Systems and methods for a unit-of-use wrap seal packing station

A system comprising a staging area and a packing area. The staging area may include a plurality of staging bins and a shuttle moveable along the plurality of staging bins. A staging bin of the plurality of staging bins may be configured to selectively retain a component of an order therein. Such staging bin may be configured to selectively release the component to the shuttle. The packing area may include a slide, a scanner, and a wrap seal conveyor. The shuttle may be configured to release the component onto the slide, and the scanner may be operable to scan and verify the component during placement of the component onto the wrap seal conveyor.

FIELD

The present application relates generally to the technical field of automated filling centers. In a specific example, the present application may relate to a high volume fulfillment center, e.g., a high volume pharmacy and to systems and devices used in filling prescriptions and prescription orders at a high volume pharmacy.

BACKGROUND

A high-volume pharmacy may process and fill a large number of prescriptions and prescription orders. Automated systems may be used by a high volume pharmacy to process and fulfill prescriptions.

Frequently, more than one prescription drug is required to complete a prescription order. Portions of the prescription order may be fulfilled in different areas of the high-volume pharmacy. After fulfillment, the fulfilled prescriptions may be gathered into a complete prescription order for shipping.

DETAILED DESCRIPTION

Example systems and methods for a unit-of-use wrap seal packing station (e.g., in a pharmacy) are described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of example embodiments. It will be evident, however, to one of ordinary skill in the art that these embodiments may be practiced without these specific details.

Generally, a prescription order is generated for a high volume pharmacy. The prescription order may include more than one prescription drug for fulfillment. Each prescription drug in a prescription order is an order component of the prescription order. Generally, the order components are pill bottles or other containers and packaging having a quantity of a prescription drug therein.

The prescription drugs may be dispensed at various sections of the high volume pharmacy. Some prescription orders may require manual fulfillment of order components. Distribution of order components necessitating manual fulfillment is provided by a distribution section and one or more the one manual sections. In general, manual handling includes manual fulfillment of prescription drugs (e.g., by a pharmacist utilizing or directly controlling certain equipment). Manual handling occurs at one or more than one manual sections, from which the order component exits the manual fulfillment device. Some prescription orders or portions of prescription orders may be filled using automated machines, which can fill prescription orders at a greater rate than manual fulfillment. Other prescriptions may be filled with unit of use products.

FIG. 1is a block diagram of an example system100, according to an example embodiment. While the system100is generally described as being deployed in a high volume pharmacy (e.g., a mail order pharmacy, a direct delivery pharmacy, an automated pharmacy, and the like), the system100may otherwise be deployed. The system100may include an order processing device102in communication with a benefit manager device106over a network104. Additional devices which may be in communication with the benefit manager device106and/or the order processing device102over network104include: database(s)108which may store one or more than one of order data110, member data112, claims data114, drug data116, prescription data118, and plan sponsor data120; pallet sizing and pucking device(s)122; loading device(s)124; inspect device(s)126; unit of use device(s)128; automated dispensing device(s)130; manual fulfillment device(s)132; review device(s)134; imaging device(s)136; cap device(s)138; accumulation device(s)140; literature device(s)141; packing device(s)142; and unit of use packing device(s)144. The system100may also include additional devices, which may communicate with each other over network104or directly.

The order processing device102may receive information about prescriptions being filled at a pharmacy in which the order processing device102is deployed. In general, the order processing device102is a device located within or otherwise associated with a pharmacy location to enable fulfillment of a prescription by dispensing prescription drugs. In some embodiments, the order processing device102may be a device separate from a pharmacy that enables communication with other devices located within a pharmacy. For example, the order processing device102may be in communication with another order processing device102and/or other devices122-144located with a pharmacy. In some embodiments, an external pharmacy order processing device102may have limited functionality (e.g., as operated by a patient requesting fulfillment of a prescription drug) when an internal pharmacy order processing device102may have greater functionality (e.g., as operated by a pharmacy).

The order processing device102may track a prescription order as it is fulfilled. A prescription order may include one or more than one prescription to be filled by the pharmacy. The order processing device102may make pharmacy routing decisions and/or order consolidation decisions for a prescription order. The pharmacy routing decisions include what device or devices in the pharmacy are responsible for filling at least a portion of the prescription order, where the order consolidation decisions include whether portions of a prescription order or multiple prescription orders should be shipped together for a patient or a patient family. The order processing device102may operate on its own or in combination with the benefit manager device106. The order processing device102may track and/or schedule the literature or other paperwork associated with each order or multiple prescription orders that are being shipped together.

Examples of the devices102,106include a set-top box (STB), a receiver card, a mobile telephone, a personal digital assistant (PDA), a display device, a portable gaming unit, a tablet, and a computing system; however other devices may also be used. For example, the devices102,106may include a mobile electronic device, such an IPHONE or IPAD device by Apple, Inc., mobile electronic devices powered by ANDROID by Google, Inc., and a BLACKBERRY device by Blackberry Limited. The order processing device102may also include other computing devices, such as desktop computing devices, notebook computing devices, netbook computing devices, gaming devices, servers, and the like. The device102may include circuitry, a processor, a memory to store data and instructions, and communication functionality. Other types of electronic devices that can use rules and instructions to execute various functions may also be used.

