U.S. patent application number 13/169470 was filed with the patent office on 2011-10-20 for systems and methods for stamping packaged goods in the nature of cigarettes.
This patent application is currently assigned to VELOCITI ALLIANCE NORTH AMERICA INC.. Invention is credited to David S. Driskill, Richard L. Froehlich, Steven D. Morrison.
Application Number | 20110252744 13/169470 |
Document ID | / |
Family ID | 46330211 |
Filed Date | 2011-10-20 |
United States Patent
Application |
20110252744 |
Kind Code |
A1 |
Driskill; David S. ; et
al. |
October 20, 2011 |
SYSTEMS AND METHODS FOR STAMPING PACKAGED GOODS IN THE NATURE OF
CIGARETTES
Abstract
A computer-implemented method for processing tobacco-oriented
goods is disclosed. The method includes moving, in a consecutive
sequence, a plurality of tobacco product containers across a path.
The path takes them within range of a pushing mechanism. The
consecutive sequence is determined based at least upon a picking
support component that causes the plurality of tobacco product
containers to interject tobacco product containers of a first order
in between two different collections of tobacco product containers
of a second order. The method also includes utilizing the pushing
mechanism so as to remove the tobacco products of the second order
from the consecutive sequence. This is done through activation of
the pushing mechanism so as to route the tobacco products of the
second order to a takeaway mechanism.
Inventors: |
Driskill; David S.;
(Greenville, SC) ; Morrison; Steven D.; (Piedmont,
SC) ; Froehlich; Richard L.; (Simpsonville,
SC) |
Assignee: |
VELOCITI ALLIANCE NORTH AMERICA
INC.
Greenville
SC
|
Family ID: |
46330211 |
Appl. No.: |
13/169470 |
Filed: |
June 27, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12046697 |
Mar 12, 2008 |
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13169470 |
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11717612 |
Mar 13, 2007 |
7844360 |
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12046697 |
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60795931 |
Apr 27, 2006 |
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60847033 |
Sep 25, 2006 |
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Current U.S.
Class: |
53/444 |
Current CPC
Class: |
B65B 19/28 20130101;
B41K 3/62 20130101; G06Q 10/06 20130101 |
Class at
Publication: |
53/444 |
International
Class: |
B65B 19/34 20060101
B65B019/34 |
Claims
1. A computer-implemented method for processing tobacco-oriented
goods, the method comprising: moving, in a consecutive sequence, a
plurality of tobacco product containers across a path that takes
them within range of a pushing mechanism configured to effectuate
an ejection of any of the tobacco product containers onto a
takeaway mechanism such that the ejection causes at least one of
the tobacco product containers to be removed from the consecutive
sequence, and wherein the consecutive sequence is determined based
at least upon a picking support component that causes the plurality
of tobacco product containers to interject tobacco product
containers of a first order in between two different collections of
tobacco product containers of a second order; and utilizing the
pushing mechanism so as to remove the tobacco products of the
second order from the consecutive sequence by activating the
pushing mechanism so as to route the tobacco products of the second
order to the takeaway mechanism while the tobacco products of the
first order continue along the path.
2. The method of claim 1, wherein when the tobacco products of the
first order continue along the path after said activation of the
pushing mechanism they continue along the path to within range of a
second pushing mechanism configured to effectuate an ejection of
the tobacco products of the second order onto a second takeaway
mechanism.
3. The method of claim 1, wherein the consecutive sequence is
determined based on batch-organized picking instructions generated
by the picking support component.
4. The method of claim 1, wherein the plurality of tobacco product
containers is a plurality of cigarette cartons.
5. The method of claim 1, wherein the path takes the plurality of
tobacco products within range of a plurality of pushing mechanisms,
including said pushing mechanism.
6. The method of claim 1, wherein said moving the plurality of
tobacco product container across the path comprises moving the
plurality of tobacco product containers in the consecutive sequence
along a conveyor belt.
7. The method of claim 1, wherein moving the plurality of tobacco
product containers comprises moving the plurality of tobacco
product containers within a product flow that includes a flow
through a tax jurisdiction stamping machine.
8. A computer-implemented method for processing tobacco-oriented
goods, the method comprising utilizing an automated pushing
mechanism to respond to instructions from a batch handling software
component by pushing a plurality of individual tobacco product
containers out of a moving consecutive flow of batch picked tobacco
product containers based on an indication that the plurality of
individual tobacco product containers are being shipped to the same
location as part of the same order.
9. The method of claim 8, wherein the plurality of individual
tobacco product containers are organized in the moving consecutive
flow such that not all tobacco product containers being shipped to
the same location as part of the same order are adjacent to one
another.
10. The method of claim 8, wherein the tobacco product containers
are cigarette cartons.
11. The method of claim 8 further comprising routing each of the
individual tobacco product containers through a stamp machine.
12. The method of claim 8, further comprising routing each of the
individual tobacco product containers through a stamp machine such
that each individual tobacco product container is stamped with a
tax jurisdiction stamp.
13. A method for processing tobacco-oriented goods, the method
comprising: picking a sequence of tobacco product containers and
placing them consecutively on a takeaway mechanism, wherein the
sequence blends individual units of multiple tobacco product orders
together such that the tobacco product orders are not completely
picked consecutively from one order to the next such that the
sequence is not organized consecutively from one order to the next;
and disrupting the sequence by diverting a set of the tobacco
product containers out of the sequence, wherein each container in
the set of the tobacco product containers is stamped with a tax
jurisdiction stamp.
14. The method of claim 13, wherein the set of the tobacco product
containers is selected based on assignment to a particular one of
the tobacco product orders.
15. The method of claim 13, wherein disrupting comprises activating
a pushout mechanism.
16. The method of claim 13, wherein disrupting comprises routing
down a takeaway mechanism.
17. The method of claim 13, wherein disrupting comprises routing to
a packing station.
18. The method of claim 13, wherein the tobacco product containers
are cigarette cartons.
19. The method of claim 13, wherein disrupting comprises activating
a pushout mechanism so as to re-route the set of the tobacco
product containers down a takeaway mechanism.
20. The method of claim 19, wherein the takeaway mechanism is a
conveyor belt.
Description
BACKGROUND
[0001] The present application is a continuation of, and is based
on, and claims the benefit of U.S. utility patent application Ser.
No. 12/046,697, filed on Mar. 12, 2008, the content of which is
hereby incorporated by reference in its entirety, which is a
continuation-in-part of, and is based on, and claims the benefit of
U.S. utility patent application Ser. No. 11/717,612, filed on Mar.
13, 2007, now U.S. Pat. No. 7,844,360, issued Nov. 30, 2010, the
content of which is hereby incorporated by reference in its
entirety, this latter application being based on U.S. provisional
application 60/795,931, filed on Apr. 27, 2006, and this latter
application also being based on U.S. provisional application
60/847033, filed Sep. 25, 2006.
[0002] Currently, there are many different types of materials
handling systems. Typically, such a system will include equipment
configured to move items between required locations on an automated
and/or manually-initiated basis. Depending on the type of items
being handled, some systems may incorporate the functionality of
specialized equipment, such as equipment for weighing or performing
some other measurement function within the materials handling
system.
