodiment,
a small cache device may nevertheless be employed to accommodate
network congestion or other communication delays at the
communications device 212.
[0041] The communications device 212 can also receive commands via
the communications network 204 to provide a feedback loop to the
laundry operation or the dispenser. These commands are transferred
to the control/monitor module 210. Such commands may include
formula updates, calibration commands, test commands, alarm
commands, interactive communications between the laundry operator
or service technician and the dispenser vendor or server computer
facility, and other remote control commands. This capability
facilitates the management of multiple, geographically dispersed
laundry operations by allowing the operator, the service
technician, or the dispenser vendor to distribute control commands
from a central location via the communications network 204. An
example of the use of the feedback loop involves updating a formula
stored in the storage medium of a dispenser.
[0042] The client computer 230 represents a thick or thin client
coupled to the server computer 226 via a communications link 234,
such as a LAN. The client 230 initiates an analysis application
resident on the client computer 230 or resident on the server
computer 226 to generate reports, such as report 232 providing
analysis of dispenser data and corporate data recorded in the
database 228, and may also include other product usage data derived
from a combination of the dispenser data and the corporate data.
Broadly, "product usage data" refers to data relating to product
usage or use of a chemical application system, which may include
without limitation chemical application system usage information,
labor usage information, utility usage information, procedural
error information, and performance information. Furthermore, in one
embodiment of the present invention, the client computer 230
initiates commands through the communications network 204 to the
communication devices of installation 200 and 202 for remotely
managing the laundry operation (e.g., changing formulas).
[0043] A server computer 250 is optionally coupled to the server
computer 226 to provide corporate data to the database 228.
Corporate data may relate to one or more accounts in association
with an alignment ID and may include without limitation labor,
energy, water, detergent, and sewage costs, shift personnel
identifiers, and the number of occupied rooms for given time
periods. By communicating the corporate data automatically from the
laundry operator's corporate or account business systems, manual
entry of corporate data can be avoided. However, in an embodiment
of the present invention, manual entry is contemplated, for
example, using the client computer 230. Furthermore, the server
computer 250 may be linked to other networks via a communications
link 252.
[0044] FIG. 2B illustrates an exemplary hub and spoke topology of
dispensers, accounts, and alignments relative to a server computer
250 in an embodiment of the present invention. Other topologies,
such as a daisy chain topology or a ring topology, are also
contemplated within the scope of the present invention. The server
computer 250 is coupled to multiple accounts (such as a hotel
account 276 or hospital account 254 ). Within each account are one
or more dispensers (such as dispenser 290 ). Each account may
include an alignment identifier to associate it with other
accounts, as indicated by groupings (or "alignment groupings") 258,
260, 262, 264, and 266. The grouping relationships may be
hierarchical (see groupings 258 and 260 ), or the grouping
relationships may cut across hierarchical boundaries (see grouping
262 ). Note also that accounts 268 and 270 are not included in a
grouping, preferably meaning that no alignment identifier is
specified for these two accounts.
[0045] For example, grouping 260 indicates an alignment within a
healthcare and lodging corporation. Accounts 256, 272, 274, 276,
278, 280 and 282 are accounts within the healthcare and lodging
corporation. Furthermore, grouping 264 indicates a grouping of
hospital accounts within the healthcare and lodging corporation,
and a grouping 258 indicates an organizational alignment of hotels,
such as a regional alignment (e.g., hotels in the Eastern United
States), within the healthcare and lodging corporation. A grouping
266 indicates an alignment within a hospital corporation and
includes accounts 254, 286, and 288. The grouping 262 is associated
with hospital accounts in general and cuts across boundaries of the
two corporate alignments. The grouping 262 is useful for analyzing
product usage data across a given industry, for example.
[0046] FIG. 3 illustrates a first portion of an exemplary database
schema in an embodiment of the present invention. Each large box
represents a data table used in the exemplary database 228 shown in
FIG. 2A. The name of each data table is label at the top of each
box (e.g., "tb1Acct"). "Table" generally refers to data arranged in
rows and columns. In relational database management systems,
information is primarily stored in the form of tables, with columns
representing individual data fields in the table and rows
representing individual entries in the table. In FIG. 3, the data
fields (i.e., columns) of each table are listed below the label of
the table.
