U.S. patent application number 13/974860 was filed with the patent office on 2014-02-27 for device for offloading capped vials useful in system and method for dispensing prescriptions.
The applicant listed for this patent is Parata Systems, LLC. Invention is credited to Steve Bouchelle, Eric X. Boupain, Matthew P. Daniels, Robert Cenk Hernandez, Mark Longley, Gary M. Owen, Thomas P. Rhoads, JR., Bradley Kenneth Smith.
Application Number | 20140058555 13/974860 |
Document ID | / |
Family ID | 49111577 |
Filed Date | 2014-02-27 |
United States Patent
Application |
20140058555 |
Kind Code |
A1 |
Rhoads, JR.; Thomas P. ; et
al. |
February 27, 2014 |
DEVICE FOR OFFLOADING CAPPED VIALS USEFUL IN SYSTEM AND METHOD FOR
DISPENSING PRESCRIPTIONS
Abstract
An offloading unit for an automated pharmaceutical machine that
dispenses filled, capped pharmaceutical vials includes at least one
offload location; at least one tote to receive the vials at each
offload location, the tote assigned for distribution to a remote
pharmacy location; at least one sensor to detect the presence or
absence of the tote; and at least one sensor to detect a fill level
of the vials in the tote.
Inventors: |
Rhoads, JR.; Thomas P.;
(Raleigh, NC) ; Longley; Mark; (Raleigh, NC)
; Bouchelle; Steve; (Raleigh, NC) ; Smith; Bradley
Kenneth; (Cary, NC) ; Boupain; Eric X.; (Cary,
NC) ; Hernandez; Robert Cenk; (Morrisville, NC)
; Daniels; Matthew P.; (Pittsboro, NC) ; Owen;
Gary M.; (Raleigh, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Parata Systems, LLC |
Durham |
NC |
US |
|
|
Family ID: |
49111577 |
Appl. No.: |
13/974860 |
Filed: |
August 23, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61692442 |
Aug 23, 2012 |
|
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61813431 |
Apr 18, 2013 |
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61834198 |
Jun 12, 2013 |
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Current U.S.
Class: |
700/215 |
Current CPC
Class: |
G07F 11/28 20130101;
G16H 20/10 20180101; G07F 11/16 20130101; G07F 17/0092 20130101;
G07F 11/30 20130101; G16H 20/13 20180101 |
Class at
Publication: |
700/215 |
International
Class: |
G06F 19/00 20060101
G06F019/00 |
Claims
1. An offloading unit for an automated pharmaceutical machine that
dispenses filled, capped pharmaceutical vials, comprising: at least
one offload location; at least one tote to receive the vials at
each offload location, the tote assigned for distribution to a
remote pharmacy location; at least one detection sensor to detect
the presence or absence of the tote; and at least one fill sensor
to detect a fill level of the vials in the tote.
2. The offloading unit of claim 1, wherein a chute guides the vials
into the tote.
3. The offloading unit of claim 2 wherein the chute is illuminated
with at least one light.
4. The offloading unit of claim 3 wherein the at least one light
communicates the status of the offload location.
5. The offloading unit of claim 4 wherein the status of the offload
location is communicated by at least one of a color or an
illumination pattern of the at least one light.
6. The offloading unit of claim 1 wherein the at least one tote
comprises a unique code.
7. The offloading unit of claim 6 wherein the unique code indicates
at least one of: information about the vials loaded in the tote and
information about the remote pharmacy location.
8. A pharmaceutical dispensing system, comprising: a frame; a
plurality of cells configured to house pharmaceutical pills; a
processor; memory coupled to the processor; and a computer program
residing in the memory that is executable by the processor for
transmitting a message to one or more pre-identified recipients
about a status or function of the system.
9. The pharmaceutical dispensing system of claim 8 wherein the
message is delivered by at least one of text message, email
message, instant message, or voice message.
10. The pharmaceutical dispensing system of claim 8 wherein the
message comprises information about at least one of: a system
error; a power failure; a fill level of a tote; an inventory level;
a prescription order status; a service requirement of the system; a
problem encountered by the system while filling orders;
instructions for responding to the message; and a service
request.
11. The pharmaceutical dispensing system of claim 8 further
comprising a camera for capturing images of filled
prescriptions.
12. The pharmaceutical dispensing system of claim 8 further
comprising a bagger for automatically bagging the filled
prescriptions.
13. The pharmaceutical dispensing system of claim 11 further
comprising a computer program residing in the memory that is
executable by the processor for automatically analyzing the images
captured by the camera.
14. The pharmaceutical dispensing system of claim 8 further
comprising a weight sensor for determining a weight of a filled
vial.
15. A pharmaceutical dispensing system, comprising: a frame; a
plurality of cells configured to house pharmaceutical pills; a
processor; memory coupled to the processor; at least one offload
location; at least one tote to receive the vials at each offload
location, the tote assigned for distribution to a remote pharmacy
location; at least one detection sensor to detect the presence or
absence of the tote; at least one fill sensor to detect a fill
level of the vials in the tote; and a GUI, wherein the GUI includes
a portion specific to filling of the at least one tote.
16. The pharmaceutical dispensing system of claim 15 wherein the
GUI communicates information about a status of the totes.
17. The pharmaceutical dispensing system of claim 16 wherein the
status is at least one of: the association of the tote with the
system, a number of prescriptions in the tote, a designation of the
pharmacy location assigned to the tote, a number of prescriptions
directed to the tote, and a fill level of the tote.