Examples of the network104include Mobile Communications (GSM) network, a code division multiple access (CDMA) network, 3rd Generation Partnership Project (3GPP), an Internet Protocol (IP) network, a Wireless Application Protocol (WAP) network, a WiFi network, or an IEEE 802.11 standards network, as well as various combinations thereof. The network104may include optical communications. The network104may be a local area network or a global communication network, such as the Internet. Other conventional and/or later developed wired and wireless networks may also be used. In some embodiments, the network104may include a prescribing network such as the electronic prescribing network operated by Surescripts of Arlington, Va.

The benefit manager device106is a device operated by an entity at least partially responsible for creation and/or management of the pharmacy or drug benefit. While this benefit manager operating the benefit manager device106is typically a pharmacy benefit manager (PBM), other entities may operate the benefit manager device106either on behalf of themselves, the PBM, or another entity. For example, the benefit manager may be operated by a health plan, a retail pharmacy chain, a drug wholesaler, a data analytics or other type of software-related company, or the like. In some embodiments, a PBM that provides the pharmacy benefit may also provide one or more than one additional benefits including a medical or health benefit, a dental benefit, a vision benefit, a wellness benefit, a radiology benefit, a pet care benefit, an insurance benefit, a long term care benefit, a nursing home benefit, and the like. The PBM may, in addition to its PBM operations, operate one or more than one pharmacy. The pharmacies may be retail pharmacies, mail order pharmacies, or otherwise.

Some of the operations of the PBM that operates the benefit manager device106may include the following. A member (or a person on behalf of the member) of a pharmacy benefit plan administered by or through the PBM attempts to obtain a prescription drug at a retail pharmacy location where the member can obtain drugs in a physical store from a pharmacist or pharmacist technician, or in some instances through mail order drug delivery from a mail order pharmacy location. The member may also obtain a prescription drug directly or indirectly through the use of a machine, such as a kiosk, vending unit, mobile electronic device, or a different type of mechanical, electrical, electronic communication device and/or computing device.

The member may have a co-pay for the prescription drug that reflects an amount of money that the member is responsible to pay the pharmacy for the prescription drug. The money paid by the member to the pharmacy may come from the personal funds of the member, a health savings account (HSA) of the member or the member's family, a health reimbursement arrangement (HRA) of the member or the member's family, a flexible spending accounts (FSA) of the member or the member's family, or the like. An employer of the member may directly or indirectly fund or reimburse the member or an account of the member for the co-pay.

The amount of the co-pay paid by the member may vary by the benefit plan of a plan sponsor or client with the PBM. The member's co-pay may be based on a flat co-pay (e.g., $10), co-insurance (e.g., 10%), and/or a deductible (e.g., for first $500 of annual prescription drug spend) for certain prescription drugs, certain types and/or classes of prescription drugs, and/or all prescription drugs.

In certain instances, the member may not pay the co-pay or may only pay for a portion of a co-pay for a prescription drug. For example, if the usual and customary cost for a generic version of a prescription drug is $4, and the member's flat co-pay is $20 for the prescription drug, the member may only pay $4 to receive the prescription drug. In another example involving a worker's compensation claim, no co-pay may be due by the member for the prescription drug. The co-pay may also vary based on the delivery channel used to receive the prescription drug. For example, the co-pay for receiving prescription drug from a mail order pharmacy location may be less than the co-pay for receiving prescription drug from a retail pharmacy location.

In conjunction with receiving the co-pay (if any) from the member and dispensing the prescription drug to the member, the pharmacy submits a claim to the PBM for the prescription drug. The PBM may perform certain adjudication operations including verifying the eligibility of the member, reviewing an applicable formulary of the member to determine appropriate co-pay, coinsurance, and deductible for the prescription drug, and performing a drug utilization review (DUR) on the member. The PBM then provides a response to the pharmacy following performance of at least some of the aforementioned operations. As part of the adjudication, the plan sponsor (or the PBM on behalf of the plan sponsor) ultimately reimburses the pharmacy for filling the prescription drug when the prescription drug was successfully adjudicated. The aforementioned adjudication operations generally occur before the co-pay is received and the prescription drug dispensed. However, the operations may occur simultaneously, substantially simultaneously, or in a different order. In addition, more or less adjudication operations may be performed as at least part of the adjudication process.

The amount of reimbursement paid to the pharmacy by a plan sponsor and/or money paid by the member may be based at least in part on the type of pharmacy network in which the pharmacy is included. Other factors may be used to determine the amount in addition to the type of pharmacy network. For example, if the member pays the pharmacy for the prescription without using the prescription drug benefit provided by the benefit manager, the amount of money paid by the member may be higher and the amount of money received by the pharmacy for dispensing the prescription drug and for the prescription drug itself may be higher. Some or all of the foregoing operations may be performed by executing instructions on the benefit manager device106and/or an additional device.

In some embodiments, at least some of the functionality of the order processing device102may be included in the benefit manager device106. The order processing device102may be in a client-server relationship with the benefit manager device106, a peer-to-peer relationship with the benefit manager device106, or in a different type of relationship with the benefit manager device106.

The order processing device102and/or the benefit manager device106may be in communication directly (e.g., through local storage or peer-to-peer connection(s)) and/or through the network104(e.g., in a cloud configuration or software as a service) with a database108(e.g., as may be retained in memory or otherwise). The database108may be deployed on the order processing device102, the benefit manager device106, on another device of the system100, or otherwise. The database108may store order data110, member data112, claims data114, drug data116, prescription data118, and/or plan sponsor data120. Other data may be stored in the database108.