[0047] A tb1Align table 300 contains information about a group of
accounts. In a preferred embodiment, each row of the tb1Align table
300 corresponds to a given customer that manages one or more
laundry accounts. The data field AlignID is a unique key for each
row of the tb1Align table 300. The data field AlignID is an example
of an alignment identifier useful for analysis of database
information for a given corporation or other organizational
category. It should be understood that, in an alternative
embodiment, multiple levels of alignment ID may be used within the
scope of the present invention. For example, a first alignment ID
may correspond to a corporate customer level, and a second
alignment ID level may correspond to regional divisions within the
overall corporation. The data field AlignName contains a textual
descriptor or label of the business entity corresponding to the
tb1Align table entry.
[0048] The data field AlignFdata and AlignLdata, exemplary time
period specifiers, indicate the first and last dates of a time
period for which valid data exists in relation to a given AlignID.
In this manner, the analysis application need not search all
available data in the database to determine whether a requested
time period contains valid data for a particular alignment ID. The
label "1", positioned relative to the data field AlignID in the
tb1Align table 300, and the infinity symbol (:), positioned
relative to the data field AlignID in the tb1Acct table 302,
indicate a one-to-many relationship between the tb1Align table 300
and the tb1Acct table 302.
[0049] A tb1Acct table 302 contains information about a given
account (e.g., the laundry operations at a particular facility
corresponding to a given AlignID). The data field AcctID is a
unique key for a given account within the database. The data field
AssocID includes a unique identifier representing a key to a
tb1Assoc table 318. The tb1Acct table 302 also contains a data
field IsActive, which specifies whether the associated account is
currently under contract, currently operational, or some other
active status. In a preferred embodiment of the present invention,
the data field IsActive is a yes/no parameter, meaning that the row
is the active row for a particular account, or it is not. The
tb1Acct table 302 also contains a data field DateMod which includes
the creation date for the tb1Acct table 302. A data field Acct#
includes an account number assigned to the given account.
Preferably, the account number is specified by the detergent
vendor, dispenser vendor, or by some other source, so as to
correspond to other corporate data. A data field AcctName is
included in the tb1Acct table 302 and specifies a textual
identifier for the account (e.g., an individual account of the
fictional corporation "MegaHotel Corp."). The data field AlignID
corresponds to an AlignID key from tb1Align table 300 to establish
a relationship between the two tables.
[0050] The data fields AcctFdata and AcctLdata, exemplary time
period specifiers, indicate the first and last dates of a time
period for which valid row data exists in relation to a given
AcctID. In this manner, the analysis application need not search
all available data in the database to determine whether a requested
time period contains valid data for a particular account ID.
[0051] A tb1AlignTgt table 314 specifies the performance targets of
the laundry operation corresponding to an alignment ID stored in
data field AlignID. The performance targets are used to determine
when a particular operational result is "out-of-spec" (i.e.,
outside of desired target parameters). The data field TargetID
represents the unique key for each row of the tb1AlignTgt table
314. The data field IsCurrent indicates whether the given row of
the tb1AlignTgt table 314 is current for the value stored in the
data field AlignID, relating back to the tb1Align table 300.
Because the tb1AlignTgt table 314 relates to the tb1Align table 300
via a data field AlignID, the table parameters stored in the
tb1AlignTgt table 314 are assigned for a given alignment (e.g.,
corporation). Alternative target parameters can be configured for
additional alignment levels or accounts by way of additional target
tables. Furthermore, the target parameters may be changed over time
using the data field IsCurrent and the data fields StIntDate and
EndIntDate, which describe the first and last date of a time period
during which the associated target parameters are valid.
[0052] The data field LbsOCR defines a target parameter for pounds
(lbs.) per occupied room. The data fields S1Lds/Day, S2Lds/Day and
S3Lds/Day define target parameters for the number of loads per day
washed during three shifts. The data field Temp defines a target
parameter for the hot water temperature supplied to a washer,
preferably as detected by the dispenser.
[0053] In an embodiment of the present invention, the target
parameters are specified with predetermined values that can be
updated manually or automatically over time by adding new rows in
the tb1AlignTgt table 314. In an alternative embodiment of the
present invention, however, the target parameters may be a function
of other data within the database. For example, by way of a
database query, the average LbsOCR may be calculated and entered in
the tb1AlignTgt table 314 for a particular time period and
alignment ID. In an alternative embodiment, the target is
dynamically set by taking the recent corporate average (i.e., the
last 30 days of detected dispenser data and corporate data) and
adjusting it by 20% to set a new target. For example, using a
corporate average of 14.7 lbs. per occupied room over the past
thirty days, a dynamic target of 17.64 lbs. per occupied room
(14.7*1.2=17.64) is set. Therefore, all accounts have a lbs. per
occupied room exceeding 17.64 are considered "out-of-spec".
