U.S. patent application number 12/470340 was filed with the patent office on 2009-09-10 for radio frequency identification application system.
Invention is credited to Thomas C. Abraham, Jr., Daniel J. Ahearn, Chandrakumar Bhumireddy, Daniel L. Frew, Balaraju Velupula, Matthew D. Wilson.
Application Number | 20090224923 12/470340 |
Document ID | / |
Family ID | 37011437 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090224923 |
Kind Code |
A1 |
Abraham, Jr.; Thomas C. ; et
al. |
September 10, 2009 |
Radio Frequency Identification Application System
Abstract
A radio frequency identification ("RFID") application system for
use with an RFID system adapted to apply an RFID tag to a product
and method of operating the same. In one embodiment, the RFID
application system includes a printer applicator controller
configured to manage an operation of a printer applicator of the
RFID system. The RFID application system also includes a compliance
manager configured to coordinate RFID compliance data to derive a
unique identification number for the RFID tag. The RFID application
system still further includes an event manager configured to
coordinate an operation of the printer applicator controller to
facilitate proper placement of the RFID tag on the product.
Inventors: |
Abraham, Jr.; Thomas C.;
(Dallas, TX) ; Ahearn; Daniel J.; (Highland
Village, TX) ; Bhumireddy; Chandrakumar; (Coppell,
TX) ; Frew; Daniel L.; (McKinney, TX) ;
Velupula; Balaraju; (Coppell, TX) ; Wilson; Matthew
D.; (McKinney, TX) |
Correspondence
Address: |
SLATER & MATSIL, L.L.P.
17950 PRESTON RD, SUITE 1000
DALLAS
TX
75252-5793
US
|
Family ID: |
37011437 |
Appl. No.: |
12/470340 |
Filed: |
May 21, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11364675 |
Feb 28, 2006 |
|
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12470340 |
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Current U.S.
Class: |
340/572.1 |
Current CPC
Class: |
G06K 17/0025 20130101;
G06K 17/00 20130101 |
Class at
Publication: |
340/572.1 |
International
Class: |
G08B 13/14 20060101
G08B013/14 |
Claims
1. A radio frequency identification (RFID) application system for
use with an RFID system adapted to apply an RFID tag to a product,
comprising: a printer applicator controller configured to manage an
operation of a printer applicator of said RFID system; a compliance
manager configured to coordinate RFID compliance data to derive a
unique identification number for said RFID tag; and an event
manager configured to coordinate said operation of said printer
applicator controller to facilitate proper placement of said RFID
tag on said product.
2. The RFID application system as recited in claim 1 further
comprising an interface configured to provide connectivity to
external systems associated with said RFID system and an electronic
data interchange configured to provide RFID compliance data from a
database of said RFID application system to said external systems
via said interface.
3. The RFID application system as recited in claim 1 further
comprising a configuration subsystem configured to setup systems of
said RFID system.
4. The RFID application system as recited in claim 1 further
comprising a workflow manager configured to derive workflow
processes associated with said RFID system, wherein said event
manager is configured to coordinate said operation of said printer
applicator controller as a function of said workflow processes.
5. The RFID application system as recited in claim 1 further
comprising a conveyor controller configured to manage an operation
of a conveyor of said RFID system employable with a manufacturing
line associated with a supply chain management system.
6. The RFID application system as recited in claim 1 further
comprising a pallet configuration subsystem configured to provide
pictorial training diagrams to direct a rebuilding of said pallet
after depalletization.
7. The RFID application system as recited in claim 1 further
comprising a user interface configured to provide a graphical user
interface with an operator of said RFID application system.
8. The RFID application system as recited in claim 1 wherein said
RFID compliance data is selected in accordance with at least one of
a license plate number, a standard and a product code.
9. The RFID application system as recited in claim 1 wherein said
printer applicator controller is configured to employ Cartesian
coordinates to facilitate proper placement of said RFID tag on said
product.
10. The RFID application system as recited in claim 1 wherein said
event manager is configured to coordinate an operation of an RFID
reader of said RFID system to validate said RFID tag.
11. A method of operating a radio frequency identification (RFID)
application system for use with an RFID system adapted to apply an
RFID tag to a product, comprising: managing an operation of a
printer applicator of said RFID system; deriving a unique
identification number for said RFID tag from RFID compliance data;
and coordinating an operation of said printer applicator to
facilitate proper placement of said RFID tag on said product.
12. The method as recited in claim 11 further comprising providing
connectivity to external systems associated with said RFID system
and providing said RFID compliance data to said external
systems.
13. The method as recited in claim 11 further comprising deriving
workflow processes associated with said RFID system and
coordinating said operation of said printer applicator as a
function thereof.
14. The method as recited in claim 11 further comprising managing
an operation of a conveyor of said RFID system employable with a
manufacturing line associated with a supply chain management
system.
15. The method as recited in claim 11 further comprising directing
a rebuilding of a pallet in accordance with pictorial training
diagrams after depalletization.
16. The method as recited in claim 11 further comprising providing
a graphical user interface with an operator of said RFID
application system.
17. The method as recited in claim 11 wherein said RFID compliance
data is selected in accordance with at least one of a license plate
number, a standard and a product code.
18. The method as recited in claim 11 wherein said coordinating
said operation of said printer applicator further comprises
employing Cartesian coordinates to facilitate proper placement of
said RFID tag on said product.
19. The method as recited in claim 11 further comprising
coordinating an operation of an RFID reader of said RFID system to
validate said RFID tag.
20. The method as recited in claim 11 further comprising
coordinating said operation of said printer applicator to
facilitate proper placement of a replacement RFID tag on said
product.
Description
[0001] This application is a continuation of patent application
Ser. No. 11/364,675, entitled "Radio Frequency Identification
Application System," filed on Feb. 28, 2006, which application is
incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention is directed, in general, to radio
frequency identification ("RFID") systems and, in particular, to an
RFID application system and method of operating the same.
BACKGROUND
[0003] Radio frequency identification ("RFID") systems include RFID
readers communicating with RFID tags via radio waves. The RFID
readers send radio signals via antennas, which are received by the
RFID tags. The RFID tags may be passive, semi-active or active. The
passive RFID tags are the most common and least costly and derive
energy for operation from the transmitted signal from the RFID
reader thereby illuminating the RFID tag. The semi-active and
active RFID tags have independent power sources for processing
functions and for independent or enhanced transmit functions. After
the RFID tag receives enough energy to respond, and the proper
interrogation sequence is generated by An RFID reader, the RFID tag
replies with information (e.g., payload information) thereabout,
which is usually a unique identification number (also referred to
as an "ID") or other information available to the RFID tag. The
RFID reader receives the identification number from the RFID tags
in response to the transmitted signal by the RFID reader.
[0004] For purposes of a brief introduction, FIGS. 1 to 6
illustrate diagrams introducing foundational concepts regarding
RFID technologies and the use thereof in the supply chain
management of the retail industry or other industries. Referring
initially to FIGS. 1A and 1B, illustrated are diagrams of typical
RFID tags, of which other physical configurations are possible. The
RFID tags each typically include an RFID microchip 110, a chip
carrier or strap 120 and an antenna 130. As an example regarding
passive RFID tags, the RFID tag collects the radiated energy of the
transmitted signal from an RFID reader and uses the collected
energy to control a modulation thereof within the RFID microchip
110. By changing an impedance of the antenna 130 of the RFID tag,
the incident signal is either substantially reflected back to the
RFID reader or it is not. This basic modulation mechanism is used
in RFID applications from tracking motor vehicles on toll roads to
tracking animals.