The order data110may include data related to the order of prescriptions including the type (e.g., drug name and strength) and quantity of each prescription in a prescription order. The order data110may also include data used for completion of the prescription, such as prescription materials and/or the type and/or size of container in which the drug is or is preferably dispensed. In general, prescription materials are a type of order materials that include an electronic copy of information regarding the prescription drug for inclusion with or otherwise in conjunction with the fulfilled prescription. The prescription materials may include electronic information regarding drug interaction warnings, recommended usage, possible side effects, expiration date, date of prescribing, or the like. The order data110may be used by a high volume fulfillment center to fulfill a pharmacy order.

In some embodiments, the order data110includes verification information associated with fulfillment of the prescription in the pharmacy. For example, the order data110may include videos and/or images taken of (i) the prescription drug prior to dispensing, during dispensing, and/or after dispensing, (ii) the prescription container (e.g., a prescription bottle and sealing lid) used to contain the prescription drug prior to dispensing, during dispensing, and/or after dispensing, (iii) the packaging and/or packaging materials used to ship or otherwise deliver the prescription drug prior to dispensing, during dispensing, and/or after dispensing, and/or (iv) the fulfillment process within the pharmacy. Other type of verification information such as bar code data read from pallets used to transport prescriptions within the pharmacy may also be stored as order data110.

The member data112includes information regarding the members associated with the benefit manager. The information stored as member data112may include personal information, personal health information, protected health information, and the like. Examples of the member data112include name, address, telephone number, e-mail address, prescription drug history, and the like. The member data112may include a plan sponsor identifier that identifies the plan sponsor associated with the member and/or a member identifier that identifies the member to the plan sponsor. The member data112may include a member identifier that identifies the plan sponsor associated with the patient and/or a patient identifier that identifies the patient to the plan sponsor. The member data112may also include, by way of example, dispensation preferences such as type of label, type of cap, message preferences, language preferences, or the like.

The member data112may be accessed by various devices in the pharmacy, e.g., the high volume fulfillment center, to obtain information utilized for fulfillment and shipping of prescription orders. In some embodiments, an external order processing device102operated by or on behalf of a member may have access to at least a portion of the member data112for review, verification, or other purposes.

In some embodiments, the member data112may include information for persons who are patients of the pharmacy but are not members in a benefit plan being provided by the benefit manager. For example, these patients may obtain drug directly from the pharmacy, through a private label service offered by the pharmacy, the high volume fulfillment center, or otherwise. In general, the use of the terms member and patient may be used interchangeably herein.

The claims data114includes information regarding pharmacy claims adjudicated by the PBM under a drug benefit program provided by the PBM for one, or more than one, plan sponsors. In general, the claims data114includes an identification of the client that sponsors the drug benefit program under which the claim is made, and/or the member that purchased the prescription drug giving rise to the claim, the prescription drug that was filled by the pharmacy (e.g., the national drug code number), the dispensing date, generic indicator, GPI number, medication class, the cost of the prescription drug provided under the drug benefit program, the copay/coinsurance amount, rebate information, and/or member eligibility. Additional information may be included.

In some embodiments, other types of claims beyond prescription drug claims may be stored in the claims data114. For example, medical claims, dental claims, wellness claims, or other type of health care-related claims for members may be stored as a portion of the claims data114.

In some embodiments, the claims data114includes claims that identify the members with whom the claims are associated. In some embodiments, the claims data114includes claims that have been de-identified (e.g., associated with a unique identifier but not with a particular, identifiable member).

The drug data116may include drug name (e.g., technical name and/or common name), other names by which the drug is known by, active ingredients, an image of the drug (e.g., in pill form), and the like. The drug data116may include information associated with a single medication or multiple medications.

The prescription data118may include information regarding prescriptions that may be issued by prescribers on behalf of patients, who may be members of the drug benefit plan, for example to be filled by a pharmacy. Examples of the prescription data118include patient names, medication or treatment (such as lab tests), dosing information, and the like. The prescriptions may be electronic prescriptions, paper prescriptions that have been scanned, or otherwise. In some embodiments, the dosing information reflects a frequency of use (e.g., once a day, twice a day, before each meal, etc.) and a duration of use (e.g., a few days, a week, a few weeks, a month, etc.).

In some embodiments, the order data110may be linked to associated member data112, claims data114, drug data116, and/or prescription data118.

The plan sponsor data120includes information regarding the plan sponsors of the benefit manager. Examples of the plan sponsor data120include company name, company address, contact name, contact telephone number, contact e-mail address, and the like.

The order processing device102may direct at least some of the operations of the devices122-144, recited above. In some embodiments, operations performed by one of these devices122-144may be performed sequentially, or in parallel with the operations of another device as may be coordinated by the order processing device102. In some embodiments, the order processing device102tracks a prescription with the pharmacy based on operations performed by one or more of the devices122-144.