18. The pharmaceutical dispensing system of claim 17 wherein the
fill level of the tote is indicated by at least one of a dynamic
fill line or a color.
19. The pharmaceutical dispensing system of claim 15 further
comprising a camera for capturing images of filled
prescriptions.
20. The pharmaceutical dispensing system of claim 15 further
comprising a bagger for automatically inserting the filled
prescriptions into bags.
21. The pharmaceutical dispensing system of claim 19 further
comprising a computer program residing in the memory that is
executable by the processor for automatically analyzing the images
captured by the camera.
22. The pharmaceutical dispensing system of claim 20 wherein the
bagger further comprises a printer for printing identifying
information on a label or on a bag.
23. The pharmaceutical dispensing system of claim 20 wherein
documentation is added to one or more of the bags.
24. The pharmaceutical dispensing system of claim 15 wherein in the
portion of the GUI specific to filling of the at least one tote
allows a user to create a manifest for the at least one tote.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of and priority
from U.S. Provisional Patent Application Nos. 61/692,442, filed
Aug. 23, 2012, 61/813,431, filed Apr. 18, 2013, and 61/834,198,
filed Jun. 12, 2013, the disclosure of each of which is hereby
incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed generally to the
dispensing of prescriptions of pharmaceuticals, and more
specifically is directed to the automated dispensing of
pharmaceuticals.
BACKGROUND OF THE INVENTION
[0003] Pharmacy generally began with the compounding of medicines
which entailed the actual mixing and preparing of medications.
Heretofore, pharmacy has been, to a great extent, a profession of
dispensing, that is, the pouring, counting, and labeling of a
prescription, and subsequently transferring the dispensed
medication to the patient. Because of the repetitiveness of many of
the pharmacist's tasks, automation of these tasks has been
desirable.
[0004] Some attempts have been made to automate the pharmacy
environment. Different exemplary approaches are shown in U.S. Pat.
No. 5,337,919 to Spaulding et al. and U.S. Pat. Nos. 6,006,946;
6,036,812 and 6,176,392 to Williams et al. The Williams system
conveys a bin with tablets to a counter and a vial to the counter.
The counter dispenses tablets to the vial. Once the tablets have
been dispensed, the system returns the bin to its original location
and conveys the vial to an output device. Tablets may be counted
and dispensed with any number of counting devices. Drawbacks to
these systems typically include the relatively low speed at which
prescriptions are filled and the absence in these systems of
securing a closure (i.e., a lid) on the container after it is
filled.
[0005] One additional automated system for dispensing
pharmaceuticals is described in some detail in U.S. Pat. No.
6,971,541 to Williams et al. This system has the capacity to select
an appropriate vial, label the vial, fill the vial with a desired
quantity of a selected pharmaceutical tablet, apply a cap to the
filled vial, and convey the labeled, filled, capped vial to an
offloading station for retrieval.
[0006] Although this particular system can provide automated
pharmaceutical dispensing, certain of the operations may be
improved. For example, the offload station of the system comprises
a series of stationary holding compartments of conventional
configuration. It may be desirable to provide an offload station
having a different configuration that can improve speed and
reliability of the system and allow for versatility of prescription
filling options for the pharmacy.
SUMMARY OF THE INVENTION
[0007] As a first aspect, embodiments of the present invention are
directed to an offloading unit for an automated pharmaceutical
machine that dispenses filled, capped pharmaceutical vials,
comprising: at least one offload location; at least one tote to
receive the vials at each offload location, the tote assigned for
distribution to a remote pharmacy location; at least one sensor to
detect the presence or absence of the tote; and at least one sensor
to detect a fill level of the vials in the tote.
[0008] As a second aspect, embodiments of the present invention are
directed to a pharmaceutical dispensing system, comprising: a
frame; a plurality of cells configured to house pharmaceutical
pills; a processor; memory coupled to the processor; and a computer
program residing in the memory that is executable by the processor
for transmitting a message to one or more pre-identified locations
about a status or function of the system.
[0009] As a third aspect, embodiments of the present invention are
directed to a pharmaceutical dispensing system, comprising: a
frame; a plurality of cells configured to house pharmaceutical
pills; a processor; memory coupled to the processor; at least one
offload location; at least one tote to receive the vials at each
offload location, the tote assigned for distribution to a remote
pharmacy location; at least one sensor to detect the presence or
absence of the tote; at least one sensor to detect a fill level of
the vials in the tote; and a GUI, wherein the GUI includes a
portion specific to filling of the at least one tote.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 is a flow chart of operations according to
embodiments of the present invention.
[0011] FIG. 2 is a top, front perspective view of a pharmaceutical
dispensing system according to embodiments of the present
invention.
[0012] FIG. 3 is a top, rear perspective view of the system of FIG.
2 with the outer panel of the system removed to show the internal
components.
[0013] FIG. 4 is an isometric view of an offload chute unit
according to the present invention.
[0014] FIG. 5 is a side view of the chute unit of FIG. 4.
[0015] FIG. 6 is a top view of the chute unit of FIG. 4.
[0016] FIGS. 7-10 are sequence views of a vial traveling through
the chute unit of FIG. 4, the chute unit being shown in side
section view.
[0017] FIG. 11 is a side section view of the chute unit of FIG. 4
illustrating that the trough thereof can hold two vials at
once.
[0018] FIG. 12 is a top view of the chute unit of FIG. 4
illustrating that the chutes can hold vials of different sizes.
[0019] FIG. 13 is an enlarged side section view illustrating a
reversible closure (RC) vial entering the chute unit of FIG. 4.