[0005] Turning now to FIG. 2, illustrated is a perspective view of
an RFID tag 210 embedded within a standard paper adhesive label 220
and applied to a product (e.g., case) 230. The aforementioned
application is a common application for RFID technologies in supply
chain management, but RFID tag only applications (i.e., without the
label) are also used. Regarding FIGS. 3A to 3D, illustrated are
diagrams demonstrating an operation of an RFID reader 310 and RFID
tag 330. FIG. 3A illustrates the RFID reader 310 transmitting a
signal through an antenna 320 to an RFID tag 330 on a product
(e.g., case) 340. FIG. 3B illustrates the RFID tag 330 absorbing
the signal from the transmitted inbound signal from the RFID reader
310. FIG. 3C illustrates the RFID tag 330 using the collected
energy to control a modulation of the transmitted signal and, by
altering the impedance of an antenna thereof, the RFID tag 330
modulates the amount of the reflected signal (and data available to
the RFID tag 330) back to the RFID reader 310. The term modulation
generally refers to a range of techniques for encoding information
on a carrier signal (e.g., a sine-wave signal) and is typically
performed by a modulator. FIG. 3D illustrates the RFID reader 310
sending information associated with the RFID tag 330 back to a
computer 350 so that the information can be used for other
applications.
[0006] The RFID tags typically include an identification number
stored in memory of a microchip thereof in a format consistent with
EPCGlobal or other standards such as International Organization for
Standardization ("ISO") ISO18006. A few examples of industry
recognized standards include EPCGlobal release EPC Specification
for Class 1 Gen 1 RFID Specification, November 2002 and EPC
Specification for Class 1 Gen 2 RFID Specification, December 2004
(see, also, a related publication entitled "Whitepaper: EPCglobal
Class 1 Gen 2 RFID Specification," published by Alien Technology
Corporation, Morgan Hill, Calif., 2005), which are incorporated
herein by reference. An example of an identification number is a
serialized global trade identification number ("SGTIN") conforming
to an EPCGlobal standard Class 1 Gen1 96 bit RFID tag. For
instance, the SGTIN "01 1234567 123456 123456789" includes a header
"01," a manufacturer code "1234567," a object class "123456," and a
serial number "123456789." The SGTIN provides an example of an
identification number for an application of RFID technologies to
supply chain management.
[0007] Significant compliance mandates are being placed on the use
of RFID technologies for use in tracking products of all types.
Present systems are unable to satisfy the mandates, in general, and
if the systems approach satisfying such mandates, the cost thereof
is prohibitive. Retailers are now adopting RFID technologies across
a broad range of products and placing mandates on suppliers to
provide products with RFID tags (and potentially a label) on cases
and pallets of products with stock keeping unit identifiers
("SKUs"). An SKU is a unique name or number assigned to a product
for ease of use and tracking throughout manufacturing and supply
chain management systems. Present mandates provide that the RFID
tags be encoded with unique values and follow prescribed RFID
standards set by the standards body of choice by the customers. In
addition, no single standard enjoys universal acceptance, so
multiple standards are being adopted.
[0008] Turning now to FIGS. 4 and 5, illustrated are diagrams
demonstrating scan points for a distribution center and retail
location, respectively, for a supply chain network. Major retailers
(e.g., Wal-Mart) are leading the RFID mandates and the Department
of Defense ("DoD") and the healthcare industry, among others, are
following their lead with RFID requirements on cases and pallets of
shipped products. Present plans for initial rollouts include scan
points at five places in the supply chain network including two at
a distribution center (including a receiving location 410 and a
shipping location 420 as illustrated in FIG. 4) and three at a
retail location (including a receiving location 510, entrance to a
retail floor 520 and a trash compactor 530 as illustrated in FIG.
5). Future plans will increase and refine tracking and tracking
locations. Requirements of this type are disruptive to suppliers'
operations, systems, personnel, costs and schedules. In addition,
RFID mandates have imposed constraints on the suppliers and the
constraints have generated additional problems as described
below.
[0009] Attempts to respond to the basic changes in the supply chain
management have not been successful. Suppliers have implemented
various manual processes to meet the compliance requirements, which
have proven to be costly, inefficient, and prone to errors that are
difficult to detect and correct. Compounding the problem is the
fact that future requirements will be more extensive (more
RFID-enabled distribution centers, SKUs and suppliers) than those
now in place and these will only further aggravate the problem. In
light thereof, existing solutions concentrate on more hardware and
labor to address the problem, which only ramps up the amount of
losses incurred to implement the processes and further aggravates
the issues of error checking, error detection and error correction.
Additionally, expanding the manual approaches is not efficiently
scalable or tenable.
[0010] Turning now to FIG. 6, illustrated is a diagram
demonstrating a manual process for the application of an RFID tag
on a product (e.g., a case and a pallet). The manual process is
performed by a computer operator 610 operating a computer 620 with
a spreadsheet and an RFID label printer with integrated reader 630
printing labels (one of which is designated 640) with RFID tags for
manual application by another operator 650 on an RFID-tagged case
660 and an RFID-tagged pallet 670. A case designated 680 is a
non-RFID-tagged case and a pallet designated 690 is a
non-RFID-tagged pallet. The illustrated approach provides a single
pallet going through the manual process, of which the manual
process becomes exponentially more difficult as multiple pallets
and cases are added thereto.
[0011] The manual process provides a first step toward the growth
of RFID technologies. For instance, the manual process enables the
encoding of RFID tags (at the case and pallet level), allows
operators to print onto a human readable label, and enables RFID
tags to be manually applied to cases and pallets. The manual
process also allows operators to track the identification numbers
for the products and the numeric constructions for the products and
customers via a spreadsheet. It is possible, however, that the same
product will have to be encoded to different standards depending
upon the customer. While the manual process allows businesses to
scale, it is labor and hardware intensive and leads to a
proportional increase in errors associated with the application of
the RFID tags on products and the like.
[0012] While the manual process provides some advantages, such a
manual process is not conducive to a full scale proliferation of
RFID technologies, especially in supply chain management. For
instance, the manual process does not automatically qualify a
uniqueness of case and pallet identification numbers (also referred
to as "case identifier or case ID" and "pallet identifier or pallet
ID," respectively). Additionally, the manual process does not
automatically integrate with external systems such as enterprise
resource planning ("ERP") systems and warehouse management systems
("WMS") to make RFID standards determinations. The manual process
also does not readily integrate multiple disparate systems and
aggregate the case identification number and pallet identification
number associations automatically. For compliance, it is beneficial
to know which unique case ID is assigned to each unique pallet ID.
As an example, suppose a pallet ID "123456789" is associated with
case IDs "1001," "1002," to "1050." If the pallet ID is read at a
scan point, it would be beneficial to know that 50 case IDs are
associated therewith. In much the same way, if any case ID of the
50 unique case identification numbers was read, it would be
beneficial to know the pallet identification number "123456789" by
default. Again, the manual process does not provide such a tracking
capability for the supply chain management system.