In some embodiments, the system100may transport prescription drug containers (e.g., between one or more than one of the devices122-144in the high volume fulfillment center) by use of pallets. The pallet sizing and pucking device122may configure pucks in a pallet. A pallet may be a transport structure for a number of prescription containers, and may include a number of cavities. A puck may be placed in one or more than one of the cavities in a pallet by the pallet sizing and pucking device122. A puck may include a receptacle sized and shaped to receive a prescription container. Such containers may be supported by the pucks during carriage in the pallet and during movement through the fulfillment process. Different pucks may have differently sized and shaped receptacles to accommodate containers of differing sizes, as may be appropriate for different prescriptions. Pucks allow the standardization of equipment engaging differently sized drug containers such that some automated equipment can move the drug container by gripping the puck that is supporting the container and allow the use of a standardized pallet that holds a plurality of pucks have a same outer dimension while having differently sized receptacles therein to hold differently sized drug containers. The pucks may also operate to ensure that a drug container is centered in a location on the pallet.

The arrangement of pucks in a pallet may be determined by the order processing device102based on prescriptions which the order processing device102decides to launch. In general, prescription orders in the order database110reside in one or more than one queues, and are generally launched in a first-in-first-out order. However, the order processing device102may use logic and a variety of factors to determine when and how prescriptions are to be launched. For example, some non-limiting factors which may alter the first-in-first-out order of launching prescriptions in a pharmacy include the age of the order, whether the order required an outreach to a physician or some other intervention, whether there are any performance guarantees with plan sponsors or members, the available inventory of a given pharmaceutical in view of existing prescriptions already launched which will require that pharmaceutical, the zip code to which the order will be shipped, the workload and volume of various parts of the pharmacy, whether valid paperwork for the order has been received, and/or similar orders for the same pharmaceutical that are already to be launched. The logic may be implemented directly in the pallet sizing and pucking device122, in the order processing device102, in both devices102,122, or otherwise. Once a prescription is set to be launched, a puck suitable for the appropriate size of container for that prescription may be positioned in a pallet by a robotic arm or pickers. The pallet sizing and pucking device122may launch a pallet once pucks have been configured in the pallet.

The loading device124may load prescription containers into the pucks on a pallet by a robotic arm, a pick and place mechanism, or the like. In one embodiment, the loading device108has robotic arms or pickers to grasp a prescription container and move it to and from a pallet. The loading device124may also print a label which is appropriate for a container that is to be loaded onto the pallet, and apply the label to the container. The pallet may be located on a conveyor assembly during these operations. In an example embodiments, the drug containers may be positioned in the pucks by the loading device124prior to the pucks being placed in the pallet.

The inspect device126may verify that containers in a pallet are correctly labeled and in the correct spot on the pallet. The inspect device126may scan the label on one or more than one container on the pallet. Labels of containers may be scanned or imaged in full or in part by the inspect device126. Such imaging may occur after the container has been lifted out of its puck by a robotic arm, picker, or the like, or may be otherwise scanned or imaged while retained in the puck. In some embodiments, images and/or video captured by the inspect device126may be stored in the database108as order data110.

The unit of use device128may temporarily store, monitor, label and/or dispense unit of use products. In general, unit of use products are prescription drug products that may be delivered to a patient or member without being repackaged at the pharmacy. These products may include pills in a container, pills in a blister pack, inhalers, and the like. Prescription drug products dispensed by the unit of use device128may be packaged individually or collectively for shipping, or may be shipped in combination with other prescription drugs dispensed by other devices in the high volume fulfillment center.

The automated dispensing device130may include one or more than one devices that dispense prescription drugs or pharmaceuticals into prescription containers in accordance with one or multiple prescription orders. In general, the automated dispensing device130may include mechanical and electronic components with, in some embodiments, software and/or logic to facilitate pharmaceutical dispensing that would otherwise be performed in a manual fashion by a pharmacist and/or pharmacist technician. For example, the automated dispensing device130may include high volume fillers that fill a number of prescription drug types at a rapid rate and blister pack machines that dispense and pack drugs into a blister pack. Prescription drugs dispensed by the automated dispensing devices130may be packaged individually or collectively for shipping, or may be shipped in combination with other prescription drugs dispenses by other devices in the high volume fulfillment center.

The manual fulfillment device132may provide for manual fulfillment of prescriptions. For example, the manual fulfillment device132may receive or obtain a container and enable fulfillment of the container by a pharmacist or pharmacy technician. In some embodiments, the manual fulfillment device132provides the filled container to another device in the system100. In an example embodiment, the container may be joined with other containers in a prescription order for a patient or member, e.g., on a pallet or at the accumulation device140. In general, a manual fulfillment may include operations at least partially performed by a pharmacist or pharmacy technician. For example, a person may retrieve a supply of the prescribed drug, may make an observation, may count out a prescribed quantity of drugs and place them into a prescription container, or the like. Some portions of the manual fulfillment process may be automated by use of a machine. For example, counting of capsules, tablets, or pills may be at least partially automated (e.g., through use of a pill counter). Prescription drugs dispensed by the manual fulfillment device132may be packaged individually or collectively for shipping, or may be shipped in combination with other prescription drugs dispenses by other devices in the high volume fulfillment center.

The review device134may process prescription containers to be reviewed by a pharmacist for proper pill count, exception handling, prescription verification, and the like. Fulfilled prescriptions may be manually reviewed and/or verified by a pharmacist, as may be required by state or local law. A pharmacist or other licensed pharmacy person who may dispense certain drugs in compliance with local and/or other laws may operate the review device134and visually inspect a prescription container that has been filled with a prescription drug. The pharmacist may review, verify, and/or evaluate drug quantity, drug strength, and/or drug interaction concerns, or otherwise perform pharmacist services. The pharmacist may also handle containers which have been flagged as an exception, such as containers with unreadable labels, containers for which the associated prescription order has been cancelled, containers with defects, and the like. In an example embodiment, the manual review can be performed at the manual station.