[0020] FIG. 14 is a Home screen of the system graphical user
interface.
[0021] FIG. 15 is a Tote View screen of the tote offload portion of
the system graphical user interface.
[0022] FIG. 16 is an In-Store screen of the system graphical user
interface.
[0023] FIG. 17 is a schematic diagram of a "hub-and-spoke"
configuration for pharmaceutical distribution that incorporates a
pharmaceutical dispensing system similar to that of FIGS. 1-12
serving as the "hub".
[0024] FIG. 18 is a rear perspective view of the system of FIG. 2
showing the addition of chutes and totes for offloading of
vials.
[0025] FIG. 19 is a front perspective view of the system of FIG. 2
showing the addition of a chute and an automatic bagging and
printing unit, with a tote for offloading of vials.
[0026] FIG. 20 is a partial perspective view of the system of FIG.
3 with some subsystems removed to show an exemplary imaging
subsystem.
[0027] FIG. 21 is a flow chart illustrating exemplary operation of
the system for filling of prescriptions in a "hub and spoke"
arrangement.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0028] The present invention will now be described more fully
hereinafter, in which preferred embodiments of the invention are
shown. This invention may, however, be embodied in different forms
and should not be construed as limited to the embodiments set forth
herein. Rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the invention to those skilled in the art. In the
drawings, like numbers refer to like elements throughout.
Thicknesses and dimensions of some components may be exaggerated
for clarity.
[0029] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0030] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein the expression "and/or" includes any and all
combinations of one or more of the associated listed items.
[0031] In addition, spatially relative terms, such as "under",
"below", "lower", "over", "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. It will be understood that the spatially relative
terms are intended to encompass different orientations of the
device in use or operation in addition to the orientation depicted
in the figures. For example, if the device in the figures is turned
over, elements described as "under" or "beneath" other elements or
features would then be oriented "over" the other elements or
features. Thus, the exemplary term "under" can encompass both an
orientation of over and under. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0032] Well-known functions or constructions may not be described
in detail for brevity and/or clarity.
[0033] As described above, the invention relates generally to a
system and process for dispensing pharmaceuticals. An exemplary
process is described generally with reference to FIG. 1. The
process begins with the identification of the proper container,
tablets or capsules and closure to be dispensed based on a
patient's prescription information (Box 20). A container of the
proper size is dispensed at a container dispensing station (Box
22), then grasped and moved to a labeling station (Box 24). The
labeling station applies a label to the container (Box 26), after
which the container is transferred to a tablet dispensing station
(Box 28), from which the designated tablets are dispensed in the
designated amount into the container (Box 30). The filled container
is then moved to a closure dispensing station (Box 32), where a
closure of the proper size has been dispensed (Box 34). The filled
container is secured with a closure (Box 36), then transported to
an offload station and offloaded (Box 38).
[0034] A system that can carry out this process is illustrated in
FIGS. 2 and 3 and designated broadly therein at 40. The system 40
includes a support frame 44 for the mounting of its various
components. The system 40 generally includes as operative stations
a controller (represented herein by a graphics user interface
monitor 42), a container dispensing station 58, a labeling station
60, a tablet dispensing station 62, a closure station 64, and an
offloading station 66. In the illustrated embodiment, containers,
tablets and closures are moved between these stations with a single
carrier 68; however, in some embodiments only a single carrier may
be employed, or one or more additional carriers may be employed.
The operation of the container dispensing station 58, the labeling
station 60, the tablet dispensing station 62, and the closure
station 64 are described in, for example, U.S. Patent Application
Publication Nos. 2008/0110921 and 2008/0110555; and U.S. Pat. Nos.
7,596,932; and 7,344,049, the disclosures of each of which are
hereby incorporated herein in its entirety. Additional components
and features of the system are described in U.S. Patent Application
Publication Nos. 2008/0283179 and 2009/0179041, and U.S. Pat. No.
8,113,492, U.S. Pat. No. 8,224,482, and U.S. Pat. No. 8,244,398,
the disclosures of each of which are hereby incorporated herein in
its entirety.
[0035] During the prescription filling process, a pharmacist
typically must view the contents of the vial to verify that the
prescription has been filled correctly. When the vial is filled in
an automated system that includes a closure station 64, such as the
system 40, the pharmacist must remove the cap on the vial to
perform this verification. In some embodiments of the invention,
the system 40 may include a camera 72 positioned such that it may
capture an image of the contents of the vial prior to the vial
being moved to the closure station 64 for capping. As shown in FIG.
20, the camera 72 may be located, for example, above an exception
assembly 70 (for offloading of vials that encounter a problem in
the filling process), but may be located in any other location
where it will not interfere with other operations of the system 40.
Once the pills have been dispensed into the vial, the carrier 68
may move the filled vial to a position, on a shelf 74, for example,
near the camera 72 so that an image of the contents of the vial may
be captured prior to capping the vial. In the illustrated
embodiment, the camera 72 is situated so as to view and capture an
image from the top of the vial. In some embodiments, the camera 72
and associated lighting system may be situated so as to capture the
image of the pills through the vial, in which case the imaging step
may occur before or after the capping step. Exemplary apparatus and
methods for imaging the prescription through the vial can be found
in U.S. Pat. No. 7,889,330; U.S. Pat. No. 8,284,305; U.S. Pat. No.
8,345,989; and U.S. Pat. No. 8,477,989, the disclosures of which
are hereby incorporated by reference herein in their entirety.