[0013] The manual processes exhibit many other limitations as
hereinafter provided. For instance, the manual process does not
instruct personnel of proper RFID tag placement, which is very
different from barcode labels that require line of sight to work.
The RFID tags also depend on RFID friendliness or physical
characteristics of the product being tagged, and the placement of
the RFID tag is important for acceptable performance. In accordance
therewith, the manual process does not automatically apply labels
to cases and qualify RFID tag placement tolerances. In addition,
the manual process does not control the material handling equipment
("MHE") systems to perform automation and integrate with other
automated systems including MHE devices such as conveyers and
forklifts used to move products in the supply chain. The manual
process further does not align cases for automatic RFID tag
application and send shipment information to a receiver. In
accordance therewith, the manual process does not validate applied
case and pallet RFID tags and automate the handling of rejected
RFID tags (e.g., for encoding failures). The aforementioned
limitations associated with the manual processes detract from the
proliferation of RFID technologies in, for instance, the supply
chain management systems.
[0014] Accordingly, what is needed in the art is a system and
method that addresses the above issues in a cost effective manner
that is scalable and capable of being integrated into existing
manufacturing and distribution center processes concentrating on
supply chain management and other applications.
SUMMARY OF THE INVENTION
[0015] These and other problems are generally solved or
circumvented, and technical advantages are generally achieved, by
advantageous embodiments of the present invention that include a
radio frequency identification ("RFID") application system for use
with an RFID system adapted to apply an RFID tag to a product and
method of operating the same. In one embodiment, the RFID
application system includes a printer applicator controller
configured to manage an operation of a printer applicator of the
RFID system. The RFID application system also includes a compliance
manager configured to coordinate RFID compliance data to derive a
unique identification number for the RFID tag. The RFID application
system still further includes an event manager configured to
coordinate an operation of the printer applicator controller to
facilitate proper placement of the RFID tag on the product.
[0016] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the invention
will be described hereinafter which form the subject of the claims
of the invention. It should be appreciated by those skilled in the
art that the conception and specific embodiment disclosed may be
readily utilized as a basis for modifying or designing other
structures or processes for carrying out the same purposes of the
present invention. It should also be realized by those skilled in
the art that such equivalent constructions do not depart from the
spirit and scope of the invention as set forth in the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a more complete understanding of the present invention,
and the advantages thereof, reference is now made to the following
descriptions taken in conjunction with the accompanying drawings,
in which:
[0018] FIGS. 1 to 6 illustrate diagrams introducing foundational
concepts regarding RFID technologies and the use thereof in supply
chain management of the retail industry that provides an
environment for an application of the principles of the present
invention;
[0019] FIG. 7 illustrates a block diagram of an embodiment of an
RFID application system employable with an RFID system constructed
according to the principles of the present invention;
[0020] FIGS. 8 and 9 illustrate system level diagrams of
embodiments of RFID systems including embodiments of RFID
application systems constructed according to the principles of the
present invention;
[0021] FIGS. 10 to 26 illustrate flow diagrams and screen shots
demonstrating exemplary steps associated with the RFID systems of
FIGS. 8 and 9; and
[0022] FIGS. 27 to 43 illustrate a system level diagram and flow
diagrams of an embodiment of an RFID system including an embodiment
of an RFID application system that demonstrate exemplary steps of
operating the same in accordance with the principles of the present
invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0023] The making and using of the presently preferred embodiments
are discussed in detail below. It should be appreciated, however,
that the present invention provides many applicable inventive
concepts that can be embodied in a wide variety of specific
contexts. The specific embodiments discussed are merely
illustrative of specific ways to make and use the invention, and do
not limit the scope of the invention. Unless otherwise provided,
like designators for devices employed in different embodiments
illustrated and described herein do not necessarily mean that the
similarly designated devices are constructed in the same manner or
operate in the same way.
[0024] The present invention will be described with respect to an
exemplary embodiment in a specific context, namely, an RFID
application system within an RFID system. The particular
embodiments described herein are applied supply chain management
systems in the retail industry. The principles of the present
invention may be applied to other applications and industries such
as the defense industry and healthcare market. The RFID application
system (also referred to as "Xterprise Automated RFID Module" or
"XARM") addresses the limitations as described above with pragmatic
automation of inefficient processes to achieve accurate compliance.
In addition to automated compliance, the RFID application system
automates error handling, integrates disparate systems, and has a
modular design to allow for different functions as well as
different physical size options.
[0025] When RFID compliance was first imposed on suppliers, there
was little equipment available to meet compliance mandates. The way
to comply was to obtain an RFID-enabled printer, converted tags
(RFID tags embedded in label stock), and start printing and
encoding RFID tags. The encoded values were maintained manually in
a spreadsheet or a stand-alone software package. Operators would
print and encode labels, peel them and apply them to single cases
on a pallet. The aforementioned process leads to extensive material
handling of the cases, detailed level control of the RFID labels,
and pallet control of the cases (case-level tracking provides that
cases physically stay associated with the pallet RFID tag like a
parent-child relationship).
[0026] As mentioned above, the problem with this method is that it
is inaccurate, inefficient, and stand-alone, thereby not completing
every task desired for compliance. True system integration
including software integration is absent from this model; the
requirements were solved via manual data entry and manual data
manipulation, both prone to error. The manual solution is also
expensive (hardware and labor intensive) for higher volumes of RFID
tagging specifications, which is inevitable with the adoption of
RFID technologies in different vertical markets. As higher volume
specifications are placed on suppliers, the manual solution is more
labor and more printers that increase their costs and errors.
[0027] The RFID application system solves the aforementioned
problems with a modular approach to RFID mandates. Designed with
separate functional subsystems and modules, the RFID application
system solves compliance mandates automatically. The RFID
application system may be employed in any number of environments
including supply chain management systems that include a
distribution center providing depalletization, RFID tagging, and
then repalletization (or palletization). Depalletization refers to
the unstacking of palletized cases to singulate the cases for RFID
tagging or any other process. Repalletization refers to re-stacking
of cases that were depalletized. It is also referred to as
"palletization," but palletization usually refers to the first time
the cases were palletized (for example, at manufacturing). In
accordance therewith, a pallet stand is an ergonomic material
handling equipment that elevates or lowers pallets of cases to
reduce the lifting requirement on the operator. While the processes
may be automated, the material handling is primarily powered at the
operator's command (usually by a foot pedal). Exemplary high-level
components of an RFID system that includes an RFID application
system include, without limitation, computer systems with a
graphical user interface and including printers and applicators,
RFID readers, RFID tags, conveyers and products (e.g., cases and
pallets).
[0028] Turning now to FIG. 7, illustrated is a block diagram of an
embodiment of an RFID application system employable in an RFID
system constructed according to the principles of the present
invention. For each respective solution, the RFID application
system is employed to accomplish tasks as defined by different
customers. Each of the subsystems or modules of the RFID
application system can be configured independently or dependent on
another subsystem to achieve the goals of a pragmatic, scalable
RFID compliant system. The RFID application system may be embodied
in hardware, software and combinations thereof. The RFID
application system includes an interface such as a legacy interface
(designated "I/F"). Systems such as external systems often contain
valuable information that is often employed by RFID compliance
solutions. The interface provides connectivity or a conduit to the
external systems for, without limitation, shipping information, WMS
license plate number ("LPN"), and inventory data.