The imaging device136may image containers once they have been filled with pharmaceuticals. The imaging device136may measure the fill height of the pharmaceuticals in the container based on the obtained image to determine if the container is filled to the correct height given the type of pharmaceutical and the number of pills in the prescription. Images of the pills in the container may also be obtained to detect the size of the pills themselves and markings thereon. The images may be transmitted to the order processing device102, and/or stored in the database110as part of the order data110.

The cap device138may be used to cap or otherwise seal a prescription container. In some embodiments, the cap device138may secure a prescription container with a type of cap in accordance with a patient preference (e.g., a preference regarding child resistance), a plan sponsor preference, a prescriber preference, or the like. The cap device138may also etch a message into the cap or otherwise associate a message into the cap, although this process may be performed by a subsequent device in the high volume fulfillment center.

The accumulation device140accumulates various containers of prescription drugs in a prescription order. The accumulation device140may accumulate prescription containers from various devices or areas of the pharmacy. For example, the accumulation device140may accumulate prescription containers from the unit of use device128, the automated dispensing device130, the manual fulfillment device132, and the review device134, at the high volume fulfillment center. The accumulation device140may be used to group the prescription containers prior to shipment to the member or otherwise.

In some embodiments, the literature device141folds or otherwise prepares the literature for inclusion with a prescription drug order (e.g., in a shipping container). In some embodiments, the literature device141that prints the literature may be separate from the literature device that prepares the literature for inclusion with a prescription order.

The packing device142packages a prescription order in preparation for shipping the order. The packing device142may box, bag, or otherwise package the fulfilled prescription order for delivery. The packing device142may further place inserts, e.g., literature or other papers, into the packaging received from the literature device141or otherwise. For example, bulk prescription orders may be shipped in a box, while other prescription orders may be shipped in a bag which may be a wrap seal bag. The packing device142may label the box or bag with the address and a recipient's name. The label may be printed and affixed to the bag or box, be printed directly onto the bag or box, or otherwise associated with the bag or box. The packing device142may sort the box or bag for mailing in an efficient manner (e.g., sort by delivery address). The packing device142may include ice or temperature sensitive elements for prescriptions which are to be kept within a temperature range during shipping in order to retain efficacy or otherwise. The ultimate package may then be shipped through postal mail, through a mail order delivery service that ships via group and/or air (e.g., UPS, FEDEX, or DHL), through delivery service, through a local delivery service (e.g., a courier service), through a locker box at a shipping site (e.g., an AMAZON locker or a post office box), or otherwise.

The unit of use packing device144packages a unit of use prescription order in preparation for shipping the order. The unit of use packing device144may include manual scanning of containers to be bagged for shipping to verify each container in the order. In an example embodiment, the manual scanning may be performed at a manual station.

While the system100inFIG. 1is shown to include single devices102,106,122-144multiple devices may be used. The devices102,106,122-144may be the same type or model of device or may be different device types or models. When multiple devices are present, the multiple devices may be of the same device type or models or may be a different device type or model. The types of devices102,106,122-144shown inFIG. 1are example devices. In other configurations of the system100, lesser, additional, or different types of devices may be included.

Moreover, the system100shows a single network104; however, multiple networks can be used. The multiple networks may communicate in series with each other to link the devices102,106,122-144or in parallel to link the devices102,106,122-144. Multiple devices may share processing and/or memory resources. The devices102,106,122-144may be located in the same area or in different locations. For example, the devices102,106,122-144may be located in a building or set of adjoining buildings. The devices102,106,122-144may be interconnected (e.g. by conveyors), networked, and/or otherwise in contact with one another or integrated with one another, e.g., at the high volume fulfillment center. In addition, the functionality of a device may be split among a number of discrete devices and/or combined with other devices.

The system100may include a single database, or multiple databases, maintained by respective devices operated by or on behalf one or a number of different persons and/or organizations. The communication may occur directly (e.g., through local storage) and/or through the network104(e.g., in a cloud configuration or software-as-a-service) with a device that stores a respective database.

FIG. 2illustrates the order processing device102, according to an example embodiment. The order processing device102may be used by one or more than one operator to generate prescription orders, make routing decisions, make prescription order consolidation decisions, track literature within the system100, and/or view order status and other order related information. For example, the prescription order may be comprised of order components. The order processing device102may receive instructions to fulfill an order without operator intervention. An order component may include a prescription drug fulfilled by use of a container through the system100. The order processing device102may direct an order component to the manual fulfillment device132and/or to the review device134, and direct other components to the automated dispensing device130. The order processing device102may direct order components to the accumulation device140for aggregation before shipping. The order processing device102may direct the order components directly to the packing device142if the prescription order does not require accumulation from various areas of the pharmacy for completion. The order processing device102may be deployed in the system100, or may otherwise be used.

The order processing device102may include an order verification subsystem202, an order control subsystem204, and/or an order tracking subsystem206. Other subsystems may also be included in the order processing device102.