Images may be stored in the system 40 or at another location
accessible to the system 40. The pharmacist may verify that the
vial contains the correct drug by viewing the image of the contents
of the vial. The pharmacist may view the image of the vial contents
at a location that is proximate to the system 40 or in a remote
location. Alternatively, automated image analysis may be employed
to automatically verify the identity of the dispensed
pharmaceutical and determine whether it matches the prescription
that was requested. An exemplary image analysis system is described
in U.S. Pat. No. 6,535,637, the disclosure of which is hereby
incorporated by reference herein in its entirety. The system 40 may
then report whether each prescription has passed the verification
step; any vial that cannot be automatically verified may be flagged
for manual verification by the pharmacist or for verification by
some other process.
[0036] In another embodiment, a scale or other implementation of a
weight sensor may be used in an additional verification process for
the filling of the prescription. Exemplary systems employing a
weight sensor to weigh the contents of a medication container are
described in U.S. Pat. Nos. 8,108,068 and 5,337,919, the disclosure
of each of which is hereby incorporated by reference herein in its
entirety. The scale may be otherwise incorporated into the system
40, including a stand-alone scale 78 (FIG. 3) on which the filled
vial is deposited so that the weight may be determined. The scale
78 may be positioned in a location that is level and not subject to
a significant amount of vibratory interference from other parts of
the system 40. The scale 78 may be located on the shelf 74 (FIG.
20) upon which vials are placed for imaging; in this position,
weighing and image capture can occur simultaneously, if desirable
to do so. By comparing the total weight of the prescription vial
and its contents with the expected weight of the filled
prescription, the controller may provide another indication as to
whether the prescription has been filled correctly. If the total
weight of the vial and its contents does not match the expected
weight of the filled prescription, the controller may direct steps
to remedy the situation. For example, the controller may direct the
carrier 68 to return the vial to the appropriate location in the
tablet dispensing station 62 so that missing pills can be added, if
the controller determines that the vial may be missing one or more
pills because the weight of the vial and its contents is lower than
expected. The controller may flag the vial with an error message
indicating that the actual weight does not match the expected
weight, so that pharmacy staff can investigate to determine if any
errors had occurred in the filling process.
[0037] Turning now to FIG. 3, the offload station 66 includes a
number of chute units 100, each of which, in the illustrated
embodiment, includes two chutes 102, 104, although those skilled in
this art will appreciate that a chute unit may include only a
single chute or may include more than two chutes. Also, the offload
station 66 may include only a single chute unit or any appropriate
number of chute units.
[0038] The chutes 102, 104 are substantially identical mirror
images of each other about a vertical plane P (see FIG. 4). As
such, only the chute 102 will be described in detail herein, with
the understanding that the description is equally applicable to the
chute 104. For the purpose of this discussion, the terms "front,"
"forward" and derivatives thereof refer to the direction that a
pharmaceutical vial travels in the chute 102, i.e., from right to
left from the vantage point of FIG. 4. The terms "rear", "back" and
derivatives thereof refer to the direction that is opposite of the
"forward" direction, i.e., from left to right from the vantage
point of FIG. 4. One may also think of the forward direction as
extending "downstream" in the chutes 102, 104 and the rearward
direction as extending "upstream" in the chutes 102, 104.
[0039] Referring again to FIG. 4 and also to FIGS. 5 and 6, the
chute 102 has a rear lip 106 that resides above the frame 44. The
lip 106 includes a shallow arc such that it is slightly concave.
The lip 106 merges smoothly at its front end with a concave ramp
110. Side walls 108, 109 rise from the lateral edges of the ramp
110, with the forward ends of the side walls 108, 109 being higher
than the rearward ends. The effect of the configuration provided by
the lip 106, the ramp 110 and the side walls 108, 109 is that of a
half-bowl that drains downwardly into the remainder of the chute
102. The lower portion of the ramp 110 rests on the frame 44.
[0040] Still referring to FIGS. 4-6, a trough 112 having an arcuate
profile extends forwardly and downwardly from the front end of the
ramp 110. The trough 112 includes a concave floor 113 that is
bounded at its lateral edges by dividers 116, 117. A rear wall 114
rises above the rear end of the trough 112; the bottom portion 114a
of the rear wall 114 angles rearwardly and has an arcuate lower
edge 114b that, in combination with the rear end of the floor 113,
forms an inlet 115 (see FIG. 7). At their rearward ends, the
dividers 116, 117 are similar in height to the rear wall 114. Each
of the dividers 116, 117 has a leading edge 118 that slopes sharply
downward in a central portion of the divider 116, 117, such that
the forward portion of the divider 116, 117 is relatively low. A
front wall 120 spans the front ends of the troughs 112 and provides
a landing area for vials. The front wall 120 may have a foam or
other shock absorbent material attached thereto to reduce any
rebound effect of the vial dropping down the chute 102 and striking
the front wall 120.
[0041] The chute unit 100 is attached to the frame 44 via four
latches 122. The latches 122 are inserted into mating apertures
(not shown) in the frame 44. In the illustrated embodiment, the
chute unit 100 is mounted so that the troughs 112 slope downwardly
from back to front; for example, the chute unit 100 may be mounted
such that the trough 112 is angled relative to a horizontal plane
at an angle of between about 20 and 35 degrees.
[0042] In the illustrated embodiment, the chute unit 100 is formed
as a unitary member, although those skilled in this art will
appreciate that the chute unit may be formed with multiple
components. The chute unit 100 may be formed of any material
recognized as being suitable for the conveying of objects such as
pharmaceutical vials; exemplary materials include polymeric
materials such as polycarbonate, ABS and copolymers and blends
thereof.
