Abstract:
A packing and shipping verification system and method operates in real-time to virtually eliminate human error. Machine-readable labels are applied to components (e.g., parts) as they are produced. The label on each component is scanned immediately prior to packing into a container thereby allowing a processing unit to verify and record packing operations. Packing errors are reported in real-time so that they are corrected before a label is generated and affixed to the packing container. After container packing is completed, the processing unit causes a label to be generated that is applied to the container in real-time. A similar process is followed when small containers are placed into larger containers. Every operation is verified by machine scanning of the labels. Labels for containers are only generated after proper packing has been verified by the processing unit. Downstream users scan the labels to extract component information.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    The Applicant herein claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 60/187,797 entitled, “SYSTEM AND METHOD FOR VALIDATION OF PACKING AND SHIPPING OPERATIONS USING TWO-DIMENSIONAL BAR CODES” which was filed on Mar. 8, 2000 by John T. Piatek, the entire disclosure of which is hereby incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention generally relates to a system and method for validation of packing and shipping.  
           [0003]    Many suppliers have experienced problems in improperly identifying shipments with incorrect labels or placing product in shipping containers designated for a different product resulting in product being sent out of the plant with incorrect labels. For example, a shipment may be sent to the wrong customer, resulting in the shipment becoming lost and never returned. At a minimum, there is the wasted expense of shipping to the incorrect customer plus the return shipping costs. Further, this often results in a delay in the product arriving at the correct customer. Customers become aggravated by these delays.  
           [0004]    Problems also arise when a shipment is incorrect. For example, a shipment may have too few or too many parts or have the wrong parts. In the first instance, a customer may be inconvenienced and the manufacturer may incur additional shipping costs to correct the error. In the second instance, the manufacturer does not inconvenience the customer, but is not paid for the excess parts.  
           [0005]    Yet another problem is when a downstream user needs information regarding a component. Finding the needed information is often time consuming and requires contacting the manufacturer, etc.  
           [0006]    These are just a few of the costly inefficiencies that plague many manufacturers, shippers, and downstream users.  
           [0007]    Most attempts at manual fixes to these problems have proven to be very labor intensive while still allowing errors to occur. As a result, many manufacturers and shippers continue to be plagued with packing and shipping errors and downstream users lack needed component information.  
           [0008]    Accordingly, it is therefore desirable to provide for a solution that significantly reduces or eliminates these problems.  
         SUMMARY OF THE INVENTION  
         [0009]    It is an aspect of the present invention to provide a system for readily validating the products (e.g., parts) placed in shipping containers and the shipments themselves in an essentially fail-safe manner. It is another aspect of the present invention to provide a validation system for packing and shipping operations that may be performed without increasing the amount of labor required or adding significantly to the cost of the packing and shipping operations. It is yet another aspect of the invention to provide part, product, or component information to downstream users.  
           [0010]    To achieve these and other aspects and advantages, the validation method of the present invention comprises various combinations of the following steps.  
           [0011]    The process begins by applying a label containing a two-dimensional symbol or portable data file on each product to be packed in a box. The label contains at least one piece of descriptive data and preferably several types of descriptive data as described below. Immediately prior to the time the product is packed in a box and the label is scanned. The information scanned from the label is communicated to a host processor where the processor automatically verifies that the product is correctly being packed in the box based upon the information contained in the product label. If the product to be packed is not being packed in the correct box or if the product is not the correct product, the system notifies the packing operator and the error is corrected. If the product is being correctly packed in the box, the host processor increments a product count.  
           [0012]    The system determines whether the product count for the box has reached a predetermined limit. If the product count for the box has not reached the predetermined limit, then the process starts over by scanning the label on another product to be packed in the box. When the product count for the box reaches the predetermined limit, a label is printed for the box. The label preferably contains some of the product specific data scanned from the product labels packed in the box. The label is immediately applied to the box to reduce the chance of labeling error.  
           [0013]    The process continues with the next phase of the packing and shipping operation where the previously packed boxes are packed into larger containers, crates, pallets, or the like. The process for packing the boxes is similar to the process for packing the product. First the label on a box is scanned just prior to the time the box is packed into the larger container. Each box is automatically verified, based on information contained in the label, that the box is being correctly packed in the pallet/container. If the box is not being packed correctly in the pallet/container the packing operator is notified and the error corrected. A box count for the pallet/container is incremented if the box is correctly packed in the pallet/container. When the box count reaches a predetermined limit, a label is printed for the pallet/container. The label preferably contains information scanned from the box labels on the boxes packed in the pallet/container. If the box count has not yet reached the predetermined limit, the process repeats by scanning the label on another box to be packed in the pallet/container. In some embodiments, the product counter may be reset to zero and the process started over by scanning the next label on a product to be packed in a box. When the pallet/container packing process is complete a pallet/container label is generated. The pallet/container label is applied to the pallet/container immediately to eliminate mislabeling errors. The process continues by resetting the box count to zero and repeating the steps above as required. 