[0029] The RFID application system also includes a configuration
subsystem (designated "CFG") that configures (e.g., setup for
operation) systems such as printer applicators, material handling
equipment ("MHE"), conveyors, RFID readers, etc. of the RFID
system. The RFID application system further includes a workflow
manager (designated "WFM") that derives workflow processes to
satisfy business objectives associated with the RFID system. As a
configurable subsystem, the workflow manager can accommodate any
workflow processes and may be modified on the fly, as necessary, to
allow for changes to the business objectives. A conveyer controller
(designated "CC") of the RFID application system allows for real
time control and management of a conveyor to stop/start products
(e.g., cases), divert bad or rejected cases, and the like. Those
skilled in the art realize that a conveyor controller may control
all types of material handling equipment like diverters or reject
equipment and is not limited to conveyors.
[0030] The RFID application system also in includes a printer
applicator controller (designated "P/A") that controls and manages
a printer/applicator/encoder device (also referred to as a "printer
applicator") so that products are sent thereto in a systemically
documented manner. The printer applicator controller further
upgrades the accuracy of the application of the RFID tags on the
products (e.g., cases). A pallet configuration subsystem
(designated "PC") of the RFID application system directs a
breakdown, building or rebuilding of the pallet, typically after
depalletization. The pallet configuration subsystem may provide
pictorial training diagrams on how to restack an RFID-tagged
pallet.
[0031] An RFID compliance manager or compliance manager (designated
"CMGR") controls and manages subsystems of the RFID application
system to properly apply RFID compliance data within the RFID
system. The RFID compliance manager coordinates the RFID compliance
data to derive a unique identification number for an RFID tag for
placement on a product such as a case. Status updates from RFID
readers are recorded in accordance with the RFID compliance manager
and documented in an organized fashion. The RFID compliance manager
also allows for RFID reader firmware upgrades. The RFID application
system also includes a database (designated "DB") that stores
information such as the RFID compliance data as well as execution
parameters for conveyor control. The database also stores product
and customer information as needed to make for ease of use by
operators.
[0032] A user interface (designated "UI") of the RFID application
system directs operators on work instructions as well as provides a
way for operators to maintain system data and a status of the
operations of the RFID application system. The user interface
typically includes a graphical user interface and a keyboard
allowing an operator to gain access to or input data into the RFID
application system and operations associated therewith. The user
interface is especially beneficial when system maintenance is being
performed. The RFID application system also includes an event
manager (designated "EM") that coordinates an operation of systems
(e.g., printer applicator controller) as a function of the workflow
processes to facilitate proper placement of the RFID tags on the
products at the proper time. As certain statuses of interest
(customer-defined) arise during the operational process of RFID
compliance for the RFID system, the events should be managed and
handled as the customer defines, which may affect other subsystems
unbeknownst to the operators. For example, if the printer
applicator runs out of labels/RFID tags, the operator may receive a
message to that effect, and the conveyor may stop sending cases
thereto for RFID tagging.
[0033] An electronic data interchange (designated "EDI") of the
RFID application system is employable when providing data (e.g.,
RFID compliance data) from the database to external systems via the
interface, or vice versa. For example, if a supplier wants to send
an RFID advanced shipment notice ("ASN") to a customer, the
information in the database should be collected and sent to the
external system. The aforementioned subsystems and modules of the
RFID application system will hereinafter be further described in
the environment of working examples of an RFID system. The RFID
application system is an adaptable solution to RFID mandates. Its
extensive capability allows for scalability, modularity in size and
in function, and reduced operator training at costs favorably
disproportionate to the utility added by the system. The following
paragraphs will describe in some detail exemplary embodiments of
RFID systems employing the RFID application system illustrating
many options to meet customer mandates. The foregoing RFID systems
are illustrative, but not exhaustive of the capabilities of the
RFID application system and those skilled in the art will readily
see that other embodiments and applications are possible and are
well within the broad scope of the present invention.
[0034] Turning now to FIGS. 8 and 9, illustrated are system level
diagrams of embodiments of RFID systems including embodiments of
RFID application systems constructed according to the principles of
the present invention. The RFID systems illustrate exemplary
methods by which the RFID application system applies RFID tags to
products (e.g., cases). The RFID systems provide a distribution
center model wherein depalletization of existing pallets for RFID
tagging of the cases is performed. The RFID systems provide a
solution for a manufacturing line associated with a supply chain
management system that employ the principles of the RFID
application system as described herein. Of course, the RFID systems
described herein are exemplary embodiments to demonstrate some of
the advantages associated with the RFID application system and the
broad scope of the present invention is not so limited.
[0035] More specifically, FIG. 8 illustrates, at a high level, that
external system integration exists to streamline a solution. The
solution could contain more or less external system integration,
for example, order management system ("OMS") integration if needed
for shipment or production order information. An order management
system is a general term used to identify the system in which a
company manages, controls, or enters customer orders for
fulfillment at a manufacturing plant or the distribution center.
The RFID system of FIG. 9 differs from the aforementioned
embodiment by adding an option for automated repalletization of the
cases. It is possible that the RFID application system described
herein may be directly applied at the manufacturing line to
potentially eliminate the depalletization process altogether. The
flow diagrams and screen shots that follow describe exemplary
processes associated with the RFID systems to more comprehensively
elucidate the advantages associated with the RFID application
system.
[0036] Turning now to FIGS. 10 to 26, illustrated are flow diagrams
and screen shots demonstrating exemplary steps associated with the
RFID systems of FIGS. 8 and 9. Beginning with FIG. 10, a pallet is
delivered to a manufacturing line of the RFID system (designated
step "1" in FIGS. 8 and 9). The pallet is moved to a staging point
for processing in preparation for SKU induction. A warehouse
management system ("WMS") or other driving system in conjunction
with the RFID application system may direct the operators to move
specified pallets within the manufacturing line. In yet another
embodiment, in addition to systems integration to streamline the
data flow, material handling equipment could also be added to
convey the pallets to the operators for depalletization. The RFID
system may incorporate additional automation with a robotic
depalletizer, which is very beneficial with heavier products for
RFID tagging and alleviates the problem of operator fatigue with
products over, for instance, 35 pounds. The RFID application system
handles the integration to such a depalletizer and other material
handling equipment. It should be understood that many subsystems
and modules within the RFID application system may be invoked to
perform the aforementioned tasks and the tasks that follow. For
instance, an interface to the external systems may be employed and
a workflow manager and event manager may coordinate an operation of
the material handing equipment.