[0043] Referring now to FIGS. 7-10, in operation, after a vial V
has been dispensed, labeled, filled and capped, it is transported
by the carrier to the offload station 66. The carrier 70 deposits
the vial V "right-side up" into the half-bowl formed by the lip
106, the side walls 108, 109, and the ramp 110 (see FIG. 7); the
angled bottom portion 114a of the rear wall 114 can also assist in
funneling the vial V into position. In some embodiments, the
dimensions of the lip 106, ramp 110, side walls 108, 109 and bottom
portion 114a of the rear wall 114 are selected to ensure that a
"right side up" vial V presented by the carrier 70 exits the
"half-bowl" with the lower (i.e., non-capped) end leading the
upper, capped end, irrespective of which of multiple common vial
sizes is presented (see FIG. 8). Typically, the length of a capped
vial V is between about 2 and 4 inches, and the diameter is between
about 1.25 and 2.0 inches. In some embodiments, the distance
between the side walls 108, 109 is between about 2.5 and 2.75
inches, the ramp 110 has a depth of about 1.5 to 2.0 inches, the
distance from the rear edge of the ramp 110 to the rear edge of the
bottom portion 114a of the rear wall 114 is between about 3.25 and
3.5 inches, and the ramp 110 generally forms an angle of between
about 20 and 30 degrees relative to an underlying horizontal
surface.
[0044] Also, the smoothly merging side walls 108, 109, lip 106 and
ramp 110 are configured such that vials do not snag or hang
thereon. In particular, vials known as "RC" vials (available from
Owens-Corning, Owens, Ill.), have a finger on the edge thereof that
might be susceptible to being caught on an unsmooth surface (see
FIG. 13).
[0045] Once the vial V enters the half-bowl formed by the ramp 110,
the side walls 108, 109 and the lip 106, the vial V, oriented
"non-capped end down", slides through the inlet 115 (see FIG. 9)
and down the trough 112 to the front wall 116 (see FIG. 10), where
it rests until pharmacy personnel remove it. In some embodiments,
it may be desirable for at least two vials V1, V2 to be stored at
once in the trough in a stacked arrangement (see FIG. 11). As such,
the trough 112 may have a length of between about 9 and 10 inches,
which enables two vials 4 inches in length to be stored and
accessible for pharmacy personnel. Also, vials of different sizes
can be stored in chutes 102, 104 (see FIG. 12).
[0046] Also, the dividers 116, 117 may be configured such that the
chute unit 100 satisfies the provisions of UL 61010A-1, 1740 (the
requirements of which are hereby incorporated herein by reference),
which requires that an object 2.95 in diameter be prevented from
entering the inlet 115 (this test is intended to simulate a human
hand entering the inlet 115 from outside of the system). In some
embodiments, the leading edges 118 of the dividers 116, 117 are
positioned between about 5 and 7 inches from the inlet 115 and are
between about 2.5 and 2.75 inches apart.
[0047] In another embodiment, instead of being deposited into the
chutes of the offload station 66, the carrier 68 may deliver a
filled and capped vial to another location where a tote 61 (FIG.
18), for example, with the capacity to hold many vials
simultaneously, is positioned. Such a location may alternatively
consist of a box, bin, or other container of appropriate capacity.
The tote's contents may be designated for delivery to a pharmacy
location different from that where the system 40 is located.
Multiple totes 61 may be used with the system 40 simultaneously; in
some embodiments each tote 61 may be allocated to a different
pharmacy such that the system 40 is filling prescriptions for
multiple pharmacies in a "hub and spoke" type of an arrangement,
such as that shown in FIG. 17. The hub-and-spoke arrangement 300
includes a pharmacy where a system 40 is located as the "hub" 302
and a number of remote pharmacies 304. Prescription orders from the
remote pharmacies 304 are received by the hub 302, filled, and
subsequently delivered to the remote pharmacies 304 with the
communication and delivery paths between the hub 302 and remote
pharmacies 304 considered the "spokes" 306. As prescriptions are
processed through the system 40, the controller 42 may, based on
the ultimate disposition of each prescription, designate the proper
location for offload of each vial from the system 40. Totes 61 may
be located in any area of the system 40 that is amenable to such
placement. An exemplary location for a tote 61 is the shelf area 65
shown at the end of the system 40 in FIGS. 2 and 3. This may be a
desirable location for a tote 61 due to, among other reasons, its
proximity to the closure station 64; as closures are applied to
filled vials, the carrier 68 would have a shorter distance to
travel to drop off the vial. The tote 61 may rest on a shelf, which
may be attached to the system 40 or free standing, or the tote 61
may be directly attached to the system 40; the attachment mechanism
may be reversible so that the entire tote 61 can be removed for
further processing and/or delivery of the contents of the tote 61.
Additionally, multiple shelves or attachment locations for tote 61
could be installed to support multiple totes 61 (FIG. 18); this may
be desirable to accommodate a large number of prescriptions to be
filled for a given pharmacy location and/or to accommodate
prescriptions for more than one remote pharmacy location 304, as
discussed above.
[0048] Modifications to the system 40 may be made to facilitate
this drop-off process such as the installation of a chute 63 (FIG.
18) or ramp to guide the movement of the vials into the tote 61
(FIG. 18). In one embodiment, the chute(s) 63 may be illuminated.