[0003] Some materials handling systems are designed specifically
for processing packaged tobacco products, such as cartons of
cigarettes. Currently, there are many disadvantages associated with
such systems. For example, in terms of operator function, most
systems require frequent movement of the operator to the product
rather than bringing the product to the operator. Further, while
some current systems support the passing of packages of tobacco
products through a stamping machine, there are usually significant
limitations on the flexibility of the stamping process. Still
further, current systems commonly support the sorting of one
package to a single order at a time.
[0004] The discussion above is merely provided for general
background information and is not intended for use as an aid in
determining the scope of the claimed subject matter. Also, the
claimed subject matter is not limited to implementations that solve
any or all disadvantages noted in this background section.
SUMMARY
[0005] Embodiments of a computer-implemented method for processing
tobacco-oriented goods are disclosed. In one embodiment, the method
includes moving, in a consecutive sequence, a plurality of tobacco
product containers across a path. The path takes them within range
of a pushing mechanism configured to effectuate an ejection of any
of the tobacco product containers onto a takeaway mechanism such
that the ejection causes at least one of the tobacco product
containers to be removed from the consecutive sequence. The
consecutive sequence is determined based at least upon a picking
support component that causes the plurality of tobacco product
containers to interject tobacco product containers of a first order
in between two different collections of tobacco product containers
of a second order. The method also includes utilizing the pushing
mechanism so as to remove the tobacco products of the second order
from the consecutive sequence by activating the pushing mechanism
so as to route the tobacco products of the second order to the
takeaway mechanism while the tobacco products of the first order
continue along the path.
[0006] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is schematic diagram of a materials handling system
for processing tobacco-oriented goods.
[0008] FIG. 2 is a flow chart diagram demonstrating process steps
that, in one embodiment, are executed within the materials handling
system.
[0009] FIG. 3 is a schematic diagram of a computing device with
materials handling system software operatively installed
thereon.
[0010] FIG. 4 is a perspective view of a portion of the materials
handling system.
[0011] FIG. 5 is a perspective view of a portion of the materials
handling system.
[0012] FIG. 6 is a simplified schematic representation of a
specialized conveyor system.
[0013] FIG. 7 is a perspective view of a portion of the materials
handling system.
[0014] FIG. 8 is a perspective view of a portion of the materials
handling system.
[0015] FIG. 9 is a flow chart diagram demonstrating steps
associated with a packing process.
[0016] FIG. 10 is a perspective view of a portion of the materials
handling system.
DETAILED DESCRIPTION
[0017] FIG. 1 is a schematic diagram of a materials handling system
100 for processing packaged tobacco products, such as, but not
necessarily limited to, cartons of cigarettes. FIG. 2 is a flow
chart diagram demonstrating processing steps that occur within
system 102. FIG. 3 is a schematic diagram of a computing device 302
having materials handling system software 304 operatively installed
thereon. Software 304 is illustratively configured to facilitate
the management of various functions associated with operation of
materials handling system 100, many of which will be described in
detail below. The components and operation of system 100 will be
described in relation to the related process of FIG. 2, as well as
in relation to related components of software 304.
[0018] In accordance with block 202 in FIG. 2, a first step in the
overall materials handling process is product picking. Generally
speaking, in the context of FIG. 1, the picking process involves
removing cartons of cigarettes from picking stations 102 and
placing them onto a conveyor 104 that moves the cartons from right
to left (relative to the orientation of FIG. 1).
[0019] In one embodiment, software component 305 is configured to
interface with system 100 so as to support management of the
picking process. The precise details of configuration will vary
depending upon the details of a given picking implementation.
Without departing from the scope of the present invention, the
picking process can be entirely automated, semi-automated or
entirely manually accomplished. In one example of a purely manual
implementation, a human selects cartons from one or more picking
stations 102 based on instructions reflected in a paper-based
listing, for example, a paper-based listing of what products should
be picked and in what sequence.
[0020] In a typical semi-automated picking system, a human selects
cartons from one or more of the picking stations 102 based on an
electronically supported system that presents automated cues (e.g.,
visual or audible cues). In one embodiment, a mechanism is employed
to verify that human has properly responded to the cues. For
example, the system may require the human to provide feedback
(e.g., pushing a button, speak a command into a microphone, etc.)
to verify compliance with a particular cue, which illustratively
triggers initiation of the next cue. An alarm or some other
response is illustratively provided if feedback from the human
picker is inconsistent with expectations based on the currently
active cue.
[0021] In a more specific example of a semi-automated picking
system, an LED is illuminated to identify a product type (e.g., the
identity, SKU and/or location) as the next candidate for picking.
The same or a different LED mechanism also indicates the quantity
to be picked. Once picked, the LED mechanism or mechanisms are
turned off in a manner that indicates compliance with the picking
instruction. This may occur in any of a variety of different ways
such as, but not limited to, depression of a button by the human
picker. Alternatively, the indicator(s) may be automatically
extinguished when determined by a sensor (e.g., an electronic eye,
a laser sensor, etc.) that the current picking instruction is
likely to have been fulfilled.
[0022] In another example, an audibly directed picking system is
implemented wherein audible commands are transmitted to an
operator-worn headset to notify a human operator of the next pick
location, quantity, description, check digit for verification
purposes, and/or some other form of instruction. In one embodiment,
the operator speaks into a microphone to notify the system, via
speech recognition, of exceptions and/or pick verification. It
should be noted that hybrid systems are also within the scope of
the present invention, such as a system wherein visual aids are
utilized to provide picking locations and audible cues are utilized
to indicate the applicable quantity, exceptions, completions,
and/or other picking-related information.
[0023] Those skilled in the art will appreciate that the picking
implementations provided in the previous paragraphs are simply
examples of many alternatives within the scope of the present
invention. Fully automated alternatives, such as where machines
handle automatically the process of moving cartons to conveyer 104,
are also within the scope of the present invention. The present
invention is not limited to any one particular means for
implementing the picking process.
[0024] In one embodiment, not by limitation, picking stations 102
include shelves containing cigarettes in bulk quantities organized
by type. For example, cartons of a particular type of Marlboro
cigarettes are grouped together in a first location while cartons
of a particular type of Camel cigarettes are grouped together in a
different location (though a given type might be stocked in more
than one location).
[0025] In one embodiment, logic is applied to selectively organize
and distribute products across and/or within the picking stations
104. For example, certain types of product may be assigned certain
locations based on an objective criteria such as, but not
necessarily limited to, anticipated quantities needed. In this
case, a type likely to be needed relatively frequently might be
assigned a location that is easier to access (e.g., by a human)
than a location assigned to a type that is likely to be less
frequently needed. Or, a type of product likely to be needed in
large quantities might be assigned a location that is easier to
access than a location assigned to a type that is more likely to be
needed in small quantities. One area might be reserved for picking
large quantities (e.g., cases of cartons) of a product while
another area might be reserved for picking small quantities (e.g.,
individual cartons) of the same product. Those skilled in the art
will appreciate that it is within the scope of the present
invention to organize products across and/or within picking
stations 102 based on any basis. The basis may include, but is not
limited to, the goal of maximizing efficiency (e.g., reducing the
amount of movement required for a human participating in the
picking process).