       
    
    
       [0014]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification and appended drawings.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    In the drawings:  
         [0016]    [0016]FIG. 1 is a block diagram of a system for reading and printing two-dimensional bar code labels in accordance with the present invention; and  
         [0017]    [0017]FIGS. 2A and 2B are flowcharts illustrating the flow of events according to a first aspect of the inventive method. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    As mentioned above and explained in more detail below, the present invention relates to a system and method for validating packing and shipping operations.  
         [0019]    Although the preferred implementation of the method is described below with respect to two-dimensional symbologies, other forms of machine-readable data may be used. The machine-readable data encoded on the labels may take many different forms. For example, the machine-readable data may be contained in a radio frequency (RF) or infrared (IR) signal transmitted from a transmitter attached to the label, or may be stored in electronic or magnetic data that may be retrieved using an appropriate reading device. Hence, the labels may include an RF or IR transmitter, smart card, smart button, or RF identification chip. Preferably, the machine-readable data is presented in the form of two-dimensional symbology, such as PDF417 or Data Matrix.  
         [0020]    [0020]FIG. 1 shows an example of one computer hardware system (or “host system”)  20  that may be used, in whole or in part, to implement the various embodiments of the verification system of the present invention. As shown in FIG. 1, computer hardware system  20  includes a central processing unit (CPU)  30 ; memory  31 , including random access memory (RAM)  31 A and read only memory (ROM)  31 B; a display monitor  32 ; a display interface  32 A connected to display monitor  32 ; a data storage device  34 ; a second input/output (I/O) interface  34 A connected to data storage device  34 ; a keyboard  33 ; a first I/O interface  33 A connected to keyboard  33 ; an information receiving device (i.e., scanner)  35  connected to a third I/O interface  35 A; a printer  36 ; a printer interface  36 A connected to printer  36 ; a portable unit  37  having a scanner  37 B and an optional printer  37 C; a wireless transceiver  37 A in communication with portable unit  37 ; and a system bus  40  for interconnecting CPU  30 , memory  31 , display interface  32 A, first I/O interface  33 A, second I/O interface  34 A, third I/O interface  35 A, and printer interface  36 A.  
         [0021]    Information receiver  35  may be any appropriate type of input device for receiving data from the particular form of machine-readable data used for a particular embodiment or for receiving machine-recognizable information that may be processed by a computer. Preferably, receiving device  35  is a two-dimensional bar code scanner capable of scanning PDF417 or Data Matrix compatible bar codes. However, those skilled in the art understand that other types of input devices may also be used in place of bar code scanners to practice the invention. Some of the various alternative technologies were mentioned above. In this specification, the term “scan” is used to refer to inputting or reading data from a label or other structure using any of these technologies.  
         [0022]    In FIG. 1, information receiving device  35  is shown with a wired connection to system bus  40  via third I/O interface  35 A. Receiving device  35  is either a fixed (i.e., non-moving) automatic scanner or a handheld manual scanner used by packing personnel. The movement of these receiving devices  35  is limited by the wire connection which keeps them tethered in a limited area. Therefore, it is envisioned that many embodiments of the invention will use a wireless device such as portable unit  37 .  
         [0023]    Portable unit  37  is a hand-held device having an attached scanner  37 B and possibly an attached printer or labeling device  37 C. Portable unit  37  is in wireless communication with system bus  40  via wireless transceiver  37 A. The mobile convenience of portable unit  37  allows an operator to roam around a plant or even to a warehouse. It is envisioned that large facilities would have multiple portable units  37  used for tracking shipping operations throughout the facility. Numerous embodiments are possible to implement portable unit  37 . One embodiment is to use personal digital assistants (PDAs); such as the hand-held units based on those manufactured by Palm, Inc. of Santa Clara, Calif. The units are equipped with a scanner and wireless communications options.  
         [0024]    Preferably, data storage device  34  is a computer hard disk drive or an application residing on the Internet. Depending on the complexity of the packing operations, storage device  34  may store vast amounts of data and a sophisticated software program. Storage device  34  stores data such as packing lists, shipping lists, parts lists, part numbers, serial numbers, manufacture dates and revision numbers, date and time of manufacture, line number, shift number, lot ID code, and other like information. One aspect of the invention is that much data can be stored in the labels applied to the components and containers, thus reducing the need for storing data on storage device  34  and enabling data to be shipped with the product. Storage device  34  communicates with CPU  30  via second I/O interface  34 A and system bus  40 .  