In another embodiment, the illumination of the chute(s) 63 may be
accomplished using different colored and/or blinking lights, which
may be used to indicate the status of the location. An example of
one such arrangement is as follows:
TABLE-US-00001 Chute light color/ state Indication
Description/Example OFF System is idle System off or no tote in
place at chute location GREEN Tote is OK Tote is in place at that
chute location and ready to receive vials YELLOW Caution, The
system is currently processing a vial in process vial that is
destined for that chute/tote FLASHING Attention needed Exemplary
reasons: Tote is full; YELLOW barcode not readable FLASHING
Fault/error/ Exemplary reasons: Tote is removed RED needs immediate
while vial in process for that chute; attention tote overfilled;
chute jammed
[0049] In one embodiment, the system 40 includes one or more
sensors to detect the presence or absence of a tote 61 in each
location. In another embodiment, the system 40 includes one or more
sensors to detect the level of the contents of each tote 61. In
still another embodiment, the tote(s) 61 may be designated to hold
filled prescriptions that are intended for pick up by patients at a
later time (a different day, for example) at the local pharmacy 302
and may be handled differently in the pharmacy's workflow than
other prescriptions requiring earlier distribution to patients,
which may be dispensed through the offload station 66. The totes 61
and their contents can be designated for any purpose that may make
it desirable to segregate a group of filled prescriptions and,
thereby, facilitate the workflow of the pharmacy.
[0050] In another embodiment, exemplified in FIG. 19, the system
40' may include an automatic bagger 67 to bag the prescription
vials once the system 40' has completed the filling process. The
bagger 67 may be positioned to facilitate receiving the filled
prescription vial, such as from a chute 76, directly from the
system 40' so that the vial may be placed in a bag prior to
placement in the tote 61. One or more filled prescription vials may
be placed in a bag; a prescription order for a patient may include
more than one vial of medication filled in the system 40' or may
include items that must be retrieved from outside the system 40',
such as unit of use medications, tubes of ointment, slave, etc.,
oral contraceptives, prescription medications that must be
retrieved from stock bottles, over the counter items, etc. The bag
also may have one or more labels 69 with identifying information
adhered to it; some nonlimiting examples of identifying information
are patient name, patient address, patient phone number,
prescription number, drug name, drug dosage, NDC number, drug
image, drug description, remote pharmacy name, remote pharmacy
identification number, remote pharmacy address, remote pharmacy
phone number, etc. The identifying information may be alpha-numeric
and/or encoded (e.g., barcode, RFID, etc.). The identifying
information may be printed on the labels 69 or directly on the bag
by a printer that is associated with or integral to the bagger 67,
as shown in FIG. 19. Alternatively, labels 69 may be printed by a
separate printing unit and fed into the bagger 67 for application
to the bags or may be otherwise applied to the bags. Exemplary
bagging and label printing/applying systems may be obtained from
Mark-Pack, Inc. of Coopersville, Mich. (www.markpackinc.com). One
of skill in the art will recognize that the bagger 67 could be a
table-top unit. Additionally, the bagger 67 may receive vials
directly from the pharmaceutical dispensing system 40', as shown,
or may be manually fed using vials that are filled and separately
offloaded from the pharmaceutical dispensing system 40'. Items that
may be retrieved from outside the system 40', as discussed above,
may be manually fed into the bagger so that they can be included in
a grouped order for a customer or, if the design of the system 40'
allows, may be dispensed from inside the system 40' as well. Paper
documentation also may be included in the bags, such as drug
information forms or insurance paperwork, which may be printed at a
separate printer or there may be a printer and automatic folding
machine included as part of the bagging system and the papers may
be automatically added to the bags. Papers may be inserted in the
bags before they are closed or may be stapled to or otherwise
attached to the outside of the bag. Bags that are released from the
bagger 67 may be loaded into a container, such as a tote 61; the
container may be used as an interim collection container, may be
designated for a particular storage location in the hub pharmacy
302, or may hold bags which are designated for an off-site
location, such as a remote pharmacy 304.
[0051] In a particular embodiment, the system graphical user
interface (GUI) includes a portion specific to the filling of totes
61 to facilitate user interaction with and monitoring of the system
40 during tote 61 filling. Details of an exemplary GUI are set
forth in U.S. Patent Application Publication No. 2009/0287350, the
disclosure of which is hereby incorporated by reference herein in
its entirety. Referring now to FIG. 14, in some embodiments the
Home screen 200 the GUI may include an In Store Summary portion
202, where a high level status of prescriptions entered into the
system 40 for fulfillment is shown. The Home screen 200 may include
a Priority button 204 which allows the user to select whether the
prescriptions for the local pharmacy 302 or the prescriptions
entered for one or more remote pharmacies 304 are given priority in
the filling process. A View button 206 allows the user to switch
between the view of the GUI for tote 61 filling and a view of the
GUI for the local system 40, which includes the offload station 66,
if desired. The GUI may include an Attached Totes display 208
showing information pertaining to those totes 61 currently
associated with the system 40 for filling. The GUI may include a
Removed Totes display 210, showing information pertaining to totes
61 currently not associated with the system 40. Each of the
Attached Totes 208 and Removed Totes 210 displays may communicate
information about the status of the totes 61 such as the number of
prescriptions in the tote 212, the designation of the store
assigned to the tote 214, and the number of prescriptions directed
to that tote 216. In one embodiment, the graphic for each tote 61
includes a dynamic fill line 218 that moves higher on the
representation of the tote 61 as vials are added to that tote 61
and serves as a graphic indicator of the fill status of that tote
61. The dynamic fill level for each tote 61 may also include a
color indicator. For example, the fill line for: a tote 61 that is
full may be colored in red; a tote 61 that is near full (over a
threshold level but not full) may be colored in yellow; and a tote
61 that under a threshold level may be colored in green.