[0026] Picking instructions are illustratively generated within
software system 304 (e.g., by support components 305) and issued
into materials handling system 100 as appropriate depending upon
the nature of the implemented picking system. In one embodiment,
the picking instructions are organized around the concept of an
order. For example, all components of a first order are picked
(e.g., placed on conveyer 104). Then, then all the components of a
second order are picked. This process continues until all orders
have been picked. Some efficiency considerations may be worked in
to the order-based picking process. For example, certain orders may
be given higher priority than others for a variety of different
reasons (e.g., truck scheduling, etc.). Or, the components within
an order may be organized to minimize how much a human picker must
move around while picking the order. However, it is typically true
that all components of a first order must be picked before moving
on to a second order. To compromise this mandate will typically
mean compromising the accuracy of order management downstream in
the system.
[0027] In one embodiment, as is shown in FIG. 3, materials handling
software system 304 includes a batch handling component 306.
Component 306 is illustratively a software tool that enables a user
to influence the quantity and type of products to be picked, as
well as the order in which picking occurs. How this influence is
translated to the picking process is dependent upon the nature of
the picking system. For example, in one embodiment, in a purely
manual system, software component 306 is configured to assist in
the generation of a list or lists from which one or more human
pickers work. In another embodiment, in a semi-automated system,
software component 306 is configured to influence what cues are
provided to one or more human pickers. In yet another embodiment,
in an automated system, software component 306 is configured to
influence the operation of the machines responsible for the picking
process. Those skilled in the art will appreciate that the precise
functionality of software component 306 is at least partially
dependent upon the nature of the applicable picking
implementation.
[0028] In accordance with one embodiment, picking instructions
generated by component 306 are organized around the concept of a
batch. Generally speaking, a single batch may contain components
from different orders. Typically, components of a first batch are
picked followed by the picking of components of a second batch, and
so on and so forth until all batches have been picked. The
assumption is that orders can be mixed because other mechanisms are
utilized downstream in the system in order to organize on an
order-specific basis. The components of a batch are typically
picked from a single inventory of product (e.g., distributed across
picking stations 102). A human participant in a batch-based picking
process illustratively may not be aware (e.g., may receive no
indication) of what specific order he or she is in the process of
picking.
[0029] In one embodiment, software component 306 is configured to
receive indications of orders and generate corresponding
batch-based picking orders in accordance with one or more
user-selected and/or default organizing principles. This
illustratively, but not necessarily, means combining components of
different orders into the same batch. This is not to say that
batch-based picking instructions must originate within materials
handling system software 306. Those skilled in the art will
appreciate that batch-based picking instructions can be generated
by an external system and transmitted to software 304 (e.g., to
component 306) for processing within the applicable picking system
(e.g., system 100).
[0030] As has been alluded to, the batch-based picking instructions
can be organized based on any of a variety of different
user-selected and/or default parameters. For example, not by
limitation, software component 306 can be configured to create
batches so as to optimize one or more of the following constraints
in any combination: 1) desired order completion cutoff time; 2)
desired truck route or routs; 3) desired carton size or sizes in a
batch; 4) target overall batch size; and/or 5) target work effort
to complete the batch. In one embodiment, all available orders are
merged into the batching process. In another embodiment; however,
software 304 and/or system 100 are configured to support either or
both batch-based and order-based picking.
[0031] FIG. 4 is a perspective view of a portion of system 100. The
view shows the two picking stations 102 that are located closest to
a pair of stamping machines 106. Stations 102 are shown as empty
but would more typically be stocked with products. Conveyer 104 is
shown in FIG. 4. Picked cartons of tobacco products move down
conveyer 104 toward stamping machines 106.
[0032] In one embodiment, items are picked in either case
quantities (e.g., 30 cartons per case) or individual cartons (based
on picking instructions). Picked cartons are placed on conveyor 104
and, in one embodiment, are oriented such that the widest dimension
of the carton is perpendicular to the direction of travel. The
flaps of the carton are illustratively oriented so as to be
conducive to properly entering stamping machines 106. A second
takeaway conveyer 108 is illustratively provided and operates
beneath conveyor 104. Case quantities are placed onto the lower
conveyor 108.
[0033] Thus, an instruction to pick a large quantity of a given
product can be picked by placing a case of the product on the lower
conveyor and then one or more individual cartons on the upper
conveyor as necessary to round out the total number of cartons
needed. In one embodiment, such a picking instruction requires the
person picking to use their intuition to determine when a case can
be picked rather than individual cartons. In another embodiment;
however, picking support components 305 are configured to automate
such determinations and incorporate the option of case picking into
the picking instructions. Depending on exactly how the rest of
system 100 is set up, assumptions based on the expectation of one
or more cases may or may not be made downstream from the picking
process. For example, if an instruction is made to pick a case,
then downstream processing may or may not require the case to turn
up on the lower conveyor rather than an equivalent amount being
picked individually and placed on the upper conveyor. Whether or
not there will be such a dependency is a detail that is likely to
be implementation-specific.
[0034] In accordance with block 204 in FIG. 2, a next step in the
process is to route picked products to stamping machines 106. At
this point, it is probably a good idea to emphasize that the
present invention is not limited to the particular configuration of
system components shown in FIG. 1. Those skilled in the art will
appreciate that a given implementation is likely to be highly
customized to match the given needs of a particular owner or
operator. With that in mind, it should be pointed out that the
present invention is not limited to incorporating two stamp
machines 106. More or fewer stamping machines can be implemented
without departing from the scope of the present invention. However,
solely for the purpose of describing various aspects of the present
invention in detail, the illustrated case of two stamping machines
will be assumed.
[0035] In one embodiment, as products exit the picking area and
approach the stamp machines, two pick conveyors feed the stamp
machines 106. As is shown in FIG. 5, a lower conveyor handles bulk
quantities. A case 116, which assumedly contains individual
cartons, is shown on the lower conveyor for illustratively
purposes. In one embodiment, case quantities are diverted from the
lower conveyor into a stamping workstation as determined to be
appropriate based on applicable processing parameters. A component
of software 304, namely, a location management component 308, is
illustratively configured to account for such parameters and
trigger mechanical functionality within system 100 as necessary to
appropriately move items through the system.
[0036] When a case arrives at a stamping work station, a human
operator (e.g., an operator of the corresponding stamping machine
106) unloads the cases and manually places the individual cartons
onto an induction conveyor associated with the stamp machine. In
one embodiment, instructions and/or information related to this
bulk unloading task are provided by way of interface 112. In one
embodiment, when the task has been completed, an indication of
completion is provided to location management component 308 by way
of input mechanism 114. When a processing error occurs (e.g., a
bulk item does not get unpacked, etc.), an exception is
illustratively triggered within component 308 and communicates
through operator interface 112. It should be noted that, it is also
within the scope of the present invention to make unloading the
bulk quantities into the stamp machine an automated process.