The order verification subsystem202may communicate with the benefit manager device106to, verify the eligibility of the member, review the formulary to determine appropriate co-pay, coinsurance, and deductible for the prescription drug, and/or perform a DUR. Other communications between the order verification subsystem202and the benefit manager device106may be performed for a variety of purposes.

The order control subsystem204controls various movements of the containers and/or pallets along with various filling functions during their progression through the system100.

In some embodiments, the order control subsystem204may identify the prescribed drug in one or more than one prescription order as capable of being fulfilled by the automated dispensing device130. The order control subsystem204may determine which prescriptions are to be launched, and may determine that a pallet of automated-fill containers is to be launched. The order control subsystem204may determine that an automated-fill prescription of a specific pharmaceutical is to be launched, and may examine a queue of orders awaiting fulfillment for other prescription orders which will be filled with the same pharmaceutical. The order control subsystem204may then launch orders with similar automated-fill pharmaceutical needs together in a pallet to the automated dispensing device130.

In some embodiments, the order control subsystem204may identify the prescribed drug in one or more than one prescription order as needing to be fulfilled manually and may direct the container or order component to the manual fulfillment device132to achieve the manual fulfillment. The order control subsystem204may determine which prescriptions are to be launched, and may determine that a pallet of manual-fill containers is to be launched. The order control subsystem204may determine that a manual-fill prescription of a specific pharmaceutical is to be launched, and may examine a queue of orders awaiting fulfillment for other prescription orders which will be filled with the same pharmaceutical. The order control subsystem204may then launch orders with similar manual-fill pharmaceutical needs together in a pallet to the manual fulfillment device132. As the devices122-144may be interconnected by a system of conveyors or other container movement systems, the order control subsystem204may control various conveyors to deliver the pallet from the loading device124to the manual fulfillment device132, for example.

In some embodiments, the order control subsystem204may identify the container as a unit-of-use container, and may direct the unit-of-use container and/or other components in that order to the unit-of-use packing device144for packing. The devices122-144may be interconnected by a system of conveyors or other container movement systems. Thus, the order control subsystem204may control various conveyors to deliver a unit-of-use container and/or other components in that order to the unit-of-use packing device144.

The order tracking subsystem206may track a prescription order as it progresses (or stops) toward fulfillment. The order tracking subsystem206may track, record and/or update order history, order status, or the like. The order tracking subsystem206may store data locally (e.g., in a memory) or as a portion of the order data110stored in the database108.

FIGS. 3A and 3Billustrate a unit-of-use packing device144, according to an example embodiment. The unit-of-use packing device144may be deployed in the system100, or may otherwise be deployed. A unit-of-use wrap seal packaging center300of a pharmacy may be deployed within the unit-of-use packing device144, or may be otherwise deployed. A unit-of-use wrap seal packaging center300may be operated by one or more than one pharmacists and/or pharmacist technicians to package unit-of-use prescription orders for shipment.

The unit-of-use packing device144may include a control unit302, a conveyor section304, a staging area306, and a packing area308. The control unit302may operate at the direction of the order processing device102. As shown inFIG. 3B, the control unit302is shown in block form. However, it will be understood that the control unit302is operatively associated with and connected to unit-of-use packing device144.

The conveyor section304may include a staging conveyor310. A single staging conveyor310or multiple staging conveyors310may be used. In some embodiments, a staging conveyor310may be a Z conveyor. An inclined conveyor or any other suitable mechanism may be used instead of or in addition to a Z conveyor. WhileFIG. 3Adepicts six staging conveyors310, a greater or lesser number of conveying mechanisms may be used.

The staging conveyor310may include cleats312to assist containers314move along the staging conveyor310. The cleats312may be constructed of rubber, PVC, or of other materials and spaced uniformly or otherwise. The staging conveyor310may include a lower horizontal section316, an inclined section318, and an upper horizontal section320. The conveyor section304may also include a feed conveyor311which brings the containers314to the unit-of-use packing device144. The feed conveyor311may include one or more than one drop door313which may be a bomb bay style drop door. Each staging conveyor310may be associated with its own drop door313, such that the drop door313drops the container314down a chute315and into a holding bin317associated with that staging conveyor310. Additionally, each holding bin317may include a door319(shown in phantom inFIG. 3B) which may open to allow a container314to ride the staging conveyor310out of the holding bin317as appropriate. The staging conveyor310conveys one or more than one container314which may be components of a prescription order from the lower horizontal section316, and up the inclined section318to the upper horizontal section320. The upper horizontal section320of the staging conveyor310leads to the staging area306.

The staging area306may include a staging bin330. A single staging big330or multiple staging bins330may be used. In some embodiments, each staging conveyor310is associated with its own staging bin330. The containers314which form a prescription order are carried by the staging conveyor310to the staging bin330, and may be deposited within the staging bin330. The staging bin330may include one of more than one door335which, when closed, hold the containers314within the staging bin330. The doors335may open to drop any containers314contained within the staging bin330out of the staging bin330. In some embodiments, other structures may be used to selectively retain the containers314within the staging bin330in place of the doors335.

