Patent Publication Number: US-2002012005-A1

Title: Method and system for providing globalized color matching capabilities

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     [0001] This application claims the benefit of provisional patent application Ser. No. 60/173,701, filed Dec. 30, 1999, the disclosure of which is incorporated herein by reference. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] The present invention relates generally to systems and methods for providing comprehensive and consistent information across distributed working environments. More particularly, the present invention relates to plastics manufacturing organizations and a method for providing globalized, uniform color matching capabilities to distributed entities within the organization.  
       [0003] Conventionally, distributed global plastics manufacturing and design organizations have struggled to efficiently meet customer requests for color matching of manufacturer products. Because of inherent differences in both site development and requirements, conventional color matching introduction processes generally evolve differently at each site, thereby requiring time consuming translation and searching across the different sites in order to avoid inconsistent or redundant determinations. In addition to problems caused by the distributed nature of the organization, the sheer number of materials for which the colors are developed (on the order of tens of thousands) also increases the time burden on color matching capabilities. Because color matching requests are conventionally handles on an ad hoc basis, there is generally no way to efficiently research prior practices.  
       [0004] In addition to delays caused by redundant processing and the lack of research capabilities, additional delays are inserted by conventional paper shuffling. In conventional systems, prior to being manufactured a color match request must be initiated by a technician, delivered to a color matcher, who, provided he has all the information he needs, makes an initial color match formulation. This is then sent back to the technician who sends a sample based upon the formulation to the customer for review. If the sample is approved, the technician must deliver the formulation to a quality assurance representative who ensures that the formulation is not in violation of any restrictions or regulations. Each of these independent steps takes time and the transfer of responsibility from one entity to another adds to the duration and confusion of the project.  
       [0005] Therefore, there is a need in the art of plastics manufacturing and design organizations for a comprehensive systems to facilitate the matching of colors requested by customer. There is a further need for a method and system for providing globalized, automated processing of color match requests across distributed locations.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006] The present invention overcomes the problems noted above, and provides additional advantages, by providing a comprehensive system for providing globalized, uniform color matching capabilities to geographically distributed entities. In response to either a customer driven or internal request, a computer program application for implementing the method and system of the present invention receives a request to open a color match request (CMR) program. Once the program has been opened, the system receives CMR initialization information and then, upon user selection, launches a color match workflow selection. The system, in response to this selection, determines whether all required information was received. If not, the system informs the user that required information was missing and enables them to supply the missing information. If all information was received, the computer system electronically notifies a color matcher about the CMR program. Once the color matcher has completed his/her tasks, the system receives a color match formulation from the color matcher. The system then electronically notifies the color technician about the matcher&#39;s formulation. A sample in accordance with the matcher&#39;s results is then sent to the customer for approval. The system then receives a determination as to whether the sample was approved by the customer or not. If not, the technician and matcher are so notified and the CMR is returned to the color matcher for re-formulation.  
       [0007] However, if the customer approves the sample, the CMR program is updated within the system to a complete status and, simultaneously, the color formula is updated to customer approved status. If the customer fails to respond to the sample, the system next receives a determination as to whether the program should be canceled or approved internally. If the formula is to be approved internally, the CMR program is updated within the system to complete status and, the color formula is updated to internally approved. If the formula is rejected internally, the CMR program is closed and the status is changed within the system to canceled, customer rejected.  
       [0008] By providing a uniform method of processing CMR&#39;s, the system of the present invention enables the streamlined matching of color requests. Further, by providing a single global system of record, the present invention improves the ability for users to search for pre-existing color matches and similar programs, thereby further increasing the speed and accuracy of the match. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0009] The present invention can be understood more completely by reading the following Detailed Description of exemplary embodiments, in conjunction with the accompanying drawings, in which:  
     [0010]FIG. 1 is a flow chart describing a preferred general embodiment of a method for providing color matching capabilities to distributed entities;  
     [0011]FIG. 2 is a flow chart describing a preferred method for facilitating progression through a first stage in a CMR process;  
     [0012]FIG. 3 is a flow chart describing a preferred method for facilitating progression through a second stage in a CMR process;  
     [0013]FIG. 4 is a flow chart describing a preferred method for facilitating progression through a third stage in a CMR process;  
     [0014]FIG. 5 is a flow chart describing a preferred method for facilitating progression through a fourth stage in a CMR process; and  
     [0015]FIG. 6 is a flow chart describing one embodiment for searching stored CMR or other product design programs to determine the need for a new CMR. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0016] The system and method of the present invention described below, are preferably implemented by an interactive computer software system incorporated within a computer-readable medium such as a hard disk drive, an optical medium such as a compact disk, or the like. Further, the medium is preferably available to a plurality of distributed users connected together over a computer network, such as a local area network (LAN), a wide area network (WAN), or the Internet. The inventive computer software system is designed to receive a plurality of color matching related information from a plurality of project participants. The application then facilitates the analysis, distribution, and implementation of this information so as to provide rapid color matching capabilities as well as an accurate and complete repository for all color matching requests and resulting formulations.  
     [0017] Referring to the Figures and, in particular, to FIG. 1, there is shown a flow chart describing a preferred general embodiment of a method for providing color matching capabilities to distributed entities. In a first step  100 , a color technician opens a Color Match Request (CMR) in the computer software system. As will be described in additional detail below, the processing of opening a CMR program requires the submission of a variety of CMR information related to the specific matching request such as a customer identity, any critical color requirements, and the grade of material that needs to be formulated into the matched color.  
     [0018] Once all required CMR information has been received and stored, the system, in step  102 , notifies a color matcher about the CMR program, and requests that the matcher review the received CMR information and make the appropriate color match. At this point, the status of the CMR program is updated to ‘Pending’. It should be understood, that while a particular individual may be notified in step  102 , a more practical method is to notify a group of matchers about the CMR, thereby more easily facilitating the match by any member of the group. This methodology substantially reduces CMR turnaround time. In response to the match request, the color matcher, typically in a laboratory environment, formulates the appropriate color match for the selected grade. The specifics of the system will be described in additional detail below, however it should be understood that the CMR computer system substantially simplifies the color matching process by providing comprehensive cross-referencing capabilities. By storing information on all CMRs which may be globally searched in a variety of manners, the present system enables color matchers and technicians to search prior CMR&#39;s to see if either the current match request has been made before, or if a similar match has been made, thereby providing a better starting point for the present match.  
     [0019] Once the color matcher has completed the match formulation, he submits the formulation to the computer system in step  104 . In a preferred embodiment, the color match formula is created in a stand alone, proprietary computer system. Following formula creation, the formula is exported into a easily understood format such as XML understood by those skilled in the art. Once in XML format, the formula and any information included therewith is easily imported and saved into the present computer system, thereby making it available for review by all participants in the CMR process.  
     [0020] In step  106 , the system notifies the color technician responsible for the particular CMR program that the matcher has submitted a color match formulation. In response to this notice, the technician sends a sample of the color formulation to the customer for review and approval in step  108 . After the customer has reviewed the sample, the system, in step  110 , receives an indication from the technician as to whether the sample was approved, rejected, or whether the customer failed to respond. If the sample was rejected by the customer, the CMR is sent back to the color matcher in step  102 , with instructions to try again. Preferably, the return of the CMR is accompanied by any comments received from the customer relating to why the match was rejected. If the sample was approved by the customer, the system proceeds to step  112 , where the status of the CMR program is updated to ‘Complete’. Simultaneously, the color formulation approved by the customer is updated to ‘Customer Approved’ status. In step  114 , the system notifies the organization&#39;s quality assurance group that the color match formulation has been approved by the customer. Upon review by a QA representative, the match formulation is exported to the legacy manufacturing systems for use in meeting production demands for the customer.  
     [0021] If, in step  110 , the system receives a ‘no answer’ indication from the technician, the system proceeds to step  116  where it receives an indication from the technician as to whether the match formulation will be approved internally or canceled. If the match formulation is to be approved internally, the system proceeds to step  118 , where the status of the CMR program is updated to ‘Complete’ and the color formulation status is updated to ‘Internal Approval’. In step  120 , the system notifies the organization&#39;s quality assurance group that the color match formulation has been approved internally. Upon review by a QA representative, the match formulation is exported to the legacy manufacturing systems for use in meeting production demands for the customer. If it is determined that the CMR program should be canceled, either through a failure to match the color or loss of interest either on the part of the customer or internally, the system proceeds to step  122 , where the program status is updated to ‘Canceled’ and the match formulation status is updated to ‘Customer Rejected’. At this point, the present CMR program is ended. However, because of the storing and searching capabilities of the present invention, the program may be reviewed in connection with a future CMR program so as to substantially reduce the amount of redundant work being done.  
     [0022] Referring now to FIG. 2, there is shown a flow chart describing a preferred method for facilitating progression through a first stage in a CMR process. In step  200 , the computer system described above receives CMR program initiation information from the color technician developer. Preferably, this information includes an identification of the site requesting the CMR, as well as the product line and type related to the request. Additionally, the initiation information may also include a program owner and a brief description of the color match request. In step  202 , the computer system automatically assigns a unique identifier to the program so that all information collected may be easily stored together and subsequently retrieved. In step  204 , the computer system displays a graphical user interface (GUI) including a plurality of stages, milestones, and checklist items. As will be set forth in additional detail below, the stages, milestones and checklist items form a hierarchical breakdown of the various tasks which must be completed in managing a CMR.  
     [0023] In a preferred embodiment, a CMR program includes at least four stages: stage  1  relating to initiation of the CMR program; stage  2  relating to making a color match; stage  3  relating to sending a match sample to the customer and receiving an associated approval or rejection; and stage  4  relating to internally signing off on the match and exporting the approved formulation to legacy manufacturing systems. Each of the above stages includes a plurality of milestones corresponding to principal elements of the stage. Likewise, each milestone preferably includes a variety of checklist items related to the associated milestone. By following each checklist, the appropriate user is easily directed through the proper, universal, process for completing the CMR program.  
     [0024] In step  206 , the system receives a color technician selection of stage  1 . In step  208 , the system, using GUI briefly described above, displays the various milestones and checklist items associated with stage  1 . In a preferred embodiment, stage  1  includes at least one milestone directed toward receiving CMR information required prior to sending the CMR to a color matcher. A plurality of corresponding checklist items are related to the specific information needed. In a preferred embodiment, the system includes checklist items related to: 1) defining the grade formula; 2) defining the color formula; 3) defining the customer for whom the match is requested; and 4) defining the color CTQ&#39;s (criticals to quality) required by the customer.  
     [0025] In step  210 , the system receives CMR information from the color technician related to the above-described checklist items. In a preferred embodiment, the receipt of CMR information is facilitated by a plurality of user-defined fields related to reference type, reference information, and comments. Upon selection of a particular checklist item, the technician can select a suitable reference type describing the type of information being attached. Then, in the reference field, the technician can insert the required information. Further, if the technician does not immediately know the reference information to be submitted, a preferred embodiment of the system provides a lookup feature that enables the technician to look up the information to be submitted. Similarly, the technician may attach any ancillary information that may be useful to the matcher in making the color match using the comments field. In this manner, the technician progresses through each of the checklist items displayed in step  208  and submits the required information in step  210 .  
     [0026] In step  212 , the system receives a technician request to launch a CMR workflow process. Preferably, this request includes a selection of a particular color matcher or group of color matchers as well as a customer response representative and a quality assurance representative responsible for the CMR. Upon receipt of this request, the system, in step  214 , checks the information received in step  210  to ensure that all required information has been properly received. If all required information has not been properly received, the system, in step  216 , displays an error message to the technician indicating what information is missing and returns the technician to step  208  for submission of this information. If all information has been properly received, the system, in step  218  electronically notifies the selected color matcher of the CMR and updates the status of the CMR program to ‘Pending’.  
     [0027] Referring now to FIG. 3, there is shown a flow chart describing a preferred method for facilitating progression through the second stage in the CMR process. As set forth above, stage  2  of the CMR process relates to tasks completed by a color matcher in making the match formulation and importing this formulation into the computer system for subsequent review and approval by the customer. In step  300 , the system receives a request from a color matcher to review a selected CMR program which they have been notified about. In step  302 , the system displays that above-described GUI illustrating the various stage  2  milestones and checklist items. In a preferred embodiment, stage  2  includes at least one milestone relating to conducting the CMR workflow. This milestone preferably includes a plurality of checklist items leading the color matcher through this process. In step  304 , the system receives a color match formulation from the color matcher. As briefly described above, this formula may be created in the present system or, alternatively, imported from a stand alone software application.  