         [0025]    Memory  31  includes both RAM  31 A and ROM  31 B which store the program data and variables used by CPU or host processor  30 . For example, RAM  31 A holds the various counters such as parts counters, box counters, and the like. These counters are incremented by processor  30  as parts are packed into boxes. Counters could also be implemented in registers or memory internal to processor  30 . In some embodiments a simple counter is not sufficient. This is the case when a multitude of various parts must be packed into a box. In this case a packing list is more appropriate since each part on the packing list can be electronically checked-off as the parts are packed. The packing process is complete and verified when all of the parts on the packing list have been scanned and packed. Then, and only then, processor  30  sends a command to a printer  36  to generate a label  36 B that is immediately applied to the box.  
         [0026]    As mentioned above, the invention alerts the packing operator when a part is being packed in error. This alert is achieved in a variety of ways including: displaying a message on the monitor  32 , disabling scanner  37 B, or preventing operation of printer or labeling device  36  or  37 C. However, it is preferred to have an alarm  38  such as a visual alarm or more preferably an audible alarm to alert a packing operator. Alarm  38  is activated by processor  30  via alarm signal  38 A. The alarm generating device may be incorporated into portable unit  37 . Similarly, the invention alerts the packing operator when the packing process is complete. This is also achieved in a variety of ways, but the two most preferable methods are: 1) to generate a label  36 B, and 2) to activate a visual or audible alarm  38 . Processor  30  activates the alarm via the done signal  38 B communicated to alarm  38 .  
         [0027]    As will be apparent to those of ordinary skill in the art, the components of computer hardware system  20  may be incorporated into a personal computer or a portable laptop computer, with the possible exception of information receiver  35  and printer  36 . Also, much of the components of the hardware system may be integrated into a small handheld mini-computer having an integral scanner and display. However, as will become apparent from the following description of the present invention, certain components of computer hardware system  20  may be eliminated depending upon the manner in which it is used within the confines of the present invention. For example, if computer hardware system  20  were used solely for producing and storing the data carried on the package (e.g., generating labels), information receiver  35  may be eliminated. On the other hand, if computer hardware system  20  were used solely for receiving data (e.g., scanning labels) and displaying the received data on a display, keyboard  33  may be eliminated and printer  36  would become optional, unless one wished to print out information displayed on display monitor  32 . By eliminating keyboard  33  and/or printer  36 , computer hardware system  20  may be implemented in a very portable, small integral device.  
         [0028]    For example, for a downstream user who merely desires to read the component or container data on a label, a portable handheld unit equipped with a scanner and a display screen may be sufficient.  
         [0029]    Clearly, the particular form taken by computer hardware system  20  will depend upon the manner and environment in which the system is used. Further, computer system  20  may also be configured with a cellular telephone, a global positioning system (GPS), digital camera, facsimile machine, image scanner, or fax/modem.  
         [0030]    Having described the host system hardware, the details of the method are described further below.  
         [0031]    As indicated in block  100  of FIG. 2A, the inventive process begins by labeling each part or product to be packed and shipped with a two-dimensional bar code that contains, preferably, at least the current part number. The bar code may also include the unique serial number (if applicable), date of manufacture, and current revision level. Other optional information that could be included in the bar code are date and time of manufacture, line number, shift number, lot identification code, and other similar applicable information. It is also envisioned that some embodiments will use a bar code or label containing only one or two items of data from those listed above or similar data.  
         [0032]    In block  101 , the host system  20  initializes box and part counters to zero. Then, as depicted in block  102 , as each part/product is packed, the two-dimensional bar code on the part is scanned with a bar code reader (such as reading device  35 ) to identify to host system  20  that the part is being placed in a box or package. Host system  20  then verifies the correct part is being packed in the box (block  104 ). If the part is correct, host system  20  increments the part count by one (block  106 ). In the alternative, some embodiments use a packing list instead of a counter. As parts are packed, processor  30  electronically tracks the parts that are packed and compares the parts packed to a packing list. If the part is not the type of part that is to be packed in the box, host system  20  alerts the operator that the part is incorrect (block  108 ). As indicated by block  110 , this process (steps  102 - 108 ) is continued until the correct part count has been reached and all the parts packed have been verified that they are the correct parts for the box. Then, as indicated in block  112 , host system  20  automatically produces the label for the box. This label is immediately applied to the box by an operator or by an automatic labeling device. As indicated in block  114 , the host system then resets the part counter for the next box to zero, and the process then either repeats itself or proceeds to step  116  (FIG. 2B).  