[0054] A tb1Census table 304 describes occupancy data relating to a
particular account, as represented by data field AcctID and a
particular alignment, as represented by data field AlignID. The
tb1Census table contains a data field CensusID, which is a unique
key for the table. The tb1Census table 304 also includes a data
field SDate and EDate, which are exemplary time period specifiers
defining the start and end date of a period for which the occupancy
data in a given row is valid. In other words, if the laundry
operator provides occupancy data, as supplied in data field
Occpncy, on a weekly basis, then the start and end dates would
define a week. Alternatively, for example, a daily occupancy result
would have start and end dates that are equal or that would span a
twenty-four hour period from one day to the next.
[0055] The tb1GenInfo table 316 contains information about costs,
energy usage, and shift start times, although other general
information parameters may be added within the scope of the present
invention. A data field GenInfoID includes a unique key for each
row of the tb1GenInfo table 316. The data fields StIntDate,
EndIntDate and IsCurrent specify the time period for which a
particular row of the tb1GenInfo table 316 is valid and whether it
is the current entry in the tb1GenInfo table 316. The data fields
StIntDate and EndIntDate are exemplary time period specifiers. The
data field AcctID relates the row of the table tb1GenInfo table 316
to a particular account in the tb1Acct table 302. The date of the
tb1GenInfo table 316 may be entered manually or it can be delivered
automatically through a computer link to an appropriate source
(e.g., a utility server, a hotel server, a corporate server,
etc.).
[0056] The data fields Shift1, Shift 2, and Shift 3, indicate the
start times of each work shift. In an alternative embodiment, start
and end times of each work shift may be included in the tb1GenInfo
table 316. The data field Labor indicates the cost per hour of the
laundry operation labor force. In an alternative embodiment, labor
can vary on a per shift basis or on an hourly basis (e.g.,
according to shift premiums) and may be specified with more detail
in the tb1GenInfo table 316 in additional fields. Utility costs are
represented by data fields Water, Sewage, and Energy. The cost of
water is preferably represented on a per 1,000 gallon basis. The
cost of sewage treatment is provided on a per 1,000 gallon basis.
The cost of energy is indicated as the total energy used in therms
by the laundry operation. A therm is a unit used to measure a
quantity of heat and equals 100,000 British thermal units (BTUs).
The data field TempRise indicates the number of degrees in
Fahrenheit or Celsius that the water from the public utility must
be heated in order to meet the target water temperature. The data
fields P1Cost, P2Cost, P3Cost, and P4Cost indicate the cost of
cleaning product on a per case basis. Alternative costing measures
may be used, including cost of product on a per capsule basis or on
a per measured amount basis.
[0057] The tb1Disp table 306 includes a unique key in data field
DispID. The tb1Disp table 306 also includes the data field storing
in an AcctID to relate the tb1Disp table 306 to an account. A data
field Disp# stores a dispenser number assigned to the dispenser
within an account. A password is stored in the data field Password,
which regulates access to the program logic of the dispenser
associated with each entry. For example, in order to change
formulas at a given dispenser, a field service manager must enter
the associated password into a keypad on the dispenser.
[0058] A data field 4thProduct is a yes/no field indicating whether
the dispenser supports the dispensing of a fourth product. A data
field MultFeeds is a yes/no parameter, indicating whether the
dispenser supports multiple feeds of a given product per formula.
That is, some dispensers support multiple cycles that request the
same detergent to be dispensed within a particular formula. The
data field MultFeeds stores the indicator of whether the dispenser
supports such a capability. The data fields DispFdata and
DispLdata, exemplary time period specifiers, define the first and
last dates for which the data in a given row in the tb1Disp table
306 is valid.
[0059] A tb1Assoc table 318 includes a unique key in data field
AssocID. An identifier of a particular sales district is contained
in the data field DistrictID. A second level of hierarchy in the
district is contained in the data field AreaID and the first and
last name of the associate is stored in the data fields FirstName
and LastName. Preferably an associate is a person responsible for
managing an account, such as a field service technician or field
service manager.
[0060] A tb1Mach table 308 contains a unique key in data field
MachID. A data field Machine# contains a number identifying the
machine (e.g., "1" or "2" in a dispenser that supports up to two
machines) for each dispenser associated with the dispenser
identifier in the data field DispID of the tb1Mach table 308.