[0052] Turning now to FIG. 15, the GUI may include a Tote View
screen 220 that displays information specific to that tote 61 and,
therefore, a particular remote pharmacy 304. The Tote View screen
220 displays the designation of the store assigned to the tote 214.
Such designation can be indicated in any of various ways such as by
number, name, color, logo or any other unique identifier, which
also can be present on the tote 61, in the form of alphanumeric
text, RFID label, barcode, logo, graphics, etc. The Tote View 220
screen also comprises status tabs 222 (Pending, Incomplete, Ready
and Complete, for example) which include an indication of the
number of prescriptions identified by that status. The user may
select a status tab to view a list of prescriptions associated with
this status and the details of each prescription.
[0053] The Tote View screen 220 may also include various buttons
for different functions or preferences related to the selected tote
61. Some of these functions may include editing the settings
associated with the tote (button 224), such as the store name,
printing a barcode for the tote (button 225), or deleting a tote
from the application (button 226). It may be desirable to fill the
prescriptions for a given tote 61 regardless of the status of the
tote 61 (i.e., even if the sensors indicate that the tote 61 is
full or absent); the Force Filling button 227 can be selected to
perform this function. When all of the prescriptions for a given
tote 61 have been filled (i.e., are in the "Ready" queue), the user
can select the Pick Up All Scripts button 228 which will move all
of the prescriptions for that tote 61 into Complete status in the
system 40 (under local filling conditions, the bar code for each
prescription would have to be scanned individually to move that
prescription to Complete status in the system 40). The Tote View
screen 220 may also include a Priority button 229; in this case the
selection of priority will assign preference in the filling process
to the prescriptions for the particular tote 61.
[0054] All of the locations for offload of filled prescription
vials may be visualized in the In-Store GUI screen 230, as
exemplified in FIG. 16. The offload station 66 is represented
graphically at 232 and 234. The locations labeled "B", "C", "D",
"E", . . . , "T" 236 represent the individual locations of the
graphical representation 232 of the offload station 66. The
locations of the other portion of the offload station 66 can be
displayed by scrolling through the other locations of section 232
and 234. The totes 61 are represented by the Side Tote locations
238.
[0055] In some embodiments, it may be desirable to allow the system
40 to operate unattended. In this way the system 40 still may be
productive when the pharmacy is closed or otherwise slow, to
maximize the volume of prescriptions filled by the system 40 and/or
for strategic use of system 40 time. For example, when the pharmacy
is closed or during slow periods when the pharmacy is open, the
system 40 can fill prescriptions for later retrieval by the
pharmacy's own customers (i.e., refills, non-urgent prescriptions
that customer indicates will be picked up at later time). In
another embodiment, the system 40 may operate to fill prescriptions
for other pharmacy locations during these slower/overnight/closed
operational periods; these prescriptions would then be delivered to
the appropriate location once the orders are complete (hub and
spoke arrangement).
[0056] In another embodiment, the imaging feature (discussed above)
may be included in the system 40 during unattended operation. With
the images available for all prescriptions filled during unattended
operation, the images for prescriptions contained in each tote 61
can be viewed by the pharmacist prior to releasing the tote 61 for
delivery to the remote pharmacy 304. In some embodiments, the
images for all prescriptions contained in a tote 61 may be viewed
by a remote pharmacist so that the remote pharmacist can provide
verification that each prescription has been filled correctly prior
to release of the tote 61 and delivery to the appropriate pharmacy.
In some embodiments, the remote pharmacist may review the images
for prescriptions filled by the system 40 to be delivered to
customers at the hub pharmacy 302; once the pharmacist has verified
that the prescription has been filled correctly, it may be released
for delivery to the customer. For clarity, a "remote pharmacist"
may be located anywhere other than with the system 40 at the hub
pharmacy 302 and may or may not be located at one of the remote
pharmacies 304. One of skill in the art will recognize that the
functions described herein as being performed by a remote
pharmacist may alternatively be performed by a pharmacist located
proximate to the system 40 (i.e., at the hub pharmacy 302). The
system 40 may be configured to provide messages via text message,
instant message, email, voice message, or any other form of
message; these messages would be delivered to pre-designated phone
number(s) or email address(es) upon certain situations that may
arise, particularly during unattended operation of the system 40.
Such messages may include indications of the following: [0057]
System error (i.e., mechanical malfunction, system inoperable,
insufficient vial/label/cap/drug/bag inventory to complete a
prescription fill, etc.) [0058] Power failure [0059] Full tote(s)
[0060] Service needed [0061] Low inventory in system (i.e., drugs,
vials, caps, labels, bags) [0062] Problems with prescription
filling process (i.e., capping error, labeling error, bagging
error, etc.) [0063] Prescription orders complete for delivery to
specific remote location Messages may include specific instructions
related to the message, as may be programmed into the system 40.
For example, a message indicating that the prescription orders are
complete for a specific remote location 304 may include
instructions to schedule the delivery of the tote(s) 61 to the
appropriate remote location 304; this message may be sent directly
to the delivery organization as notification that the prescriptions
are ready for pick-up and delivery to the remote location 304. A
message indicating that one or more totes 61 is/are full may
include instructions to remove the tote(s) 61 and replace it/them
with an empty tote 61, possibly of a specific type (i.e., a
specific size and/or belonging to specific remote location). A
message indicating low inventory in the system 40 may include
information regarding which locations of the tablet dispensing
station 62 need to be refilled and with which drug, or that the
vials or caps (of a specific size) need to be refilled, etc.