The staging area306may also include a shuttle340which moves along a track345. The track345may extend beneath each of the staging bins330, so as to allow the shuttle340to move beneath the staging bins330. The track345may be positioned below the staging bins330to allow the shuttle340to be positionable beneath the doors335such that the shuttle340receives any of the containers314housed within the staging bin330when the doors335of that staging bin330are opened. In some embodiments, the shuttle340and the track345may be positioned elsewhere rather than directly beneath the staging bins330, such as when a structure other than the doors335is used to selectively retain and release the containers314from the staging bins330. For example, if a structure which allows the containers314to exit from one side of the staging bin330rather than through the bottom of the staging bin330is used, the track345and the shuttle340may be positioned proximate the staging bins330. The shuttle340may be controllable by the control unit302.

The packing area308may include a slide350, a wrap seal conveyor360, and a pre-scan gathering area355which may be positioned generally above the wrap seal conveyor360and at the bottom of the slide350. As can be best seen inFIG. 4, the packing area308may also include a scanner357which may be a manual scanner. In an example embodiment, the scanner357may be a secured overhead high speed camera or scanner357, although it will be recognized that an undermounted scanner357may instead or also be used. An operator manually passes a container314across the scanner357to scan the container314. The wrap seal conveyor360may include wrap seal pockets365into which the containers314may be placed for sealing and shipping.

Once the shuttle340receives one or more than one container314from the staging bin330, it may move to a position proximate the slide350. The shuttle340may then release the containers314via the door342so as to allow the containers314to slide down the slide350and into the pre-scan gathering area355. As the containers314land in the pre-scan gathering area355, a worker may pick up each container314and scan the container314via the scanner357before placing the container314into a wrap seal pocket365on a wrap seal conveyor360. A wrap seal pocket365may be a flexible mailer bag which may be pre-formed. In some embodiments, the wrap seal pocket365may be a portion of a flexible mailer bag, into which containers314are placed, after which the wrap seal pocket365is covered and sealed.

The staging area306may, in some embodiments, include an exception zone for the containers314which are determined to be an exception. An exception determination may occur during scanning of the containers314at the scanner357, while the containers314reside in the staging bin330, after the containers314have been dropped by the staging bins330to the shuttle340, or at any location in unit-of-use wrap seal packaging center300in which the containers314may be imaged, or scanned, and/or viewed. A worker may make the exception determination based on the scan, and may physically place the container314in the exception zone. In some embodiments, the shuttle340may take the container314to the exception zone. The exception zone may be a separate bin, or a tote, or a conveyor which takes the containers314deemed exceptions to, for example, the review device134.

FIG. 5illustrates a control unit302, according to an example embodiment. The control unit302may be deployed in the unit-of-use wrap seal packaging center300, or may otherwise be deployed. The control unit302may be communicatively connected to one or more than one components in the conveyor section304, the staging area306, and/or the packing area308, such as the staging bins330, the shuttle340, the scanner357, and the like. The control unit302may include a staging subsystem502and a verification subsystem504. The staging subsystem502may enable the control unit302to stage a single container314or multiple containers314which make up a prescription order in the shuttle340while a previous prescription order is being acted upon by a worker in the packing area308. The verification subsystem504may enable the control unit302to determine whether the container314or containers314scanned by the worker via the scanner357are the correct containers314are ready for shipping.

FIG. 6illustrates an example staging subsystem502that may be deployed in the control unit302, or may be otherwise deployed in another system. One or more modules are communicatively coupled and included in the staging subsystem502to enable the staging subsystem502to stage prescription orders. The modules of the staging subsystem502that may be included are a staging bin module602, a conveyor module604and/or a shuttle module606. Other modules may also be included.

In some embodiments, the modules of the staging subsystem502may be distributed so that some of the modules are deployed in other devices within the system100. In one embodiment, the modules are deployed in memory and executed by a processor coupled to the memory. The functionality contained within the modules602-606may be combined into a lesser number of modules, further divided among a greater number of modules, or redistributed among existing modules. Other configurations including the functionality of the modules602-606may be used.

The staging bin module602may instruct a selected staging bin330to open or close its doors335. The conveyor module604may instruct the staging conveyor310associated with an empty staging bin330to advance and deposit the next prescription order of one or more than one containers314into that staging bin330. The shuttle module606may instruct the shuttle340to move beneath a selected staging bin330. In some embodiments, the shuttle module606may also instruct the shuttle340to move to the slide350and release a prescription order of one or more than one containers314onto the slide350.

FIG. 7illustrates an example verification subsystem504that may be deployed in the control unit302, or may be otherwise deployed in another system. One or more modules are communicatively coupled and included in the verification subsystem502to enable the verification subsystem504to verify prescription orders. The modules of the verification subsystem504that may be included are a scanning module702, an exception module704, and/or a wrap seal conveyor module706. Other modules may also be included.

In some embodiments, the modules of the verification subsystem504may be distributed so that some of the modules are deployed in other devices within the system100. In one embodiment, the modules are deployed in memory and executed by a processor coupled to the memory. The functionality contained within the modules702-706may be combined into a lesser number of modules, further divided among a greater number of modules, or redistributed among existing modules. Other configurations including the functionality of the modules702-706may be used.

The scanning module702may communicate with the scanner357to receive the result of the scan of the container314. The exception module704may determine whether an exception has occurred. In one embodiment, if the container314which does not belong in the present prescription order is detected in the scan, or if not all of the containers314which should be present for the given prescription order are scanned, the exception module704may determine that an exception has occurred. The exception module704may alert a worker to the exception via a visual or auditory alert, or the like. Alternatively, the worker may be responsible for determining when an exception has occurred. The wrap seal conveyor module706may instruct the wrap seal conveyor360to advance when no exceptions are found by the exception module704.