[0037] In one embodiment, in order to facilitate routing to an
appropriate stamping machine 106, individual cartons on the upper
conveyor are transferred onto a specialized conveyor system. FIG. 6
is a simplified schematic representation of the specialized
conveyor system, which is identified in the Figure as conveyor 600.
Conveyor 600 has a plurality of partitions 606 (a representative
few of which have been labeled) that extend generally perpendicular
to the surface 602 of the conveyor. The spacing between partitions
is illustratively slightly more than the narrowest dimension of a
carton positioned perpendicular to the direction of conveyor
travel.
[0038] In one embodiment, as cartons are transferred from the upper
conveyor 104 into specialized conveyor system 600 (e.g., similar to
the two sample cartons 604 shown in FIG. 6), a reader reads an
identifier from each carton. Those skilled in the art will
appreciate that this identification process could involve
application of any of a number of different identifying
technologies including but not limited to an RFID identification
system, a barcode identification system, a CCD device
identification system, or any other identification system. In one
embodiment, this information is fed into an item tracking component
310, which is part of software system 304. Component 310
illustratively associated the carton's ID with its position in the
partitioned conveyor 600.
[0039] In one embodiment, item location management component 308
receives item location information from item tracking component 310
and utilizes it as a basis for sorting cartons into appropriate
stamping machines. For example, as cartons move on conveyor 600
proximate to the entry points of stamping machines 106, component
308 selectively energizes one or more pushing devices to
selectively push cartons into appropriate stamping machines. The
determination as to the optimum path for a given carton (i.e.,
which is the correct stamping machine) is illustratively based upon
system parameters that are set by system default and/or on a
user-selectable basis (e.g., set by an operator of software
304).
[0040] In one embodiment, software 304 is configured to support
sorting cartons through stamping machines based upon the taxing
authority or authorities for which each individual stamping machine
is set up to support stamping functionality. It is specifically
within the scope of the present invention for multiple taxing
authorities to be picked in a single batch. For example, the
components of a single picked batch may move through different
stamp machines set up to support different taxing authorities. This
is particularly interesting in light of the fact that, as has been
discussed, a given batch may contain components from more than one
order (e.g., multiple orders headed to different locations).
[0041] In another embodiment, software 304 is configured to support
sorting cartons through stamping machines based upon optimization
of the total order fulfillment cycle for a given batch, or for some
other measurement standard such as but not limited to a period of
an entire shift. Those skilled in the art will appreciate that
software 304 can be configured to support sorting cartons through
stamping machines based on many different factors in addition to
those specifically listed herein, to which the scope of the present
invention is not limited.
[0042] In one embodiment, cartons may be sorted among stamping
machines based upon an administrator- or operator-defined set of
rules that are created within software system 304. In one
embodiment, if a carton is not destined for any of the stamping
machines for any reason, the software is configured to stop the
partitioned conveyor, as well as all conveyors upstream as
required. Or, in one embodiment, the software is configured to push
the carton(s) into an exception handling area, for example. In one
embodiment, the handling of such exceptions is configurable based
upon an administrator- or operator-selectable option.
[0043] Those skilled in the art will appreciate that the display
112 and input mechanism 114 (FIG. 5) associated each stamp machine
106 can be configured to support a variety of different functions.
Software system 304 includes stamp machine support components 312
for supporting such functionality.
[0044] In one embodiment, as cartons are scanned (e.g., while being
moved into conveyor 600), components 312 are configured to indicate
on display 112 the quantity of cartons scanned compared against a
total required for each stamping machine and/or the tax
jurisdiction(s) for which the stamping machine is configured. In
one embodiment, components 312 are configured to enable an operator
to input (e.g., through mechanism 114, through a touch screen
implementation of display 112, etc.) information or exceptions as
cartons are stamped. For example, the operator is able to enter
commands or notifications to cause software 304 to initiate an
appropriate response in unusual circumstances such as, but not
limited to, if there is damage to a carton, if a stamping machine
becomes inoperable, or if other unusual situations arise during
stamping.
[0045] In one embodiment, software components 312 are configured to
provide, through display 112, instructions for operators who
receive full case quantities (e.g., on the lower conveyor coming
from the picking area) so that they know how many cartons to remove
from the case and route into the stamping machine. For example, it
is conceivable that the system may be configured to enable less
than all cartons (e.g., less than all 30 cartons) in a bulk amount
received to be indicated for processing.
[0046] In one aspect of the present invention, as cartons move
through stamping machines 106 and are stamped with their unique tax
jurisdictional stamp or stamps, an additional step is taken to
support the subsequent tracking of each carton within system 100.
In one embodiment, a first identifying mark is applied to each
carton. The first identifying mark illustratively does not deface
the carton and, in one embodiment, is invisible in that it is
generally imperceptible to the human eye but can be made visible
(e.g., by placing under a black light), and/or is visible to a
scanner designed to "see" such marks. In addition or alternatively,
a second identifying mark that does deface the carton (e.g., a bar
code label) is applied (e.g., blown onto) to each carton. The
application and tracking of labels is illustratively managed by one
or more of the sub-components of software system 304.
[0047] Various embodiments and components of the present invention
involve applying identifiers to product units and/or reading
identifiers associated with product units. Those skilled in the art
will appreciate that these identification processes could involve
application of any of a number of different identifying
technologies including but not limited to an RFID identification
system, a barcode identification system, a CCD device
identification system, or any other identification system. To the
extent that the present description identifies specific
technologies, the specific technologies are provided as but one
example of an implementation within the scope of the present
invention.
[0048] In accordance with block 206 in FIG. 2, a next step in the
process is to route cartons from stamp machines 106 to one or more
sorting mechanisms 140. In FIG. 1, each stamp machine 106 is
associated with a separate sorting mechanism. Those skilled in the
art will appreciate that this is not the only configuration within
the scope of the present invention.
[0049] For example, in one embodiment, multiple stamp machines 106
feed into the same sorting mechanism 140. In another embodiment,
one stamp machines feeds into multiple sorting mechanisms 140. In
general, it is within the scope of the present invention to
customize the configuration of system 100 (add, subtract and/or
re-arrange the system components) as necessary to fulfill
applicable needs. It is also within the scope of the present
invention that software system 304 is flexibly configured to
effectively support all such configurations.
[0050] In one embodiment, as is generally shown in FIG. 5, cartons
are transferred out of a stamp machine 106 and onto a conveyor that
is configured to transport the cartons such that the longest
dimension travels parallel to the direction of conveyor flow.
However, it is also within the scope of the present invention for
cartons to be ejected from a stamping machine 106 directly into a
sort mechanism 140. Whether cartons are directly or indirectly
transferred into a sorting mechanism is dependent on a variety of
implementation-specific details such as physical space limitations
and configurations at a particular site where a system 100 is to be
installed.