[0037] Turning now to FIG. 11 (collectively FIGS. 11A to 11C),
illustrated is a flow diagram demonstrating SKU induction (referred
to as "Subsystem 2" and designated step "2" in FIGS. 8 and 9). Once
a product is delivered for RFID tagging, the product "next to be
tagged" is identified by the RFID application system, at least
partially embodied in a server (also referred to as an "XARM
Application Server ("XAS")) so that the RFID application system
knows specifically which RFID standard (as part of the RFID
compliance data) to apply for encoding. In addition, the quantity
of cases on the pallet is identified, and that information may be
obtained via integration from the WMS or advising system via an
interface from the RFID application system. Clearly, other
information could be employed by the RFID system, for example,
order management system order information or production order
information could be obtained by the RFID application system to
complete the SKU induction. A compliance manager of the RFID
application system coordinates the RFID compliance data (e.g.,
product code) to derive a unique identification number for the RFID
tags.
[0038] As operators begin processing a pallet, the SKU and pallet
license plate number ("LPN") data are recorded in the RFID
application system and stored in a database embodied in a database
server. The license plate number is an identifier (usually a
barcoded number or alphanumeric value) that identifies a specific
lot/batch or unit of measure (pallet, case, etc.) of a particular
SKU. The advantage in using LPNs is so that operators do not have
to enter the variable attributes of that SKU each time the
operators are trying to identify the unit of measure of the product
to be moved, stored, etc. An operator will scan the LPN of the
pallet being inducted, and the RFID application system will call
for data (e.g., RFID compliance data) from the warehouse management
system. In the event that an LPN is not available to scan, or no
touch point exists between the RFID application system and the
warehouse management system, the operator may select the SKU from a
list provided by the compliance manager of the RFID application
system. The RFID application system will alert operators if SKUs
are being inducted which have not been setup for RFID
processing.
[0039] Turning now to FIGS. 12A to 12E, illustrated are screen
shots generated by the RFID application system to facilitate SKU
induction. A first screen shot or SKU induction allows the operator
to scan or enter the LPN for the next SKU to be processed (see FIG.
12A). If the LPN was already processed (pallet re-inducted by
mistake), a screen appears to indicate the exception to the
operator (see FIG. 12B). Per customer request, the RFID application
system supports messaging when changing to a different product
code. The RFID application system supports this operation as the
operator acknowledges the SKU change with a button on a screen (see
FIG. 12C). A main screen associated with the SKU induction process
automatically tracks the status of a pallet dynamically and
provides dynamic instructions to the operator along with graphical
cues or instructions for processing (see FIG. 12D). Another screen
appears after the full number of expected cases has been verified
to indicate to the operators that the pallet is complete and that
the RFID application system is ready to start the next pallet when
the operator is ready (by pressing the "OK" button) (see FIG. 12E).
As a result of the SKU induction process facilitated by the RFID
application system, operator error and operator training are
reduced. This is especially beneficial in warehouses that have high
labor turnover rates associated with the operators.
[0040] Turning now to FIG. 13, illustrated is a flow diagram
illustrating the RFID application system sending the appropriate
data (i.e., RFID tag values, human readable information to be
printed, etc.) to a printer applicator (referred to as "Subsystem
3" and designated step "3" in FIGS. 8 and 9). A printer applicator
controller of the RFID application system can automatically adjust
the printer applicator based on the XYZ coordinates to control
label (and RFID tag) placement outcome on the product. The XYZ
coordinates are Cartesian coordinates utilized in the RFID
application system to control a desired outcome of RFID tag
placement on actual cases. The coordinates may be stored in a
database of the RFID application system for automatic or manual
RFID tag placement so that the coordinates are known at the time of
SKU induction. The coordinates may also be necessary to make
automated or manual adjustments to physical hardware (via a
configuration subsystem of the RFID application system) so that the
desired RFID tag placement is achieved while RFID tagging. The
placement of the RFID tag can be important for products and
especially for reading an RFID tag thereon so automating the
process will not only reduce operator error and training, but
augment an efficiency of the RFID system.
[0041] Turning now to FIG. 14 (collectively FIGS. 14A and 14B),
illustrated is a flow diagram illustrating depalletizing the cases
of the pallet onto a conveyor (referred to as "Subsystem 4" and
designated step "4" in FIGS. 8 and 9). Line operators may manually
remove the cases from the pallet and place the cases on the
conveyor in an orientation that is depicted on a user interface of
the RFID application system. The RFID application system also
tracks the total expected cases on that particular pallet as well
as how many cases have been validated and rejected (see, e.g., FIG.
12D).
[0042] Additionally, ergonomic pallet stands may be incorporated to
mechanically adjust the height of the pallet to facilitate the
depalletization of the cases, especially where the cases are more
than 35 lbs. The RFID application system provides direction to the
operator as to case orientation requirements on the conveyor and/or
line setup activities that should be performed (i.e., changing Y
location settings for printer applicator equipment if the XYZ
automation option is not chosen).
[0043] The conveyor will accumulate cases intelligently in that the
conveyor singulates or separates the cases and knows if the printer
applicator is in a "ready" state for RFID tag application. The
conveyer does this via a machine interface between the printer
applicator and the RFID application system (e.g., a printer
applicator controller and a conveyer controller thereof), thereby
substantially eliminating an overrun of the printer applicator.
What is meant by "overrun" is that if the printer applicator and
the conveyor are not integrated, then the conveyor will send cases
regardless of the status of the printer applicator, which can
result in poor and expensive consequences. The event manager of the
RFID application system coordinates the actions of the printer
applicator controller and conveyer controller to control the
printer applicator and conveyer, respectively.
[0044] As an example, if the printer applicator skips a bad RFID
tag (a common internal printer applicator process), then the
printer applicator will automatically take an appropriate amount of
additional time (e.g., hold the next steps) to produce a good RFID
tag ready for application on the next case. Without intelligent
integration, the conveyor would send the next case to the printer
applicator, and no RFID tag would be applied to that case. Since
the RFID tag would fail validation (no RFID tag applied), the RFID
system would reject that case thus creating rework. As the RFID
application system is designed to include integration, the rework
is substantially eliminated in that the conveyor waits until the
"ready" signal from the printer applicator before allowing the next
case reach the printer applicator.
[0045] Turning now to FIG. 15, illustrated is a flow diagram
directed to encoding the actual RFID values and printing the
readable information on the RFID tags after cases are depalletized
(referred to as "Subsystem 5" and designated step "5" in FIGS. 8
and 9). The printer applicator writes the RFID data to an RFID
circuit in a label and prints any needed, for instance,
human-readable information on the label per the advised information
from the printer applicator controller of the RFID application
system. Unique serializations for the RFID compliance data will be
managed across multiple sites/locations and can be managed by the
compliance manager of the RFID application system. The printer
applicator will verify the RFID tags written for RFID readability,
and failed RFID tags will be collected by the printer applicator.
Since only good RFID tags will be applied to cases, the chances of
rework are reduced. The RFID application system will also alert
operators of printer applicator error conditions such as out of
media jams, etc. via the printer applicator controller, thereby
further enhancing overall substantially error-free operation.