FIG. 8illustrates a method800for wrap seal unit-of-use packaging, according to an example embodiment. The method800may be performed by the unit-of-use packing device144as instructed by the control unit302, or may be otherwise performed.

At block805, it is assumed that each staging bin330already contains one or more than one container314which comprise a prescription order. At block810, the shuttle340may be moved to a position beneath the selected staging bin330, and the doors335of the selected staging bin330may be opened to drop the containers314from that staging bin330to the shuttle340. At block815, the shuttle340may be moved adjacent to the slide350. If a worker is still handling a previous prescription order, the shuttle340may wait to drop its containers314onto the slide350until the previous prescription order has been verified by the worker. The shuttle340may then release the containers314onto the slide350. At block820, the doors335of the selected staging bin330may be closed, and at block825, the staging conveyor310associated with the selecting staging bin330may be advanced to deposit the next prescription order of the containers314into the selected staging bin330. At block830, a new staging bin330may be selected, which may or may not be the same as the previously selected staging bin330. Once the new staging bin330is selected, the process may revert back to block810in which the shuttle340may be moved to a position below the newly selected staging bin330and the process repeats.

In some embodiments, after performing operations at block815in which the shuttle340may release its containers314onto the slide350once the previous prescription order has been verified by the worker, the process800may advance to block835in which the containers314have slid down slide350and have gathered in the pre-scan gathering area355. A worker may scan each container314in the prescription order via the scanner357. At decision block840, a determination may be made as to whether all of the containers314in a prescription order have been scanned and are accounted for. Such determination may be made by a worker who scans the containers314in some embodiments, and by the control unit302in other embodiments. If not, at block845, the order may be deemed an exception. In an example embodiment, an order may also be deemed an exception if product literature associated with the order is missing, incomplete, incorrect or the like. If all containers314in the prescription order are scanned and are account for, the order may then be verified at block350, and the containers314may be placed in a wrap seal pocket365. The wrap seal conveyor360may then be advanced, and the method800may revert back to block835after the shuttle340has released the next prescription order of the containers314onto the slide350as per block815.

In some embodiments, process steps805-830may occur simultaneously with process steps835-850. As a non-limiting example, once one or more containers314have been transported to the pre-scan gathering area355and the worker begins scanning such containers314, the shuttle340may have already moved to a position below another staging bin330to receive another prescription order and continue the process. By pre-staging the next prescription order as the worker is actively verifying the previous prescription order, the process800may result in more efficient unit-of-use packing.

FIG. 9shows a block diagram of a machine in the example form of a computer system900within which a set of instructions may be executed causing the machine to perform any one or more of the methods, processes, operations, or methodologies discussed herein. The devices102,106,122-144may include the functionality of the one or more computer systems900.

The example computer system900includes a processor902(e.g., a central processing unit (CPU) a graphics processing unit (GPU) or both), a main memory904and a static memory906, which communicate with each other via a bus908. The computer system900further includes a video display unit910(e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system900also includes an alphanumeric input device912(e.g., a keyboard), a cursor control device914(e.g., a mouse), a drive unit916, a signal generation device918(e.g., a speaker) and a network interface device920.

The drive unit916includes a computer-readable medium922on which is stored one or more sets of instructions (e.g., software924) embodying any one or more of the methodologies or functions described herein. The software924may also reside, completely or at least partially, within the main memory904and/or within the processor902during execution thereof by the computer system900, the main memory904and the processor902also constituting computer-readable media.

The software924may further be transmitted or received over a network926via the network interface device920.

The term “based on” or using, as used herein, reflects an open-ended term that can reflect others elements beyond those explicitly recited.

Certain systems, apparatus, applications or processes are described herein as including a number of modules. A module may be a unit of distinct functionality that may be presented in software, hardware, or combinations thereof. When the functionality of a module is performed in any part through software, the module includes a computer-readable medium. The modules may be regarded as being communicatively coupled.

The inventive subject matter may be represented in a variety of different embodiments of which there are many possible permutations.

In an example embodiment, a system is provided with a conveyor section, a staging area, and a packing area. The conveyor section is adapted to direct order components to a staging bin. The staging area is adjacent the conveyor section, and includes staging bins which may hold order components and distribute such components to a shuttle. The shuttle may release the components to the packing area when the packing area is ready, and may then receive another set of components from a staging bin to stage the next order. A worker in the packing area may scan the components as the components are placed in a wrap seal pocket to verify the components.

The present disclosure makes reference to a robot and words of similar import. A robot can be a machine capable of carrying out a complex series of actions automatically. These complex series of actions may include picking up, orientating, positioning and/or releasing a container or other structure. The robot may be dedicated to a single series of movements or may be able to execute multiple series of movements. A robot may include a processor that received instructions and then executes instructions to control its movement. In another example, a robot may resemble a human being and replicate certain human movements and functions, e.g., a robot may move location, have an articulated arm, have grasping structures that replicate like fingers and do not damage containers, and the like.

Thus, methods and systems for unit-of-use packing have been described. Although embodiments of the present invention have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the embodiments of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

The methods described herein do not have to be executed in the order described, or in any particular order. Moreover, various activities described with respect to the methods identified herein can be executed in serial or parallel fashion. Although “End” blocks are shown in the flowcharts, the methods may be performed continuously.