Alternative embodiments of the present invention may serve more
than two machines. The data field MachWt indicates the capacity of
the corresponding machine (e.g., thirty-five pounds or one hundred
pounds). The data field ChartStop indicates whether the machine
supports a command that puts the washing machine on hold,
particularly during a bath cycle. A data field MicroMode indicates
whether the dispenser is capable of taking signals in a specific
format. Preferably, the specific format specifies both the product
that the washing machine requests as well as the formula. In this
fashion, the laundry operator can merely program the washing
machine, for example, for "sheets", and the washing machine can
communicate the corresponding formula identifier to the dispenser,
rather than relying on manual settings on both the washing machine
and the dispenser.
[0061] A tb1Formulas table 310 contains information about the
formulas supported by a particular machine, which is specified by
the identifier in the data field MachID. A unique key is stored in
the data field FormID. A number associated with a particular
formula is stored in the data field Formula#. In a preferred
embodiment, the data field Formula# typically includes the numbers
1 through 10; however, the number of formulas need not be limited
to ten formulas within the scope of the present invention. A data
field FrmLkUpID stores a unique identifier used to look up a
particular formula name and weight factor in the tb1FormLk table
312. The data fields P1Amt, P2Amt, P3Amt, and P4Amt store amounts
of products to be dispensed during requested cycles of the washing
process. P1, P2, P3, and P4 correspond to product numbers assigned
to the various receptacles in the dispenser, such as detergents,
bleaches, stain remover and rinse agents. Although only one amount
is illustrated for each product in the tb1Formulas table 310 of
FIG. 3, additional amount fields may be added for each product in
support of the multiple feed capability identified in the tb1Disp
table 306. In a preferred embodiment, three amounts are allowed for
P1, three amounts are allowed for P2, one amount is allowed for P3,
and three amounts are allowed for P4.
[0062] A tb1Signal table 320 contains information about signals
received in a given dispenser. A unique key is stored in the data
field SignalID. The dispenser ID associated with the dispenser
receiving the signal is stored in the data field DispID. The unique
key is stored in the data field ProdID and used to look up product
information in the tb1PrdLkUp table 322. The data field Signal
contains a number for the signal received from a given dispenser.
In one embodiment of the present invention, the data fields PFA,
PFB, and PFC contain product factor codes useful in determining the
amount of cleaning product dispensed by a given dispenser. In an
alternate embodiment, one or more product factor codes (e.g.,
PF1-PFn) may be used for each signal. Furthermore, one or more of
the illustrated data fields may contain a null value (e.g.,
representing that the product factor is not used).
[0063] The tb1FormLk table 312 contains information relating to
particular formulas supported by a dispenser. The data field
FrmLkUpID is associated with a corresponding ID in the tb1Formulas
table 310. The data field Formula contains a textual or numerical
formula name or label for a given formula. The data field WtFactor
contains an industry and vendor develop factor correlating the
weight supported by a particular washer with a given laundry item.
For example, the proper loading of a 100 lbs. washing machine basin
with sheets is deemed by the industry or vendor to be 90 actual
lbs. of dry linen, whereas the proper loading of a 100 lbs. basin
with blankets is 70 lbs. Therefore the WtFactor for sheets is 0.9
and the WtFactor for blankets is 0.7.
[0064] A tb1PrdLkUp table 322 provides lookup data for given
products. The data field ProdID contains a unique key for each
product. The data field ProdType contains a product number or
category relating to a product in a vendor's inventory. The data
field ProdName contains a textual or numerical label identifying a
given product. A data field g/Caps indicates the number of grams
per capsule of product. The data field Caps/Case indicates the
number of capsules in a case of the given product. A data field
EmptyWt indicates the weight of an empty capsule. A data field
DisplayNm indicates a name to be displayed on an LED (light
emitting diode) display on a dispenser.
[0065] FIG. 4A illustrates a second portion of an exemplary
database schema in an embodiment of the present invention. A
tb1DataArch table 400 contains exemplary detected dispenser data
communicated by a dispenser and communicated to the database. The
data field ID is a unique key for each tb1DataArch table 400 entry.
A data field DateArch contains the date of the recording of a given
row of the tb1DataArch table 400. Date fields AcctID and AlignID
correspond to unique keys of the tb1Acct table 302 and the tb1Align
table of FIG. 3. The data fields Date and Time correspond to the
date and time of a given event in the dispenser. The data field
Date Time is preferably a concatenation or other combination of the
date and time field entries. The data fields MachID, FormID, and
SignalID correspond to the unique keys in the tb1Mach table 308,
the tb1Formulas table 310, and the tb1Signal table 320 of FIG. 3.