[0051] In one embodiment, a carton approaches a sorting mechanism
140 and is loaded into a specialized sorting conveyor system. In
one embodiment, the specialized sorting conveyor system is
configured the same or similar to conveyor 600 shown in FIG. 6. The
conveyor has a plurality of partitions that extend generally
perpendicular to the surface of the conveyor. The spacing between
partitions is illustratively slightly more than the narrowest
dimension of a carton positioned perpendicular to the direction of
conveyor travel. Cartons feed into the specialized sorting conveyor
system as was described in relation to FIG. 6.
[0052] FIG. 7 is a schematic illustration demonstrating movement of
cartons into and through a sorting mechanism 140. At point 702,
cartons are transferred from a conveyor that moves cartons (moving
parallel to the longest dimension) to a partitioned conveyor the
same or similar to conveyor 600 in FIG. 6 (e.g., wherein cartons
are moved perpendicular to the longest dimension). It should be
noted that, referring to FIG. 7, the sorting mechanism located more
toward the top of the Figure is equipped with its own specialized
sort conveyor for moving the other stream of cartons through the
other sorting mechanism 140. Also, it should be emphasized that it
is also within the scope of the present invention to transfer
cartons directly from a stamping machine 106 into one of the
partitioned sorting conveyors associated with the sorting mechanism
140.
[0053] In one embodiment, as cartons are transferred into the
specialized sorting conveyors, a devices reads an identifier
associated with each carton (e.g., a barcode scanner reads the
manufacturer-applied barcode from each carton) (though this
additional item tracking step may be optional for a given
implementation). Those skilled in the art will appreciate that this
identification process could involve application of any of a number
of different identifying technologies including but not limited to
an RFID identification system, a barcode identification system, a
CCD device identification system, or any other identification
system. In one embodiment, this information is fed into item
tracking component 310, which is part of software system 304.
Component 310 illustratively associated the carton's ID with its
position in the partitioned conveyor.
[0054] In one embodiment, item location management component 308
receives item location information from item tracking component 310
and utilizes it as a basis for selectively ejecting cartons (e.g.,
by selectively energizing one or more pushing mechanisms) onto a
takeaway conveyer. FIG. 7 shows ejected cartons moving (longest
dimension parallel to the direction of motion) along the takeaway
conveyor toward a plurality of boxes 704. The determination as to
the optimum path for a given carton (i.e., which boxes 704 to move
toward) is illustratively based upon system parameters that are set
by system default and/or on a user-selectable basis (e.g., set by
an operator of software 304).
[0055] Thus, as a carton moves into the eject window of a conveyor,
a pushing mechanism ejects the carton onto the takeaway conveyor.
In one embodiment, the ejection determination is based at least in
part on the order to which the carton is assigned (e.g., the
assignment of orders being tracked by a component of software
304).
[0056] Those skilled in the art will appreciate that it is within
the scope of the present invention to adjacently line up multiple
takeaway conveyors. In one embodiment, each takeaway conveyor has
its own specialized sorting conveyor system (e.g., similar to
conveyor 600), the hardware and software being configured to
appropriately route a given carton to the takeaway conveyor
associated with the carton's final destination while bypassing the
other takeaway conveyors. In another embodiment, a single
specialized sorting conveyor feeds multiple takeaway conveyors
(e.g., the carton moves along all the takeaway conveyors until
ejection from the specialized sorting conveyor is appropriate based
on system parameters).
[0057] Regardless of the configuration of sorting mechanisms 140,
and regardless of whether there is more than one, the purpose of
the mechanism or mechanisms is illustratively to sort the cartons
based on parameters set within software 304. The parameters are
indicative of one or more bases for organization such as but not
limited to order-oriented organization. Those skilled in the art
will appreciate that software 304 can be configured to support
sorting cartons through sorting mechanisms 140 based on many
different factors in addition to order-oriented organization, to
which the scope of the present invention is not limited. In one
embodiment, cartons may be sorted based upon an administrator- or
operator-defined set of rules that are created within software
system 304. Finally, it is worth specifically pointing out that it
is within the scope of the present invention for cartons to be
picked on a batch-oriented basis (e.g., with multiple orders
distributed across a single batch) and then, after the stamping
process, sorted on an order-specific or some other basis.
[0058] In accordance with step 208, a next step in the process is
to collect the cartons from the end of the sorting mechanism
takeaway conveyers and pack them into boxes 704. When cartons
arrive at the end of the sort mechanism takeaway conveyor, they are
sorted to the extent that an operator can simply pick them up
directly from the end of the conveyor and place them into a
corresponding box 704. FIG. 8 is a schematic illustration showing
an operator 802 standing in front of boxes 704.
[0059] Cartons that are grouped along parallel sort mechanism
takeaway conveyors are presented for packing in such a manner that
multiple cartons can be picked up and packed into boxes 704 in a
single motion (as opposed to packing cartons one at a time). The
packer must, however, still determine how many cartons to pack into
which boxes. Without departing from the scope of the present
invention, the process of moving cartons from the end of the
sorting mechanism takeaway conveyor into boxes 704 can be entirely
automated, semi-automated or entirely manually accomplished.
Packing system software components 314 are illustratively
configured to support the implemented packing functionality.
[0060] In one example of a purely manual implementation, a human
operator picks up the cartons and simply places them in
pre-assigned boxes. The operator may be guided by instructions
reflected in a paper-based listing, for example, a paper-based
listing of what products should be packed where. In one embodiment,
software component 314 is configured to support the generation of
the paper-based listing based on default and/or administrator- or
operator-selectable system parameters.
[0061] In one embodiment of a semi-automated implementation, the
operator picks up cartons and decides which box to put them based
on an electronically supported system that presents automated cues
(e.g., visual or audible cues). In one embodiment, a mechanism is
employed to verify that human has properly responded to the cues.
For example, the system may require the human to provide feedback
(e.g., pushing a button, speak a command into a microphone, etc.)
to verify compliance with a particular cue, which illustratively
triggers initiation of the next cue. An alarm or some other
response is illustratively provided if feedback from the operator
is inconsistent with expectations based on the currently active
cue. In one embodiment, software component 314 is configured to
support the management of the semi-automated packing process
(including the handling of exceptions or errors) based on default
and/or administrator- or operator-selectable system parameters.
[0062] In a more specific example of a semi-automated
implementation, an LED is illuminated to identify cartons (e.g.,
the identity, SKU and/or location) as the next candidate for
packing. The same or a different LED mechanism also indicates the
quantity to be packed. The same or different LED mechanism
identifies what box to pack the cartons in. Once packed, the LED
mechanism or mechanisms are turned off in a manner that indicates
compliance with the picking instruction. This may occur in any of a
variety of different ways such as, but not limited to, depression
of a button by the operator. Alternatively, the indicator(s) may be
automatically extinguished when determined by a sensor (e.g., an
electronic eye, a laser sensor, etc.) that the current picking
instruction is likely to have been fulfilled. In one embodiment,
software component 314 is configured to support the management of
the semi-automated process (including the handling of exceptions or
errors) based on default and/or administrator- or
operator-selectable system parameters.