         [0033]    If the box is to be packaged as part of a larger box, container, crate, or pallet, each box label is scanned as it is being placed into the larger container (block  116 ). Host system  20  will again verify the correct box of parts is being packed in the correct container (block  118 ) and keep a current box count (block  120 ). If the wrong box is being packed in the container/pallet, host system  20  alerts the operator (block  121 ). Once the correct box count (standard pack size) has been reached (block  122 ), host system  20  will automatically print a pallet label applicable to the type of parts and package being packed (block  124 ). This label is immediately applied to the pallet or container by an operator or by an automatic labeling device. Host system  20  will record the availability and existence of the pallet/container in tables that it stores in its memory (block  126 ) and the box count is reset (block  128 ) and the process is repeated.  
         [0034]    A box, container, or pallet can be relocated to a warehouse or shipping area by scanning the associated bar code, which will automatically update host system  20  so that it will know the current location of each part, box, container, or pallet.  
         [0035]    One can easily understand that the invention may be extended throughout the packing and shipping process. Parts are labeled and scanned before they are packed into boxes. Boxes are labeled and scanned before they are packed into larger boxes or containers. The larger boxes and containers are labeled and scanned before they are loaded into or onto shipping crates or pallets. Finally, the crates and pallets are labeled and scanned before they are loaded onto trucks, trailers, railroad cars, and the like. Every step of the process is monitored and verified by the host system.  
         [0036]    To facilitate error-free shipping, software in host system  20  is used to assign specific pallets to be shipped to a customer against a specific shipping order based on available product at hand. Host system  20  then instructs the operator via a radio frequency (RF) terminal or by printing out a two-dimensional bar coded ship list (if the system is not RF) to pull and scan specific boxes by serial number or similar identifier. If the correct serial numbers are then scanned by the operator as he or she pulls them, the data collection device will verify the correctness of the boxes loaded for this shipment. If pallet serial numbers are the ones that are correct for the order, the host system software will verify and generate a pallet label immediately from the portable printer possessed by the person who scanned the pallet. The label will be immediately affixed to that pallet by the operator. The host system software will then assign this serial number as ready for shipment. This process is repeated until the order for the customer is fulfilled. Upon filling the order, the host system may generate a master pallet label, if necessary. Software will continuously monitor the scanning process to verify that proper labels have been scanned. Upon completion of an order, the same verification process used for packing may be applied to loading a truck with a shipment to a customer.  
         [0037]    To facilitate a foolproof inventory management and error-proof shipping and labeling system, the proposed system preferably mandates the use of two-dimensional bar codes to mark individual parts. All transactions are reported to the host system by bar code scan. Manual entry is prohibited except for rare exceptions. Further, it is desirable that labels are not preprinted, but rather are printed only when the process that is being performed is verified by the host system to be correct. By using this model, the human factor for error is absolutely minimized or removed. This system relies on the host system to provide instructions, interpret bar codes, verify that correct parts are being packaged, and the printing of the proper labels for the shipment as a system-controlled process. Labels are preferably only printed when the host system determines that the reported information has been verified as correct. If it is not, a label is not printed.  
         [0038]    The system described here will work with batch data collection terminals (e.g., terminals wired to the system bus) or when connected to an RF infrastructure to allow real time interaction between the host software and portable data collection and printing devices. All data input sent to the host system software is preferably by bar code scan to minimize human error. All labels are produced on an “as needed” basis as determined by the host system. This ensures that only correct labels are applied to the boxes, containers, pallets, and the like. This real time communication allows the host system software to monitor the packing, handling, and shipping label generation on all aspects of the selecting, packing, and shipping processes. In addition, a verification requirement of having an operator scan the exact serial numbers that the software is asking for when packing a shipment allows the system to determine the type of label needed and produce the correct label for each pallet.  
         [0039]    By using a two-dimensional symbol such as PDF417 to mark individual parts with information such as a part number, a serial number, a part revision level, engineering changes, lot numbers, quality information, lot traceability, etc., the individual part becomes a portable database of information. This information is used to verify the proper packing of containers, to generate content lists and shipping labels, and is also used beyond the supplier by downstream users such as customer sites, dealers, repair shops, and insurance companies, etc. Hence, the more types of information that are put in the original two-dimensional part label, the more benefit to the downstream users who need to capture, collect, and process information that is contained within the two-dimensional label.  
         [0040]    In this specification and claims the terms “component” and “container” are used as generic terms. Component refers to product, parts, boxes, containers, and the like that are packed into larger containers. Containers refer to anything into which items are packed. Therefore, containers refer to boxes, crates, pallets, trucks, railroad cars, and the like.  
         [0041]    The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention.