Consumable supplies monitoring/ordering system for reprographic equipment

A reprographic machine includes an inventory tracking system for monitoring consumable supplies. Usage data from a plurality of networked reprographic machines is supplied to a single tracking system for monitoring inventories of supplies consumed by the network. Automatic or semi-automatic ordering can be provided via a remote interactive communication system. Order confirmation, projected shipment dates and shipment confirmations can be provided from the reorder site. The system can provide inventory monitoring customized to a local network.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to reprographic machines. In particular, it concerns 
systems for tracking and reordering consumable supplies for reprographic 
equipment. 
2. Description of Related Art 
A reprographic machine having the capability of storing indications of a 
machine consumable supply, such as developer, displaying the status of 
such consumable supply and remotely transmitting such indications of usage 
is known. An example of such a reprographic machine is disclosed in U.S. 
Pat. No. 4,496,237, the disclosure of which is incorporated herein by 
reference. While the machine disclosed in the above-identified patent can 
provide status information regarding usage of elements and supplies, it 
does so only with respect to element or supplies within that machine. It 
has no capability for tracking an overall inventory of consumable supplies 
maintained exterior to the machine or to track usage of consumable 
supplies from a plurality of machines. 
However, the control of inventory levels for consumable supplies has been 
recognized as very desirable, particularly with large volume reprographic 
operations that operate several reprographic machines at one location. A 
goal is to achieve just-in-time inventory control so that inventory 
carrying costs can be minimized. 
SUMMARY OF THE INVENTION 
The invention provides a consumable supplies monitoring system for 
monitoring an inventory of consumable supplies consumed by the plurality 
of reprographic machines. At least one of the reprographic machines 
includes an inventory tracking system. The inventory tracking system is 
provided with information relating to usage of each of the consumable 
materials by the plurality of reprographic machines. A display on the 
reprographic machine, or on each of the reprographic machines, displays 
requested information from the inventory tracking system. Through remote 
interactive communication capabilities, the system can automatically or 
semi-automatically submit orders for supplies, receive information 
relating to estimated and/or delayed shipping dates, and update the status 
of the inventory on the basis of confirmed shipment or order receipt 
information.

DESCRIPTION OF PREFERRED EMBODIMENTS 
Referring to FIG. 1, a reprographic machine 10, such as an 
electrophotographic machine, an ink jet printer, etc. for producing hard 
copies of documents by applying marking materials, such as electrostatic 
toners or inks, to recording media, such as paper sheets. Basic printing 
and document handling systems are known and are shown, for example in the 
above mentioned U.S. Pat. No. 4,496,237. Other than as noted below, the 
particular details of such a system are not necessary for an understanding 
of the present invention and the system is represented by the three 
dimensional box 16, schematically representing the printing system within 
the reprographic machine 10. 
Preferably, the reprographic machine 10 utilizes a user interface 12 having 
a touch screen 14 for providing operator input for control of the machine 
and for displaying operating information, diagnostic results, and, in 
accordance with the present invention, inventory information. Such user 
interface systems are known and are disclosed, for example, in U.S. Pat. 
Nos. 5,038,319 and 5,057,866, the disclosures of which are incorporated 
herein by reference. The user interface 12 is linked to a user interface 
control module 18 that controls the display of information on the touch 
screen 14 and communicates control information from the touch screen 14 to 
subsystems within the reprographic machine 10. With particular reference 
to the present invention, the user interface module is connected by a 
suitable data bus 19 for providing signals to and receiving signals from 
an inventory tracking system module 20 that tracks the inventory and 
reorder status of consumable supplies, such as marking materials in the 
form of toners or inks, and recording media, such as paper sheets. The 
module 20 can comprise a printed wire board (PWB) with a microprocessor 
and memories for storing, updating and calculating inventory information 
using appropriate software routines. The detailed operation of the 
tracking system will be described below. 
The reprographic machine 10 preferably includes an input/output port 22, 
such as a floppy disk port, for providing programs, program updates and, 
if desired, inventory updating information. 
The reprographic machine 10 also includes one or more counters 24. The 
counters 24 receive information from sensors in the printing system 16 
relating to the number of impressions or number of copy sheets cycled 
through the printer 16. Preferably, after the completion of a copy run, 
each counter 24 is updated. A counter 24 is provided for each consumable 
supply item being tracked, such as paper sheets in several sizes and toner 
or ink cartridges. From this data, usage information can be derived 
relating to the number of sheets of each size of paper or the amount of 
toner or ink used in the predetermined time period. Alternatively, based 
on paper sheet usage, toner and ink consumption can also be derived on the 
basis of average marking material usage per sheet. 
A communication systems module 26 is also associated with the reprographic 
machine 10. The communication system 26 includes a shared line 27a for 
linking other similar reprographic machines 10a, 10b . . . 10n (FIG. 2) in 
a local area network 28. The shared line 27a provides for linking of a 
plurality of counters 24 in each of the reprographic machines 10a, 10b . . 
. 10n to the tracking system module in the reprographic machine 10. 
Further, the shared line 26a can provide for commands to be initiated at 
the user interfaces 12a, 12b . . . 12n of the other reprographic machines 
in the network to the tracking system module 20 so that commands to and 
requested information from the tracking system 20 can be displayed on any 
selected one of the user interfaces 12a, 12b . . . 12n. 
The reprographic machine 10 is provided with a remote communication 
capability, for example, via a remote interactive communication (RIC) 
system, so that information to and from a remote supplies ordering 
location can be effected. In this regard, the communication system module 
26 includes a suitable printed wire board and associated software 
constituting a modem for connecting the reprographic machine 10 to a 
public switched telephone network. Alternatively machine 10 can 
communicate via a dedicated telecommunication system or other form of data 
transmission system. At the supplies reordering location, a modem 40 
receives data from or provides data to the link 27b. Data from the network 
28 comprises primarily orders for supplies consumed in the network 28. 
Information from the reorder site can comprise order confirmations, 
expected delivery dates and shipment confirmations. To enable such 
communication at the remote ordering site, a personal computer 42 with 
modem 40 is provided. The personal computer 42 drives a display, such as a 
CRT or flat screen 44 and a printer 48. Incoming ordering information can 
be controlled by the personal computer 42 to display the information on 
display 44 and/or provide a hard copy of the order via printer 48. A 
manual input device, such as a keyboard 46, is provided so that supply 
point personnel can enter expected delivery dates and confirm shipments. 
Expected delivery and shipment information can be transmitted via link 27b 
to reprographic machine 10 and displayed on the UI 12 of reprographic 
machine 10 or another of the reprographic machines in the network 28. 
FIGS. 3 and 4 graphically describe the inventory tracking process which 
takes place in the tracking system module 20 (FIG. 5) for each consumable 
supply being tracked and also illustrate the form of inventory information 
that can be provided to UI 12. The system is initialized at start up and 
upon receipt of each shipment by providing quantity information to a 
microprocessor 30 which, as is conventional, contains a random access 
memory for performing data calculations and manipulations and a read only 
memory for storing software to enable the various operations of the 
tracking system 20. Input information may be provided to the 
microprocessor 30 through the user interface 14, for example when an order 
is received, or through the communications module 26, where shipment 
confirmation data is received through the communications system linking 
reprographic machine 10 to the material supply location. This initializing 
information is stored in non-volatile memory 32 for each consumable 
material being tracked. Counters 24, 24a, 24b in each of the plurality of 
reprographic machines provide usage data to microprocessor 30. On the 
basis of this data, sheet counts or cartridge counts are accumulated in 
non-volatile memory 32 to provide actual usage data, which is decremented 
against the initial inventory amount to show remaining inventory. Actual 
usage data is utilized to calculate a curve S, for each consumable item 
being tracked. Curve S includes an actual usage portion and a projected 
usage portion. The intersection of the projected usage portion with the 
ordering threshold yields a reorder point. The curve S may be periodically 
recalculated on the basis of new actual usage data to modify the reorder 
point. The thresholds for each item being tracked can be modified by 
inputs through a user input, such as touch screen 14 or port 22. The 
reorder point calculation is performed in a determining means 34 forming a 
portion of the processing portion of microprocessor 30. 