[0063] In another example, an audibly directed system is
implemented wherein audible commands are transmitted to an
operator-worn headset to notify a human operator of the next box to
pack in, a quantity to be packed, and/or some other form of
instruction. In one embodiment, the operator speaks into a
microphone to notify the system, via speech recognition, of
exceptions and/or packing verification. It should be noted that
hybrid systems are also within the scope of the present invention,
such as a system wherein visual aids are utilized to provide
packing locations and audible cues are utilized to indicate the
applicable quantity, exceptions, completions, and/or other
packing-related information. In one embodiment, software component
314 is configured to support the management of the packing process
(including the handling of exceptions or errors) based on default
and/or administrator- or operator-selectable system parameters.
[0064] In one embodiment, pick-up sensors are provided at the
carton pick-up point on the proximal end of the sorting mechanism
takeaway conveyor. The sensors are illustratively configured to
produce a signal indicating when cartons have been picked up, and
to identify which parallel row of the sorting takeaway conveyor the
picked up cartons belong to. Put-down sensors are illustratively
provided proximate boxes 704 and are configured to identify in
which box 704 picked up cartons have been placed.
[0065] FIG. 9 is a flow chart diagram demonstrating steps
associated with one implementation of pick-up and put-down sensors.
In accordance with box 902, pick-up sensors identify a pick-up
instance. In accordance with block 904, put-down sensors identify a
putdown instance. In accordance with block 906 a determination is
made as to whether the put-down is consistent with the pick-up
(e.g., whether it was an accurate put-down). If not, in accordance
with box 908, an exception or error-handling process is initiated
(e.g., an alarm is triggered, etc.). In accordance with box 910, if
the put-down was accurate, the process is repeated following the
next sensed pick-up instance. In one embodiment, software component
314 is configured to support the management of the pick-up/put-down
process (including the handling of exceptions or errors) based on
default and/or administrator- or operator-selectable system
parameters. In one embodiment, the described pick-up/put-down
system is implemented in conjunction with a system, such as but not
limited to those described herein, for instructing the operator as
to which items to pick up and where to put them.
[0066] Those skilled in the art will appreciate that the
implementations provided in the previous paragraphs are simply
examples of many alternatives within the scope of the present
invention. Fully automated alternatives, such as where machines
handle automatically the process of moving cartons into boxes 704,
are also within the scope of the present invention. The present
invention is not limited to any one particular means for
implementing the packing process.
[0067] In accordance with one embodiment, one or more display
panels are made visible to an operator responsible for packing
boxes 704. When a shipping container (i.e., a box 704) is full,
software system 304 causes the display panel(s) to show a graphical
depiction of what the full container should look like from the
operator's point of view. For example, the brand logos on the end
of the cartons collectively form an image of sorts. The operator
compares the graphical representation on the display panel to the
appearance of the cartons in a full box. In this manner, the
operator uses the display panel as a mechanism to verify that the
shipping container has been properly filled. In one embodiment,
filling exceptions or errors are reported and/or corrected by
interacting with software system 304 through inputs into the
display panel or an associated input mechanism.
[0068] In one embodiment, after a container (e.g., a box 704) has
been properly filled, a shipping label is manually or automatically
applied (though it is also within the scope of the present
invention to apply the shipping label before or during the packing
process). In one embodiment, the box content (e.g., by SKU, by
quantity, etc.) is indicated on the label. Once labeled, the
container is put on a takeaway conveyor. In one embodiment, with
reference to FIG. 8, user 802 can send out a fully packed and
labeled box 704 simply pushing the box backwards onto a takeaway
conveyor located behind the boxes.
[0069] In accordance with block 210, another step in the process is
the routing of the packed containers for final shipping. FIG. 10 is
a schematic representation of an accumulation area 1004. Full
containers (e.g., the containers pushed back onto takeaway
conveyors by user 802 in FIG. 8) are moved into the accumulation
area on conveyors 1002. Two conveyors, an upper conveyor configured
to move boxes 704 stacked on top and a lower conveyor configured to
move boxes 704 stacked on bottom, are shown in FIGS. 1 and 8.
However, more or fewer takeaway conveyors can be implemented to
support a particular packing station configuration (e.g., to
support more or fewer sorting mechanisms 140).
[0070] In one embodiment, as containers approach accumulation area
1004, a reader (e.g., a radio frequency reader, a barcode reader,
etc.) is configured to identify the packages. Based on default
and/or administrator- or operator-defined parameters set within
software system 304, some packages are illustratively diverted into
the accumulation area 1004, while other packages may be allowed to
continue past the accumulation area to a shipping area. Shipping
containers in the accumulation area are illustratively
re-circulated, read, and routed to the shipping area when system
parameters indicate that such action is appropriate.
[0071] There are a variety of interesting features associated with
the embodiments of materials handling systems described herein. For
example, various system components enable products to be brought to
a human operator rather than requiring the operator to move to the
products.
[0072] Further, sorting mechanism 140 is configured to sort
products into specific orders, rather than requiring operators to
pick up the products and sort them, for example based on digital
lights, etc.
[0073] Further, products can be routed through multiple stamping
machines while maintaining product identity. If one stamping
machine is stamping for one state, a second stamping machine can be
stamping for a different state. However, orders from both states
can be picked in the same batch.
[0074] Further, multiple products can be handled simultaneously.
For example, at the end of sorting mechanism 140, multiple cartons
(e.g., six cartons) can be picked up. Cartons can be picked up in
groups of three, two, six, etc.). In one embodiment, due to the
functionality of a sorting mechanism 140, when the operator
retrieves a group of cartons, the cartons come directly proximate
to the case in which they are to be located. This list of benefits
is not exhaustive. These are just examples of many potential
benefits.
[0075] As has been described, the picking process that occurs early
on within the flow of materials handling system can be organized
around the concept of a batch. As has been described, a single
batch may contain products from different orders. The assumption is
that orders can be mixed up within a batch because other mechanisms
are utilized downstream in the system in order to organize on an
order-specific basis. In one embodiment, the process of organizing
into order-specific groups occurs not just downstream of the
picking process but also downstream from the stamping process
(i.e., downstream from one or more incorporated stamping machines).
Thus, in one embodiment, products are not organized into
order-specific groups when they are moved through the stamping
process.
[0076] As has been described, FIG. 5 is a perspective view of the
stamping area within materials handling system 100. FIG. 5
illustratively shows products as they are exiting the picking area
and approaching stamping machines 106. The products are
illustratively organized around the concept of a batch as described
in the immediately previous paragraph. The details of how products
are identified and moved relative to the stamping machines are
discussed elsewhere in the present specification.
[0077] FIG. 5 shows the interface 112 associated with each stamping
machine. FIG. 11 is an example of a screenshot 1100 that, in one
embodiment, is provided through interface 112. As is indicated in a
header 1102, the associated stamp machine is processing a batch
numerically identified as batch 07170.sub.--001. Assumedly,
different batches are assigned different numerical identifiers. As
is also indicated in header 1102, the batch includes 286 cartons of
which none have yet been processed through the stamp machine.