[0046] Turning now to FIG. 16, illustrated is a flow diagram for
applying an RFID tag to a product (e.g., case) (referred to as
"Subsystem 6" and designated step "6" in FIGS. 8 and 9). Consider
that the printer applicator has just discharged an encoded RFID tag
onto an applicator pad. Once the printer applicator has peeled or
discharged a good RFID tag, the printer applicator sends a ready
signal to the printer applicator controller of the RFID application
system. Then, the RFID application system, in conjunction with the
event manager, releases the next case for application from the
waiting zone or queue prior to the printer applicator. As the case
passes a photo eye triggering device, the applicator pad is
activated to apply or tamp the RFID tag onto the case. Tamping the
RFID tag is but one application method and other application
methods such as air apply (a/k/a, "blow on") and "wipe on" are
equally acceptable.
[0047] Timing and physical tuning of the RFID system is necessary
to have the RFID tag applied in the appropriate place for each SKU,
and the RFID application system in conjunction with the workflow
and event managers allows for digital configuration of delay and
positioning criteria for the RFID system. For example, the RFID tag
placement x-coordinate is dependent on the speed of the conveyor as
well as a time delay after the photo eye RFID tag application
triggering event. The time delay could be zero, but it could be set
to a longer time to delay, for instance, by causing the photo eye
triggering device to place the RFID tag closer to a trailing edge
of the case.
[0048] As the printer applicator encounters bad RFID tags, it will
fail the RFID tags internally and print a readable overstrike
graphic (e.g., horizontal and vertical grid lines or void) on the
label. Some printer applicators are intelligent enough so as not to
peel or discharge the bad RFID tags, which are then skipped by the
printer applicator and the printer applicator queues up the next
RFID tag for encoding. Depending on the intelligence of the printer
applicator, the RFID application system may be configured to reject
cases that have no RFID tag or bad RFID tags applied thereto. The
RFID application system in conjunction with the printer applicator
controller and compliance manager tracks the number of overstrikes
in the printer applicator so that statistics on RFID tag yields may
be tracked in a database thereof.
[0049] Turning now to FIG. 17, illustrated is a flow diagram
demonstrating a verification of the application of the RFID tag
(referred to as "Subsystem 7" and designated step "7" in FIGS. 8
and 9). Since mechanical devices may not be 100% reliable, the RFID
application system allows for an independent, secondary validation
of the RFID tag. The validation also provides confirmation that the
RFID tag was, in fact, applied to the case, as sometimes labels
fall off the printer applicator. Additionally, the RFID application
system verifies that the RFID tag can be read according to the RFID
specifications as determined by the standards bodies. If the
encoded RFID tag value is read by an RFID reader (via an interface
to the RFID reader), then the case is counted as "validated" and it
is aggregated or associated with a pallet identification number
("pallet ID") in the RFID application system. The RFID application
system will continue to validate the cases until the total expected
cases on that pallet equals the total number of validated cases for
that pallet. Again, the RFID reader may be configured by the
configuration system of the RFID application system, and the
validation process invokes several subsystems thereof such as the
event manager to coordinate an operation of the RFID reader and the
compliance manager to validate the RFID tag and the RFID tagged
case.
[0050] Turning now to FIG. 18, illustrated is a flow diagram of an
operation should a case fail validation for, as examples,
operational reasons, mechanical printer applicator failures, or
programmable logic controller ("PLC") failures (referred to as
"Subsystem 8" and designated step "8" in FIGS. 8 and 9). In this
instance, the RFID reader will not read the expected RFID value on
that case and the RFID application system via the event manager
will notify a reject pusher or diverter to reject the case. The
RFID application system (via the compliance manager) counts a
rejection and the RFID application system triggers a new "request"
for a replacement number to print a new RFID tag for that case. A
counter is updated in real time automatically by the RFID
application system and a sample screen shot of the operation is
illustrated in FIG. 12D.
[0051] Turning now to FIG. 19, illustrated is a flow diagram
demonstrating an operation of the RFID system should a reject occur
(referred to as "Subsystem 9" and designated step "9" in FIGS. 8
and 9). In this instance, the case is physically removed from the
main processing line without impacting production rates of
subsequent cases and the information is conveyed back to an inbound
operator for processing. The illustrated flow diagram illustrates
the rejected case being returned to the inbound operator for
removal of the bad RFID tag (if one was applied), and the placement
of that case back on the inbound conveyor. This process makes it
easier for inbound operators as the data is accounted for on the
RFID application system with reduced operator intervention (just to
remove a bad RFID tag).
[0052] The RFID application system also allows for the recording
(either electronically or in a manual paper log) of bad RFID tags
in a log with disposition codes in accordance with a compliance
manager thereof. The logs, combined with proper conveyor
intelligence, help to refine the RFID process and reduce the
rejected cases. For example, conventional manual systems typically
apply bad RFID tags an average of 10% of the time. Without
delineating the reasons for the bad RFID tags, the conventional
systems will not be able to define and solve the rejection
problems.
[0053] In contrast, the RFID application system averages a reject
rate around 0.25% or less, which is a cost effective alternative to
scaling the manual solution that may be crippled with high
rejection percentages. The reject logs have determined that the
majority of the 0.25% of cases is due to mechanical printer
applicator failures to peel the RFID tags, not the RFID tags
themselves. The system data mining included within the RFID
application system in accordance with the compliance manager
clearly provides the information for future system and process
improvements.
[0054] Turning now to FIGS. 20A (collectively FIGS. 20A-1 and
20A-2) to 20E, illustrated are flow diagrams and screen shots
demonstrating palletizing the RFID cases onto a pallet ready for
storage or outbound shipment to customers (referred to as
"Subsystem 10," designated step "10" in FIG. 8 and referred to as
"Subsystems 10A and 10X" and steps "10," "10A," and "10X,"
respectively, in FIG. 9). Beginning with FIG. 20D, illustrated is
an outbound user interface that tracks the total expected number of
cases as well as the number of validated and rejected cases. In
this way, the operators know what to expect from a completion of
the pallet stand point and are better aware of the total RFID
process. In addition, since each SKU can potentially have a
different stack pattern to create stable pallets for shipment and
handling, the RFID application system displays a pallet
configuration graphic to instruct outbound operators how to restack
the cases. This approach enables the operators to receive on the
job training that reduces the impact of high turnover, a common
occurrence in operations, as well as operator errors. The screen
shot in FIG. 20D displays palletizing RFID-tagged cases. The RFID
application system (in conjunction with the pallet configuration
subsystem) automatically tracks the status of the pallet
dynamically and provides dynamic instructions to the operator along
with graphical cues or instructions for processing.
[0055] Turning to FIG. 20E, illustrated is a screen shot of a
"pallet complete" message that indicates to the operators that the
RFID application system has validated as many cases as expected
and, thus, the current pallet is complete. The system is ready to
RFID tag the next pallet. This screen follows the main
palletization screen. After the operators palletize all the cases
on the conveyor, the operators press the "OK" button indicating
that they are ready for the next palletization screen.
[0056] Turning now to FIG. 20B (collectively FIGS. 20B-1 and
20B-2), illustrated is a flow diagram for automatically palletizing
RFID cases instead of manually restacking the cases, including the
steps for interfacing to an automated palletizer. A secondary user
interface is employed to know when the palletizer jams, but this is
substantially avoided or eliminated if the palletizer is
sufficiently intelligent to "know" this information. The flow
diagram assumes that the palletizer does not possess any additional
diagnostic intelligence to substantially eliminate the operator
interface, which of course may be accommodated by the RFID
application system.