The data field Amount preferably contains a detected amount of
product dispensed for a particular event or for a given event. A
data field Code contains an event code to identify a particular
event, as described in the tb1EvntCde table 402. A data field Inf
contains informational data such as end of formula, start of
formula, capsule empty signals, and other informational data
detected by the dispenser.
[0066] A tb1EvntCde table 402 includes an EvntCode data field
associated with the data field Code in tb1DataArch table 400. A
data field Text includes text relating to the event code. The text
may be displayed in a report to improve the readability of archived
data.
[0067] Table 1 illustrates exemplary dispenser data communicated to
a database of an embodiment of the present invention. Dispenser
data can also include information based on detection of water
temperature from a remote or integrated temperature probe,
detection of the actual weight of laundry items in a wash basin,
detection of water flow volume through a hose, and other detection
operations at the dispenser site. In one embodiment of the present
invention, code 68 indicates "start of formula", code 4 indicates a
dispensing event, and code 36 indicates an "end of formula". Other
codes are contemplated within the scope of the present invention,
including a code indicating an empty product capsule. Furthermore,
in an embodiment of the present invention, the "INFO" field
indicates either water temperature (in association with codes 68
and 4) or complete formula time (in association with code 36 ).
1TABLE 1 Exemplary Dispenser Data ACCNT# DISP# DATE TIME MACH#
FORM# PROD# AMOUNT INFO CODE 98494825 1 Apr. 1, 1998 2:44:00 AM 1 6
1 60 120 68 98494825 1 Apr. 1, 1998 2:56:00 AM 1 6 4 4 122 4
98494825 1 Apr. 1, 1998 2:57:00 AM 1 6 3 8 13 36 98494825 1 Apr. 1,
1998 3:22:00 AM 1 1 1 120 116 68 98494825 1 Apr. 1, 1998 3:31:00 AM
1 1 2 25 118 4 98494825 1 Apr. 1, 1998 3:49:00 AM 1 1 4 4 120 4
98494825 1 Apr. 1, 1998 3:49:00 AM 1 1 3 8 27 36 98494825 1 Apr. 1,
1998 4:07:00 AM 1 1 1 120 122 68 98494825 1 Apr. 1, 1998 4:16:00 AM
1 1 2 25 116 4 98494825 1 Apr. 1, 1998 4:33:00 AM 1 1 4 4 118 4
98494825 1 Apr. 1, 1998 4:34:00 AM 1 1 3 8 27 36 98494825 1 Apr. 1,
1998 4:42:00 AM 1 1 1 120 120 68 98494825 1 Apr. 1, 1998 4:52:00 AM
1 1 2 25 122 4 98494825 1 Apr. 1, 1998 5:10:00 AM 1 1 4 4 116 4
98494825 1 Apr. 1, 1998 5:10:00 AM 1 1 3 8 28 36 98494825 1 Apr. 1,
1998 5:29:00 AM 1 4 1 125 118 68 98494825 1 Apr. 1, 1998 5:40:00 AM
1 4 2 25 120 4 98494825 1 Apr. 1, 1998 5:56:00 AM 1 4 3 0 27 36
98494825 1 Apr. 1, 1998 6:16:00 AM 1 2 1 100 122 68 98494825 1 Apr.
1, 1998 6:26:00 AM 1 2 2 18 116 4 98494825 1 Apr. 1, 1998 6:44:00
AM 1 2 4 4 118 4 98494825 1 Apr. 1, 1998 6:45:00 AM 1 2 3 8 29 36
98494825 1 Apr. 1, 1998 7:41:00 AM 1 1 1 120 120 68 98494825 1 Apr.
1, 1998 7:51:00 AM 1 1 2 25 122 4 98494825 1 Apr. 1, 1998 8:08:00
AM 1 1 4 4 116 4 98494825 1 Apr. 1, 1998 8:08:00 AM 1 1 3 8 27
36
[0068] FIG. 4B illustrates a third portion of an exemplary database
schema in an embodiment of nt invention. A tb1FieldStp table 404
includes information captured by a field service technician at an
account site. A data field FSID is a unique key in the tb1FieldStp
table 404. A data field AcctID is a unique key from the tb1Acct
table 302 of FIG. 3. A data field Date contains the date of a given
field stop by a technician. Data fields InvP1, InvP2, InvP3, and
InvP4 contain data entered into a dispenser or into a corporate
database that can be communicated to the database of an embodiment
of the present invention, representing the inventory of products
P1, P2, P3 and P4 at a given account. Data field AddP1, AddP2,
AddP3, and AddP4 represent the amount of given products shipped to
an account, preferably received from a corporate database.