[0078] A batch breakdown area 1104 shows, on a product-by-product
specific basis, the components of the batch about to be processed
through the stamp machine. A photograph-type presentation of a
label is provided for each product. In an embodiment, the
photo-type labels or other types of labels are in color. In some
embodiments, the labels are representative of cigarette carton
packaging. The number associated with each label photo is an
indication of how many cartons of the product are included in the
batch. For example, the illustrated batch (i.e., batch
07170.sub.--001) includes 49 cartons of the Marlboro Light 100
brand, 55 cartons of the regular Marlboro brand, 47 cartons of the
Kool brand, 95 cartons of the Marlboro Light brand, and 40 cartons
of the Newport brand, which added together equals the total 286
cartons in the batch. In one embodiment, the product labels within
1104 are ordered from top to bottom based on an expected order in
which cartons are to be moved through the stamping machine (e.g.,
the Marlboro Light 100 brand is expected before the regular
Marlboro brand and so on and so forth with the Newport brand being
the last expected brand).
[0079] In one embodiment, within area 1104, the number associated
with each label photo is dynamically updated to reflect the current
status of processing. For example, upon confirmation that a first
Marlboro Light 100 carton has been properly accounted for, the
number 49 is updated to 48. Upon confirmation that a second
Marlboro Light 100 carton has been properly accounted for, the
number 48 is updated to 47, and so on and so forth. Once all 49 of
the Marlboro Light 100 cartons have been accounted for, the regular
Marlboro brand cartons are similarly counted down. In one
embodiment, once all cartons have been accounted for within a given
category, the visual indicator for that category is either removed
or remains on the display with an indication that all cartons
within that category have been accounted for. The process repeats
until all cartons within the batch have been accounted for.
[0080] In the immediately preceding paragraph, it was mentioned
that the display is dynamically updated upon confirmation that a
product has been properly accounted for. In one embodiment, this
means confirmation by human-actuated input (e.g., through interface
114 of the stamping machine 106) that sends a signal to the
appropriate software component. For example, a human-initiated
button press can be utilized to generate the feedback that is
provided to the software system and used as a basis to confirm the
product of a correct next type moving into the stamping
machine.
[0081] Also or alternatively, the confirmation could be automated.
For example, a barcode scanner configured to scan a carton barcode
can be utilized to generate the feedback that is provided to the
software system and used as a basis to confirm product of a correct
next type moving into the stamping machine. Also or alternatively,
a photographic scanner that captures an image of some or all of a
carton can be utilized to generate the feedback that is provided to
the software system and used as a basis to confirm a product of a
correct next type moving into the stamping machine. Also or
alternatively, an RFID reader configured to read a carton RFID tag
can be utilized to generate the feedback that is provided to the
software system and used as a basis to confirm a product of a
correct next type moving into the stamping machine. These are just
examples of automated feedback systems. Those skilled in the art
will appreciate that any other automated feedback system could be
similarly integrated without departing from the scope of the
present invention.
[0082] It should also be mentioned that a feedback system as
described can be implemented in a variety of different places
within the system flow. In other words, the identity of a carton
can be gathered in a number of different places. For example, the
information can be gathered from a carton before it enters the
stamping machine (e.g., anywhere upstream from the stamping
machine). Alternatively, it could be gathered while the carton is
within the stamping machine. These are but two alternatives to be
considered within the scope of the present invention.
[0083] Turning back to the description of screenshot 1100, a carton
breakdown area 1106 shows, on a carton-by-carton basis, the
components of the batch expected to arrive on the upper conveyor. A
bulk breakdown area 1108 shows, on a case-by-case basis, the
components of the batch expected to arrive on the lower conveyor.
An Indicator 1110 demonstrates that the top line is what is
immediately expected next. In other words, similar to area 1104,
the lists within areas 1106 and 1108 are ordered from top to bottom
based on an expected order in which products are to be moved
through the stamping machine.
[0084] In one embodiment, area 1106 and/or 1108 is configured to
dynamically update based on human-initiated and/or automated
feedback in a manner similar to that described in relation to area
1104. For example, in one embodiment, upon confirmation of the
processing of the top carton listed in area 1106, the list will
"move up" by removing the top entry, shifting each entry up one
position, and then adding a new entry to the bottom of the list. In
another embodiment, upon confirmation (e.g., through
human-initiated feedback) that the 30 cartons in the top case
listed in area 1108 have been manually removed from the bottom
conveyor and placed in cue for entry into the stamping machine, the
top case listed in area 1108 will be removed and each remaining
entry will be shifted up one position.
[0085] Accordingly, one skilled in the art will appreciate how the
user interface associated with screenshot 1100 will systematically
update on a dynamic basis so as to provide an excellent visual
representation of the processing of the batch through the stamping
machine. Area 1112 provides a space for displaying data gathered by
one or more of the described automated systems for gathering
feedback for carton identification purposes (no actual data is
shown within area 1112 in FIG. 11).
[0086] As cartons move through the stamping machine, it is
certainly conceivable that some sort of error will occasionally
occur. For example, certainly not by limitation, a stamp head might
misfire, an unexpected carton might be encountered by one of the
feedback systems, a heavily damaged carton might need to be removed
from the process, etc. The software associated with screenshot 1100
illustratively includes functionality for managing such errors. In
one embodiment, the software is configured to halt the movement of
products upstream from the stamping machine (e.g., within the
picking area, transportation from the picking area to the stamping
area, etc.) until such errors have been addressed and/or resolved.
In one embodiment, user interface 1100 provides an operator of the
stamping machine with access to functions and/or tools (e.g.,
functions and/or tools accessed by activating buttons 1114, 1116,
etc.) for managing and/or resolving errors in the processing of the
products and/or the update and flow of the user interface 1100.
User interface 1100 is advantageous in an exception scenario
because it provides an easy to understand visual representation of
the correct sequence. In one embodiment, the system is configured
to provide, through interface 1100 or an associated interface,
visual cues as to what action needs to be taken to remedy an
exception or error scenario.
[0087] In one embodiment, a user interface (or function integrated
into interface 1100) is provided that enables the operator to
explain what they did to remedy an error or an exception. The
software is illustratively configured to analyze all available
information (including the operator input when available) and
automatically derive the cause of the exception. In one embodiment,
the software system includes a reporting functionality that
supports creation of reports that explain when exceptions occurred,
how frequently they occurred, why they occurred, who was watching
the stamping machine when they occurred, etc.
[0088] Notably, screenshot 1100 contains no information that
associates an individual carton with a particular order. In one
embodiment, the 286 cartons included in batch 07170.sub.--0001 are
associated with different orders. As was described in the context
of the picking process, the components of a batch can be organized
based on any of a variety of different user-selected and/or default
parameters. For example, not by limitation, batches can be created
so as to optimize one or more of the following constraints: 1)
desired order completion cutoff time; 2) desired truck route or
routes; 3) desired carton size or sizes in a batch; 4) target
overall batch size; and/or 5) target work effort to complete the
batch. Notably, in all of these examples it is not necessary for
cartons in the batch to come from a single order. The components of
multiple orders can be mixed within the batch. In one embodiment,
all available orders are merged into the batching process.