[0057] Turning now to FIG. 20C (collectively FIGS. 20C-1 and
20C-2), illustrated is a flow diagram illustrating an exemplary
automated palletizer failure decision tree, with automated systems,
and specifically denoting that the failure points are accounted for
and handled with a solution, either manual or automatic. The RFID
application system handles the possible failures with reduced input
from the operators to maintain a streamlined operational process
flow. Obviously there are different palletizer machines, which may
have different failure points. The RFID application system can plan
for, control and manage an RFID solution to accommodate any number
of failures. A pallet configuration subsystem of the RFID
application system directs a rebuilding of the pallets. It is also
contemplated that RFID pallets can be combined to form a combined
(e.g., a single) RFID pallet and the RFID application system can
accommodate such a task without having to run the pallets through
the entire process. In other words, the RFID application system
will redirect palletizing the combined RFID pallet and update a
database to reflect the case IDs with a pallet ID of the combined
pallet.
[0058] Turning now to FIGS. 21A to 21E, illustrated are flow
diagrams and screen shots demonstrating RFID pallet tag encoding
(referred to as "Subsystem 11" and designated step "11" in FIG. 8
and steps "11" and "11B" in FIG. 9). FIG. 21A illustrates a flow
diagram that includes manual triggering of the RFID pallet tag
encoding. The RFID application system reads for unique case
identification numbers ("case IDs") that are systemically
associated with a unique pallet identification number ("pallet ID")
as well as a license plate number ("LPN"). The pallet ID is to the
case ID like a parent/child relationship. This parent/child
relationship is useful in determining which pallet RFID tag value
should be encoded and printed. By RFID reading the children, the
identification number of the parent is located in the database and
sent, via the printer applicator controller, to a printer
applicator or a table top printer for encoding/printing.
Additionally, the printer applicator may create and print an RFID
tag directly onto the product without a need for a separate label,
or the like.
[0059] Turning now to FIG. 21B (collectively FIGS. 20B-1 and
21B-2), illustrated is flow diagram of an automated version of the
RFID pallet tag encoding subsystem. Instead of the manually
triggered event, a photo eye triggers the child read with the
parent lookup. Those skilled in the art understand that there could
be any number of triggering events that fall within the scope of
the present invention. Again, several subsystems such as the
compliance manager and printer applicator controller of the RFID
application system are invoked to perform RFID pallet tag encoding
and verification.
[0060] The screen shots provided in FIGS. 21C to 21E illustrate
exemplary screens generated by the RFID application system to
facilitate pallet RFID tag writing (and encoding) and verification.
In addition, operator instructions are provided as needed, thereby
reducing operator error and operator training. More specifically,
FIG. 21C is an initial operator screen when performing the pallet
RFID tag write/verify process. On this screen, the operator
triggers the reading of case IDs so that the RFID application
system will know to which pallet ID the cases belong. Once the RFID
application system has identified which pallet ID and LPN goes on
the pallet, it triggers the print jobs to the appropriate printers.
The screen shot of FIG. 21D shows exemplary graphical instructions
as to pallet RFID tag and LPN placement locations on the pallet.
After the pallet RFID tag is applied, the operator will validate
that the pallet RFID tag can be read. Once read successfully, the
screen as illustrated in FIG. 21E will update dynamically with an
icon. In the illustrated embodiment, an icon in the form of a light
indicates a passing validation. If the validation failed, the light
indicator may be red and the operator would be given the
opportunity to reprint the pallet RFID tag and/or revalidate the
pallet.
[0061] Turning now to FIG. 22, illustrated is a flow diagram of the
application of an encoded and printed pallet RFID tag to a pallet
in a location per an RFID mandate (referred to as "Subsystem 12"
and designated step "12" in FIGS. 8 and 9). This is an illustration
of a manual and automated application of the pallet RFID tag. In
the manual process, the printed RFID tag is removed from a table
top RFID printer, peeled, and applied to the pallet. The RFID
application system provides the operator a user interface with a
photo or graphic of where to apply the RFID tag on the pallet by
specifying side and x-, and y-coordinates when facing that
side.
[0062] The RFID application system in conjunction with the
compliance manager provides a methodology by which the RFID tag may
be located in a different place for different RFID mandate
standards or in different places based on SKU. In either case, the
user interface will provide the appropriate instructions to
accomplish the task. Those skilled in the art understand that the
location may vary SKU to SKU as the RFID properties of every
product are not the same. The ability to account for this variation
is within the context of the RFID application system.
[0063] Turning now to FIG. 23 (collectively FIGS. 23A and 23B),
illustrated is a flow diagram of a validation of the applied pallet
RFID tag once placed on the pallet (referred to as "Subsystem 13"
and designated step "13" in FIGS. 8 and 9). Since this is how the
specification is defined by the retail establishment's standard in
this embodiment (pallet ID should be read on the pallet), it is
preferable that a validation read be performed in the same manner
in which the retailer will be reading that pallet at their
facility. There are automatic and manual methods described in the
flow diagram that explain how the validation is performed. Again,
an RFID reader may be configured by the configuration system of the
RFID application system, and the validation process invokes several
subsystems thereof such as the event manager to coordinate an
operation of the RFID reader and the compliance manager to validate
the RFID tag and the RFID tagged pallet.
[0064] The RFID application system also accommodates non-RFID
pallets in these processes and has ways of determining if these are
RFID pallets or not. For example, a non-RFID pallet would not have
case IDs on the cases. The RFID application system leverages this
knowledge in that upon sensing a pallet, it first attempts to read
case IDs (indicated in a header value on the case ID). If no case
RFID tags are read, then the RFID application system deduces that
the current pallet is a non-RFID pallet and skips RFID processes
therefor. This additional flexibility is important to a complete
solution offering since current mandate volumes need not be at 100%
of production, and "RFID only" is not a requirement of the RFID
application system. As such, customers have the capability to RFID
tag a small percentage of their products and scale that volume up
as mandates evolve. The RFID application system pragmatically
accommodates these operational realities while existing as a
scalable solution.
[0065] After the pallet RFID tag is applied, operators may take the
pallet away to storage or to shipping for loading onto an outbound
vehicle. If the pallet is still to be moved with a warehouse
management system ("WMS") or with any other type of inventory
tracking system, it will likely be necessary to re-apply the
license plate number ("LPN") so that the WMS can locate the product
efficiently.
[0066] Turning now to FIG. 24 (collectively FIGS. 24A and 24B),
illustrated is a flow diagram that demonstrates printing and
re-application of the LPN which, as an integration of the RFID
application system in cooperation with the WMS operations, further
makes the system more seamless to operator (referred to as
"Subsystem 14" and designated step "14" in FIGS. 8 and 9). In
addition, this step in the process allows for better inventory
control of RFID tagged pallets so that the additional cost of RFID
tags and labor do not to go to waste if the pallet were to be
accidentally shipped to a customer that is not equipped to receive
RFID pallets/cases.