[0069] A tb1FSData table 406 contains data corresponding to each
dispenser serviced during a field stop. FSDataID is a unique ID in
the tb1IFSData table 406. The data field FSID corresponds to a
unique key of the tb1FieldStp table 404. The data field DispID
corresponds to a unique key of the tb1Disp table 306 of FIG. 3.
Data fields P1Wt, P2Wt, P3Wt, and P4Wt contain information recorded
by a technician as to the amount of product left in a capsule of a
given product during the field stop.
[0070] A data field Mach# includes a machine number for the washing
machine connected to a given dispenser. The machine number stored
in data field Mach# corresponds to the machine from which tests are
performed by the technician in the basin of the washing machine.
Preferably, the technician extracts a sample of wash water from the
basin of the machine to test the accuracy of the dispenser. A data
field Form# indicates the current formula being dispensed by the
dispenser to a given machine. A data field AlkTitrn indicates the
results of a titration procedure measuring the alkalinity of the
water in the basin of the machine under test in parts per million
(PPM). A data field CL2Titrn indicates the results of a titration
procedure measuring the chlorine in the water in the basin of the
machine under test in PPM. A data field pH indicates the acidity of
the water in the wash basin. A data field Hours indicates the
number of hours for which the dispenser has run in a given account.
A data field Notes contains any notes recorded by the technician
during the field stop. A data field PrevDate indicates the last
time a field stop was made at a given dispenser. Data fields
PrevP1Wt, PrevP2Wt, PrevP3Wt, and PrevP4Wt indicate the amount of
product left in a capsule for each product during the last field
stop.
[0071] FIG. 5 illustrates an exemplary corporate summary report 500
for a fictional laundry operator in an embodiment of the present
invention. The report 500 is generated by an analysis application
executing within the client/server architecture illustrated in FIG.
2A. Examples of analysis applications include small-scale and
medium-scale database applications written in Microsoft Access
running on a client computer but can also include large
server-based database applications, pattern recognition
applications, and neural net systems using minicomputers and
mainframes. The dispenser data and/or corporate data used to
generate the report is preferably retrieved from the database 228
of FIG. 2A, analyzed by the analysis application, and displayed to
a user on the client computer 230. Alternatively, the report may be
saved as a document file or printed out in hard copy.
[0072] Various elements of the report 500 correspond to data fields
described by database schema of FIGS. 3 and 4 or are derived from
data in such data fields. The report 500 relates to a summary of
laundry operations (i.e., accounts) for a fictional hotel
corporation. The hotel corporation in this example owns or manages
multiple hotel facilities, each hotel facility having a
corresponding account ID. Furthermore, each account reported in
report 500 shares a common alignment ID to indicate, for example,
that the individual accounts are managed by the same hotel
corporation.
[0073] In an alternative report (not shown), summary and historical
reports are available on an account-by-account basis, allowing the
laundry operator a means of tracking and detecting wash errors and
cost issues for an individual account. However, some laundry
operation problems are not apparent on an account-by-account basis,
and only reveal themselves when analyzed across multiple accounts.
Therefore, a corporate summary, spanning multiple accounts
corresponding to a single alignment ID, is useful in identifying
trends and corporate-wide laundry operation problems. Accordingly,
the hotel corporation can effectively manage its laundry operations
on both an account-by-account basis and a corporate-wide basis to
manage costs and improve efficiency. Such information, for example,
may be useful in developing training programs for laundry
employees, negotiating washer and dispenser maintenance agreements,
negotiating chemical product supply agreements, and coordinating
scheduled maintenance throughout a corporation's multiple laundry
operations.
[0074] The exemplary report 500 shows summary data relating to a
time period from May 1, 1999 to May 30, 1999, as shown in report
section 502. The number of days in the time period is also shown.
The number of units ("# of Units") field shows the number of
accounts included in the summary report, as grouped according to
their alignment ID. The "occupancy" label shows the number of
occupied rooms within all of the corporation's accounts (e.g.,
individual hotel facilities) included in the summary. The "Laundry
Lbs" label shows the number of pounds of laundry washed during the
time period. The "Lbs/Occupied Rm" label shows a calculation based
on the "Occupancy" and "Laundry Lbs" fields. The Lbs/Occupied Rm
result is an example of product usage data derived from a
combination of dispenser data and corporate data, demonstrating an
advantage of an embodiment to the present invention. A dispenser is
capable of detecting the number of washes performed during a
particular time period by virtue of the number of times it provides
cleaning product to a washing machine. This dispenser data can be
communicated to the database via a communications device. In
addition, the number of occupied rooms corresponding to a
particular account is corporate data used to manage the business
operations within a corporation. This corporate data may also be
communicated to the database, for example, via a communications
link from a business server computer.