[0089] As mentioned previously, FIG. 5 interface 112 need not be
limited to the interface shown in FIG. 11 screenshot 1100. In
another embodiment, a screenshot does contain information that
associates an individual carton with a particular order. For
example, in an embodiment, interface 112 includes information
indicating what orders are in a batch, which order each carton
belongs to, what tax authority is associated with each carton, and
what stamp head or heads are used for each carton. In an
embodiment, user interface 112 is configurable to include and
display whatever categories of information are desired. In another
embodiment, user interface 112 is configured to be toggled so as to
alternate between displaying different sets of information.
[0090] A scenario was described above wherein an automated feedback
system is implemented in order to gather the identity (e.g., the
brand) of a carton before it is stamped by the stamping machine,
indeed, in one embodiment, even before the carton enters the
stamping machine (i.e., upstream from the stamping machine). Above,
this was described as a means for producing a feedback signal that
is utilized as a basis for analyzing the sequence in which products
are received (e.g., for determining whether a sequence error or
exception should be triggered) and, as a basis for generating
corresponding updates to a user interface, such as updates to the
information presented within areas 1104, 1106 and 1108 of the user
interface described in relation to FIG. 11. In one embodiment, the
feedback signal is also or alternatively utilized as a basis for
controlling the stamping functionality of the stamping machine.
[0091] FIG. 12 is a flow chart diagram demonstrating a stamping
process 1200 in accordance with one embodiment of the present
invention. Process 1200 is illustratively managed by a component of
software system 304, for example by stamping machine support
components 312. For example, system 304 and components 312 are
illustratively computer-readable instructions embedded on a
computer readable medium. Some of the instructions, when executed
by a computing device, cause a computer to carry out steps such as
those illustrated and described in relation to FIG. 12.
[0092] In accordance with block 1202, a feedback signal is received
and identifies an individual product. For example, the signal
illustratively identifies the brand of an individual carton. In one
embodiment, the feedback signal is produced by obtaining image data
from an optical scanner that processes an outside surface of the
individual product, and then analyzing the image data to identify
the correct brand. In one embodiment, the scan is captured before
the product enters the stamping machine (e.g. upstream from the
stamping machine). In one embodiment, the scan is captured while
the product is within the stamping machine but before the product
has been stamped. As was described in other areas within the
present description, the present invention is not limited to an
optical scan scenario.
[0093] In accordance with block 1204, a stamping command is
obtained (e.g., retrieved or generated) based on the feedback
signal. The stamping command is illustratively an instruction
indicative of how the individual product should be stamped. In
accordance with block 1206, the stamping command is provided to the
stamping machine for execution. The stamping machine illustratively
stamps the individual carton in accordance with the stamping
instruction. In accordance with one embodiment, process 1200 is
repeated for subsequent individual products as they move through
the stamping process. Accordingly, in one embodiment, a separate
stamping command is obtained on the fly for each carton that passes
through the stamping machine.
[0094] It should be noted that process 1200 need not necessarily be
carried out exclusively on an individual product basis. In one
embodiment, an optical scan is conducted so as to collect image
data indicative of multiple products approaching the stamping
process. For example, a single image of three consecutive cartons
can be captured to support a brand identification of all three
cartons and then acquisition (e.g., generation or acquisition) of
three corresponding stamping commands, each stamping command being
separately executed by the stamping machine. Notably, it is
conceivable that each stamping command might involve firing a
different stamping head. In other words, there is no restriction
that the cartons must be stamped by the same stamping head.
[0095] The significance of the described system configurations
becomes quickly apparent when compared to prior art systems. For
example, in one prior art configuration, a stamping machine
receives and executes a collective stamping command. In essence,
the collective stamping command dictates how (i.e., which stamping
head) the products (note plural) within a particular order are to
be stamped. As a product enters the stamping machine, or while the
product is well within the stamping machine, the product bar code
is scanned and, based on that collected information, a verification
process is applied in order to confirm that the product is part of
the particular order being stamped in accordance with the
collective stamping command.
[0096] There are several disadvantages associated with the noted
and similar prior art configurations. For example, the noted system
is quite limited in terms of how quickly it is able to move
products through the stamping machine. Because scanning occurs
while the product is entering or within the stamping machine, the
finalization of how the product will be stamped occurs very close
in time to the actual stamping of the product. There is an inherent
limit as to how fast products can be fed through the stamping
machine and still leave enough time to confirm or deny inclusion of
each product within a currently active standing stamping command.
The limit forces processing to move at a speed that is less than
the maximum reasonable speed at which the stamping machine is
capable of stamping a stream of products.
[0097] In contrast, in one embodiment, the present invention
proposes identifying a product further upstream and finalizing the
stamping instruction for a product much earlier, even before the
product ever enters the stamping machine. Accordingly, products can
be stamped at a much greater rate.
[0098] Another disadvantage associated with the noted system is
that group-oriented stamping typically involves many instances of
consecutive products being stamped with the same stamp head (i.e.,
because it is most common for products in the same order to require
the same stamp). Of course, a given stamp head can only stamp one
product at a time. Thus, this also limits the rate at which
stamping can be conducted. Of course, multiple stamp heads can be
configured to apply the same stamp, but this limits the flexibility
of the stamping machine. Another way of looking at the prior art
systems is that, in such systems, the stamping machine is
instructed to activate a particular stamp head. Following
activation, the stamping machine is essentially locked into that
head.
[0099] In contrast, the present invention proposes instructing the
stamping machine to activate a particular head on a carton by
carton basis. Thus, the present system is not limited to organizing
cartons into order-based groups. The prior art links a stamp head
specifically to a set of cartons, while the present invention links
a stamp head to a specific carton. Being carton specific is an
advantage because as products move through the stamping machine
organized based not on order but on batch, there will be more
instances where stamping heads will alternate. This increases
opportunity for moving products through the stamping machine at a
faster rate. Every product can move in and through the stamping
machine before its predecessor has exited the stamping machine.
More than two products can be within the stamping machine at the
same time (e.g., two in a machine while a third one is entering).
This is better than the prior art stop and go alternative. Every
product can be associated with a different order, and every product
can use a different stamping head than its predecessor.
[0100] Further, embodiments of the present invention are not
limited to scanning barcodes to identify which order is associated
with a product. The scan information necessary to support
embodiments of the present invention is less invasive. All that is
required is an identification of brand. For example, as has been
described, a visual scanner can be utilized. As has been described,
multiple products can even be simultaneously scanned for especially
efficient identification, which leads to especially efficient
generation and execution of the carton-specific stamping commands.
This is not to say that embodiments of the present invention cannot
also incorporate a barcode scan process. For example, a barcode can
be incorporated in combination with the visual scanner, for
example, to validate or confirm the visual brand identification
process. In one embodiment, not by limitation, the barcode scan
and/or the optical scan is conducted upstream from the stamping
machine rather than within the stamping machine itself, though
either or both could be conducted within the stamping machine.
[0101] Although the subject matter has been described in language
specific to structural features and/or methodological acts, it is
to be understood that the subject matter defined in the appended
claims is not necessarily limited to the specific features or acts
described above. Rather, the specific features and acts described
above are disclosed as example forms of implementing the
claims.
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