[0067] Turning now to FIG. 25, illustrated is a flow diagram
demonstrating a pallet leaving the RFID system area once the LPN or
moveable unit identification is on the pallet (non-RFID labeled in
this example) (referred to as "Subsystem 15" and designated step
"15" in FIGS. 8 and 9). The RFID application system allows for
fully integrated RFID/LPN tags. The FIGURE illustrates how fork
lift operators or material handling equipment are capable of
removing the product from a line of the RFID system for movement
into storage racks, loading into shipping trucks, or any other
pre-designated function. An event manager of the RFID application
system may coordinate the activity associated with moving the
pallets.
[0068] Turning now to FIGS. 26A (collectively FIGS. 26A-1 and
26A-2) to 26F, illustrated are flow diagrams and screen shots
demonstrating a rework operation in the event of damaged cases or
post-application RFID tag failure (referred to as "REWORK" and
designated step "RW" in FIGS. 8 and 9). While the RFID application
system alleviates many of the errors associated with the
conventional processes, the RFID application system provides
end-to-end RFID solution capabilities and includes a capability for
reworking RFID tagged products in the event of emergencies or
accidents and can maintain records of the specific errors (e.g.,
RFID tag in the wrong location or defective RFID tag) for quality
assurance.
[0069] For example, if an RFID tagged pallet is stored in the
warehouse racks and an operator of a forklift hits and damages two
RFID tagged cases, the RFID tags may survive the impact, but the
cases may be damaged to the point of loss. Instead of negating the
entire pallet of RFID cases and removing them from the database,
the rework process allows for the operator to add two more cases in
good condition while the RFID application system automatically
provides two more case IDs with correctly encoded values via the
compliance manager. Not only are the RFID case labels encoded, but
the RFID application system automatically updates the damaged RFID
tags as damaged status as well as automatically appends the two new
tag identification numbers as children of the original pallet ID.
The solution provides that operators tell the RFID application
system for which RFID tags they want replacements, and they have
three options for identifying the rework candidates.
[0070] FIGS. 26B to 26F illustrate exemplary screen shots generated
by the RFID application system to facilitate the rework process. In
addition, operator instructions are provided as needed and,
consequently, operator error and operator training are reduced. The
options of the screen in FIG. 26B illustrate how operators may scan
the tag identification barcode printed on the case label. The RFID
application system automatically queries the barcoded value,
automatically prints/encodes a replacement, and updates the
database records. The options of the screen in FIG. 26C illustrates
how operators may RFID scan the tag identification number via an
RFID reader and antenna. The RFID application system in conjunction
with the event manager, compliance manager and printer applicator
controller automatically queries the case tag value, automatically
prints/encodes a replacement RFID tag, and updates the database
records. The options of the screen in FIG. 26D illustrate how
operators may RFID scan the entire pallet of cases and pallet IDs
in the event that some case RFID tags are missing entirely. The
RFID application system automatically queries the RFID read values,
automatically identifies and displays the expected RFID tags on
that pallet, allows for the operator to manually choose which RFID
tags to replace, automatically prints/encodes a replacement, and
updates the database records. The screen in FIG. 26E illustrates an
example of how the RFID application system will trap errors if
operators supply errant, invalid, or non-existent tag
identification numbers. The screen in FIG. 26F illustrates how
operators may receive rework RFID tag confirmation so that
operators have feedback that the RFID tag entered is located in the
system from which it was originally created.
[0071] The exemplary FIGUREs and accompanying description contained
herein are indicative of actual RFID applications, and those
skilled in the art realize that many embodiments and permutations
of the RFID application system could exist from the systems,
subsystems or objects disclosed herein. The aforementioned example
is intended to convey an understanding of how the RFID application
system can be employed to enable RFID compliance and is not
restricted to the illustrations and application provided above.
Additionally, exemplary subsystems and modules within the RFID
application system were illustratively and non-exhaustedly invoked
to perform the aforementioned steps. The RFID application system is
preferably an automated system that controls and monitors the RFID
system and provides status, alarms, logs and/or corrective measures
therefor.
[0072] Turning now to FIGS. 27 to 43, illustrated are a system
level diagram and flow diagrams of an embodiment of an RFID system
including an embodiment of an RFID application system that
demonstrate exemplary steps of operating the same in accordance
with the principles of the present invention. For purposes of
illustration, FIGS. 37, 38 and 39 have been divided into FIGS. 37A
and 37B, 38A and 38B, and 39A and 39B, respectively. The
aforementioned RFID system and steps of operating the same provide
yet another exemplary method of operating the RFID application
system. The figures assist in the understanding of a flow of
information and goods therefor. As before, the illustrated
embodiments provide specific examples associated with the RFID
application system, and variations therefrom are well within the
broad scope of the present invention. Also, the FIGUREs herein and
accompanying description may use definitive language for the sake
of specific examples. It should be understood that the definitive
language may be replaced with permissive language in accordance
with the principles of the present invention.
[0073] For a better understanding of RFID technologies, in general,
see "RFID Handbook," by Klaus Finkenzeller, published by John Wiley
& Sons, Ltd., 2.sup.nd edition (2003), which is incorporated
herein by reference. For a better understanding of RFID tags in
compliance with the EPC, see "Technical Report 860 MHz-930 MHz
Class I Radio Frequency Identification Tag Radio Frequency &
Logical Communication Interface Specification Candidate
Recommendation," Version 1.0.1, November 2002, promulgated by the
Auto-ID Center, Massachusetts Institute of Technology, 77
Massachusetts Avenue, Bldg 3-449, Cambridge Mass. 02139-4307, which
is incorporated herein by reference. For a related application, see
U.S. Patent Application Publication No. 2006/0212141, entitled
"Radio Frequency Identification-Detect Ranking System and Method of
Operating the Same," Abraham, Jr., et al., filed Feb. 24, 2006,
which is incorporated herein by reference. For a better
understanding of conventional RFID readers, see the following RFID
readers, namely, "MP9320 UHF Long-Range Reader," provided by SAMSys
Technologies, Inc. of Ontario, Canada, "MR-1824 Sentinel-Prox
Medium Range Reader," by Applied Wireless ID of Monsey, N.Y. (see
also U.S. Pat. No. 5,594,384 entitled "Enhanced Peak Detector,"
U.S. Pat. No. 6,377,176 entitled "Metal Compensated Radio Frequency
Identification Reader," and U.S. Pat. No. 6,307,517 entitled "Metal
Compensated Radio Frequency Identification Reader"), "2100 UAP
Reader," provided by Intermec Technologies Corporation of Everett,
Wash. and "ALR-9780 Reader," provided by Alien Technology
Corporation of Morgan Hill, Calif. The aforementioned references,
and all references herein, are incorporated herein by reference in
their entirety.
[0074] Also, although the present invention and its advantages have
been described in detail, it should be understood that various
changes, substitutions and alterations can be made herein without
departing from the spirit and scope of the invention as defined by
the appended claims. For example, many of the systems, subsystems
and methodologies discussed above can be implemented in different
methodologies and replaced by other related systems and subsystems,
or a combination thereof, to advantageously form an RFID
application system for an RFID system as described herein.
[0075] Moreover, the scope of the present application is not
intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one of
ordinary skilled in the art will readily appreciate from the
disclosure of the present invention, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed, that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized according to the present invention. Accordingly, the
appended claims are intended to include within their scope such
processes, machines, manufacture, compositions of matter, means,
methods, or steps.
* * * * *