Periodically, or each time the inventory for a particular item is 
decremented, a judging means 36, for example, a comparator, makes a 
judgment to determine if the inventory level has passed the ordering 
threshold. If the judgment means 36 makes an affirmative determination, 
the microprocessor 30 controls Ul 12 to show a reorder message to alert 
the operator that reorder is necessary. Alternatively, the reorder 
information can be either automatically sent by the communications module 
26 to the reorder location directly, or semi-automatically after 
confirmation via the touch screen 14 by the operator. 
Referring to FIG. 6A, when the inventory control system is initialized, a 
starting threshold is input from the communication system 26 or the user 
interface 12 and is identified at step S2 as a threshold input for one of 
the consumable materials being tracked. When the information is identified 
as initializing data at S2, the information is stored in the non-volatile 
memory 32, at step S3. The value stored at S3 is used as a starting value 
for inventory of a plurality consumable materials being tracked. 
Similarly, FIG. 6B is a flowchart showing the processing of inventory 
delivery information. In Step S1A, delivery information is supplied by the 
communication system 26 from the personal computer 42 at the remote 
reorder site or, alternatively, by an operator through the user interface 
12. At step S2A, the information input is identified by quantity and type 
as inventory delivered. The quantity identified at S2A is added to the 
balance in non-volatile memory 32 to update the amount of the particular 
consumable material concerned. 
FIG. 7 is a flowchart illustrating the inventory tracking and reorder 
system as usage occurs. At step S4, an event representative of usage of a 
consumable material, such as the exit of a paper sheet from the printer 
16, is sensed by sensors (not shown) within each of the document systems 
10, 10A . . . 10.sub.n. The output of the sensor updates local counters 24 
at step S.sub.5 in each of the document systems. Periodically, or upon 
inquiry by the microprocessor 30, the counts of the local counters 24 are 
subtracted from the value stored in NVM 32, as in step S6, in the 
determining means 34 of the microprocessor 30. The flow from step S6 then 
proceeds to S7 wherein a judgment is made in the judging means 36 whether 
or not the new inventory amount stored in NVM 32 is below the threshold. 
If the present amount is not below the threshold, the flow ends. If the 
present amount is below the threshold, two alternative routes can be 
followed. The processing can proceed to step S8 where a decision is made 
to raise an alert and that alert is displayed at step S9 on the user 
interface 12. An operator can, with an appropriate input to the touch 
screen 14, confirm the need for resupply and, through a suitable software 
or hardware switch direct the flow to S10 wherein an order, identifying 
the machine or network, the material needed, and the quantity, is sent via 
the communications module 26 to the remote reorder site. Alternatively, 
the flow can proceed directly from step S7 to step S10, thereby effecting 
an automatic reordering without operator input. The information 
identifying the machine or network from which the order is placed can be 
stored in NVM 32. As well, a standard reorder amount for the material 
being reordered is stored in NVM 32 and can be changed by operator input 
through touchscreen 14 or from the reorder site via the link 27b. 
The above described system has many advantages. An instantaneous status of 
the inventory of consumable supplies is available to an operator or the Ul 
12. Reordering of supplies can be automated or semi-automated, thereby 
providing for just-in-time inventory control. Reorder thresholds can be 
customized for unique conditions at each customer site to accommodate for 
differences in the amount of supplies storage available, usage rates and 
delivery times. A single inventory tracking system can be utilized to 
monitor inventory levels for a network comprising a plurality of 
reprographic machines.