Messages indicating that the system 40 is inoperable or that
service is needed may be sent directly to a repair person with a
request for service on the system 40 and may contain specific
information on the type of service required.
[0064] An exemplary process for filling prescriptions in a hub and
spoke pharmacy arrangement, as discussed above, is illustrated in
FIG. 21. As shown in FIG. 21, a patient's prescription is entered
into the pharmacy management system of a remote pharmacy 304 and
scheduled to be picked up at the same location (Block 400). For a
prescription to be entered in the system, the patient may drop off
a paper prescription at the remote pharmacy 304, may request a
refill (over the phone or in person), or may place an order
electronically. Additionally, the prescription may be entered at
the remote pharmacy 304 by a phone call or electronic order from
the ordering physician or by transfer from another pharmacy. Once
the details of the prescription order are entered, the system
queries whether the prescription order meets criteria for filling
of the prescription at the hub pharmacy 302 (Block 402). The
criteria that are evaluated may include considerations such as
pharmaceutical inventory at the hub pharmacy 302, urgency of the
prescription, scheduled pick-up date/time, etc. If the criteria for
fulfillment at the hub pharmacy 302 are not met, the prescription
is filled at the remote pharmacy 304 (Block 404). If the criteria
for fulfillment at the hub pharmacy 302 are met, the prescription
information is sent to the hub pharmacy 302 (Block 406). The
prescription may be received by a component of the hub pharmacy's
pharmacy management system, a separate server, or the system 40
itself. The prescription enters the queue of the system 40 (Block
408), its location in the queue determined by criteria at the hub
pharmacy 302; these criteria may include filling priority, the
availability of the appropriate drop-off location (tote 61), system
40 inventory, delivery schedule for the tote 61, etc. The
prescription is filled (Box 410) by the steps illustrated in FIG.
1. The offloading of the filled, secured container (Box 38 of FIG.
1) is accomplished by delivery of the prescription to the
appropriate tote 61 for the remote pharmacy 304. The system 40 also
may include a camera 72 to capture an image of the vial contents or
a scale to obtain the weight of the vial and its contents,
respectively, as discussed above. The next step in the process is
verification by a pharmacist that the prescription has been filled
as ordered (PV2) (Block 412). The PV2 step may be completed by a
pharmacist at the hub pharmacy 302; this process can be facilitated
by the pharmacist's review of the images of each prescription so
that the pharmacist does not have to open each vial (this approach
is a particular advantage if the prescriptions are bagged prior to
release into the tote 61). Alternatively, automated image analysis
of the captured images may be performed for the PV2 step, which
also is advantageous when the vials are bagged prior to release
into the tote 61. PV2 may be performed by a pharmacist at a remote
location, whether it be that of the remote pharmacy 304 from which
the prescription was received or another pharmacy different from
the hub pharmacy 302; the images of the filled prescriptions and
the prescription information may be sent electronically to another
location where a pharmacist can view the available information and
perform the verification of the filled prescription. An indication
of the prescription's verification status, such as verified or
rejected, may be indicated on the label or bag. When all
prescriptions for a given remote pharmacy location 304 have been
filled, the tote 61 is prepared and sent to the remote pharmacy 304
(Block 414). Preparation of the tote 61 may include the preparation
of a manifest or other documentation, which may include order
identification numbers, item numbers, quantity, barcodes, etc., in
addition to delivery information or other information; information
about the tote 61, its destination, contents, etc. may be in
alphanumeric text, or may take the form of a unique code, which may
be a bar code, RFID label, or other code. The manifest or other
documentation may be printed by choosing a button on the GUI (not
shown). Preparation of the tote 61 also may include bagging of the
filled prescriptions, if they have not already been bagged prior to
release into the tote 61, as discussed above, or packaging into a
secondary type of package. Alternatively, the prescriptions may be
placed in bags at the remote pharmacy 304, prior to distribution to
the patient or patient representative picking up the prescription
from the remote pharmacy 304. When the tote 61 is received by the
remote pharmacy 304 (Block 416), the prescriptions are distributed
to the patient or their representative when they arrive for pick-up
(Block 418). The filled prescriptions may be temporarily stored in
a will call device or will call area of the remote pharmacy 304 to
await pick up.
[0065] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although exemplary
embodiments of this invention have been described, those skilled in
the art will readily appreciate that many modifications are
possible in the exemplary embodiments without materially departing
from the novel teachings and advantages of this invention. For
example, many types of error messages, specific message content,
instructions and message delivery destinations are possible and
evident to one of skill in the art with the teachings of this
invention. As another example, the types of GUI screens,
information displayed and functional buttons may be tailored to
facilitate the workflow of the pharmacy and the particular
assignment of totes (i.e., whether for delivery to a remote
pharmacy, for in-store patient pick-up, or other destination or
categorization). Additionally, a variety of different light
locations as well as different color and pattern combinations can
be implemented to provide information regarding the status of the
system and specific totes or chutes. While prescriptions may be
entered at a remote pharmacy and scheduled to be picked up at the
same pharmacy, the prescription can be scheduled to be picked up at
any pharmacy, without changing the teachings and advantages of this
invention. Prescriptions may be verified (PV2) manually by a
pharmacist at either the hub pharmacy or when they are received at
the remote pharmacy, prior to delivery to the patient. Accordingly,
all such modifications are intended to be included within the scope
of this invention as defined in the claims. The invention is
defined by the following claims, with equivalents of the claims to
be included therein.
* * * * *