[0075] Typically, the pounds of laundry washed is estimated based
on the capacity of each washing machine unit in an account and the
number of washes performed, which are examples of dispenser data. A
method of estimating the pounds of laundry washed calculates the
product of the washing machine size (e.g., 100 lbs.) times the
WtFactor assigned to given type of laundry item. Over a period of
time, the estimated pounds of laundry in each washed load are
summed. In an alternative embodiment, a laundry operation having
the capability of actually weighing the items in each load of
laundry, perhaps by having a weighing mechanism within the washer
itself, is also contemplated within the present invention.
[0076] The bar graph 504 shows the average occupancy (in units of
1,000 occupied rooms) on a monthly basis over a one year period.
The bar graph 504 data is generated from real-time or historical
occupancy data, which is an example of corporate data, received
from the corporation and entered manually or automatically into the
database. Bar graph 506 illustrates the pounds per occupied room on
a monthly basis over a one year period. The data reflected in bar
graph 506 is also derived from dispenser data and corporate data
recorded in the database.
[0077] FIG. 6 illustrates an exemplary unit summary report for a
fictional corporation in an embodiment of the present invention.
The unit summary report 600 is generated by an analysis application
running on the client computer or the server computer in an
embodiment of the present invention. The bar chart 602 shows the
number of units (i.e., accounts) having a calculated average pounds
of laundry per occupied room. The bars indicated by region 614
indicate the number of units that are "out of spec" or outside of a
desired threshold or target, as defined by target parameters from
an alignment target table or account target table in database 228
of FIG. 2A. Such information is useful to control energy costs, for
example. If a washing machine is not being run with full loads (as
detectable in graphs 506 and 602 and report 608 ), energy needed to
heat the water and run the washing machines is wasted on extra
loads.
[0078] The report section shown at 608 profiles the pounds of
laundry washed per occupied room, including the corporate average,
the number of units out of spec, the number of units out of spec
for more than ninety days, and the potential utility and labor
savings available if the out-of-spec units were brought within
target parameters. The "potential savings" result demonstrates a
particularly useful advantage in combining dispenser data and
corporate data into a central repository or database for analysis
of remotely distributed laundry operations. Furthermore, if the
out-of-spec units are distributed across multiple accounts, the
magnitude of potential utility and labor savings would not have
been as significant as they are when analyzed on a corporate-wide
basis. The use of an alignment identifier allows analysis of
selected aligned accounts across the entire corporation, an
organizational component, or a geographical region, and amplifies
management possibilities on a corporate-wide basis.
[0079] The bar chart 604 shows the number of units having a given
average hot water temperature within a corporation. Hot water is a
particularly crucial factor in the efficient performance of
cleaning products and washing machines. In an embodiment of the
present invention, a hot water temperature of 120.degree. F. or
greater is preferred for optimal cleaning performance, particularly
for bleaching and oil removal. The bar chart 604 provides means for
analyzing the hot water temperature on a corporate-wide basis. The
results indicated by region 616 indicate the number of units that
are out-of-spec relative to hot water temperature. In a preferred
embodiment of the present invention, hot water temperature is
measured by the dispenser as it flows through the dispenser and
mixes with the solid cleaning products, although in an alternative
embodiment, the hot water temperature may be measured separately by
a remote sensor and provided to the database as corporate data.
[0080] Procedural error bar graph 606 and a report section 612 show
the number of units having a given average of loads with procedural
errors. A procedural error results when a dispenser setting and the
washer setting are not set to correspond to the same wash item
type. A procedural error is detected when the dispenser, being set
to a given setting, expects washer signals in accordance with the
selected formula. If the washer fails to provide the expected
signals (e.g., if the dispenser is expecting a bleach signal from
the washer, but never receives it), a procedural error will be
flagged and communicated to the database. The analysis application
sums the number of units having an average given number of errors
during a specified time period and generates the bar graph 606 to
illustrate the results. The results indicated by region 618
indicate the number of units that are out-of-spec relative to the
average percentage of loads with procedural errors. The report 612
illustrates the corporate average across all or a predetermined set
of accounts. The report 612 also indicates the number of units that
are out-of-spec and the number of units that are out-of-spec for
greater than ninety days.
[0081] An alternative method of detecting procedural errors uses
timing discrepancies between an actual formula time and an expected
formula time. For example, when the washer program is correct a
formula may require 25 minutes to complete from signal 1 to signal
3. If a wrong formula is used on the washer (relative to the
setting on the dispenser), the washer program may only require 20
minutes (e.g., without a bleach cycle). This discrepancy is flagged
as a procedural error.
[0082] FIG. 7 illustrates exemplary shift productivity and cost
reports for a fictional laundry account in an embodiment of the
present invention. A corresponding report may be generated for an
entire corporation or other organization subdivision, in accordance
with the alignment ID. The report 700 includes individual reports,
such as summary report section 702, a pie chart 706, and shift
productivity bar graphs 704, 708 and 710. A legend 712 is also
illustrated in report 700. The report section 702 includes a time
period, the number of days included in the time period, the total
occupancy during the time period, the pounds of laundry washed
during the time period, the average water temperature during the
time period, the number of wash loads during the time period, and
the number of procedural errors detected during the time period.
Using corporate data available from the database, in combination
with industry accepted formulas or other actual corporate data, a
pie chart 706 illustrates the allocation of expenses relating to
the time period shown in report section 702.
[0083] The bar graph 704 illustrates the number of loads per day
washed during the time period and divided by shifts. As shown by
the legend 712, the bar graph 704 shows both the average loads
washed per day during the time period, and a historical average
calculated over the life of the account. The bar graph 708
illustrates the number of procedural errors detected per day on a
per shift basis. As shown by the legend 712, the bar graph 708
shows both the average errors occurring during the time period, and
a historical average calculated over the life of the account. In
bar graph 710, the percentage of procedural errors is shown on a
per shift basis. As shown by the legend 712, the bar graph 710
shows both the average percentage of errors occurring during the
time period, and a historical average calculated over the life of
the account.
[0084] FIG. 8 illustrates exemplary general productivity and cost
basis reports for a fictional laundry account in an embodiment of
the present invention. The report 800 includes bar graphs 802, 804,
806, 810 and 812. The bar graph 802 illustrates the pounds of
laundry washed per occupied room. The bar graph 804 shows the cost
of labor per occupied room associated with the laundry operation.
The bar graph 806 illustrates the number of procedural errors per
occupied room. The bar graph 810 illustrates the cost of chemistry
per occupied room. The bar graph 812 illustrates the cost of
utilities per occupied room. As indicated by legend 808, the bar
graphs 802, 804, 806, 810 and 812 include actual results (i.e.,
detected over the time period shown in report section 702 of FIG.
7), an average of a particular account, the overall corporate
average, and the corporate target.
[0085] The report section 814 summarizes the cost basis used in the
report 800. The components of the report section 814 illustrate
exemplary corporate data elements recorded in the database. The
labor cost basis, for example, may be an average labor cost, or may
be further broken out into specific labor costs for the laundry
operators or for individual shifts. Likewise, the water, sewage and
energy costs may be averages or estimates, or they may be updated
on a real time basis. The temperature rise data element indicates
the differential between the water temperature received from a
public utility and the hot water temperature detected in a
dispenser.
[0086] The embodiments of the invention described herein are
implemented as logical steps in one or more computer systems. The
logical operations of the present invention are implemented (1) as
a sequence of processor-implemented steps executing in one or more
computer systems and (2) as interconnected machine modules within
one or more computer systems. The implementation is a matter of
choice, dependent on the performance requirements of the computer
system implementing the invention. Accordingly, the logical
operations making up the embodiments of the invention described
herein are referred to variously as operations, steps, objects, or
modules.
[0087] The above specification, examples and data provide a
complete description of the manufacture and use of the composition
of the invention. Embodiments of the present invention; however,
may be applied in areas other than laundry operations. For example,
in an agriculture applications, a herbicide dispenser may be supply
herbicide to a chemical application system, such as an irrigation
system or a herbicide sprayer on a crop duster or tractor. The
herbicide dispenser data (e.g., timing, amount, and identity of
herbicide being dispensed) may be combined with corporate data
(e.g., chemical costs, labor costs, field production results,
weather conditions, soil conditions, and type of plants) to manage
chemical usage. Furthermore, sanitation systems in the food and
beverage industries and water treatment industries are also
contemplated within the scope of the present invention. As many
embodiments of the invention can be made without departing from the
spirit and scope of the invention, the invention resides in the
claims hereinafter appended.
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