     [0028] In step  306 , the system receives a color matcher request to initiate a customer approval workflow. In response, the system electronically notifies the color technician that the color match has been completed and that a sample needs to be sent to the customer for review and approval.  
     [0029] Referring now to FIG. 4, there is shown a flow chart describing a preferred method for facilitating progression through the third stage in the CMR process. As set forth above, stage  3  of the CMR process relates to tasks completed by a color technician in sending a sample of the color match to the customer and the associated approval or rejection of the match. In step  400 , the system receives a request from a color technician to review the CMR program which they have been notified about. In step  402 , the system displays that above-described GUI illustrating the various stage  3  milestones and checklist items. In a preferred embodiment, stage  3  includes at least one milestone relating to sending a sample to the customer and receiving approval or rejection of the sample. This milestone preferably includes a plurality of checklist items leading the color technician through this process. At this point, the color technician, using the guidelines set forth as checklist items, sends a sample of the color match to the customer for approval or rejection. In step  404 , the system receives a customer response workflow initiation request. In step  406 , the system, as part of the customer response workflow, receives an indication from the color technician that the sample was either approved, rejection, or a response was not forthcoming.  
     [0030] If, in step  406 , the system received an indication that the sample was rejected, the system receives, in step  408 , any comments associated with the rejection and, returns the color match formulation from the color matcher in step  218  of FIG. 2. As briefly described above, this formula may be created in the present system or, alternatively, imported from a stand alone software application. If, in step  406 , the system received an indication that the sample was approved by the customer, the system, in step  410 , updates the status of the CMR program to ‘Complete’ and updates the status of the match formulation to ‘Customer Approved’. Simultaneously, in step  412 , the system electronically notifies a quality assurance representative that the match formulation has been approved by the customer.  
     [0031] If, in step  406 , the system received an indication that no response was received from the customer, the system next receives, in step  414 , a determination as to whether or not to internally approved the match formulation or to cancel the program. If a determination to internally approve the match formulation is received, the system, in step  416 , updates the status of the CMR program to ‘Complete’ and updates the status of the match formulation to ‘Internally Approved’. Simultaneously, in step  418 , the system electronically notifies a quality assurance representative that the match formulation has been approved internally. However, if the system receives a determination to cancel the program, the system, in step  420 , updates the status of the CMR program to ‘Canceled’ and further updates the status of the match formulation to ‘Customer Rejected Status’.  
     [0032] Referring now to FIG. 5, there is shown a flow chart describing a preferred method for facilitating progression through the fourth stage in the CMR process. As set forth above, stage  4  of the CMR process relates to tasks completed by a quality assurance representative in ensuring that the customer or internally approved match formulation does not conflict with existing material use restrictions for the selected facility. In step  500 , the system receives a request from a quality assurance representative to review the CMR program which they have been notified about. In step  502 , the system displays the above-described GUI illustrating the various stage  4  milestones and checklist items. In a preferred embodiment, stage  4  includes at least one milestone relating to approving a color match formulation and uploading the formula into the legacy systems for subsequent use in manufacturing. This milestone preferably includes a plurality of checklist items leading the quality assurance representative through this process.  
     [0033] At this point, the system receives in step  504  a determination from the quality assurance representative as to whether the ‘Customer or Internally Approved’ formulation is acceptable or must be modified in view of any facility restrictions that may exist. If the system receives an indication that the formulation must be modified, a modified formula is saved as a ‘Next Version” in step  506 . However, if the existing formulation is acceptable, the system, in step  508 , receives an approval from the quality assurance representative in the form of an load color workflow initiation. In a preferred embodiment, only an authorized quality assurance representative can initiate a load color workflow, thereby preventing the unauthorized manufacture of unapproved color match formulations. In step  510 , the system transfers the color match formulation and any ancillary information to the organization&#39;s manufacturing system for use in subsequent productions. Once the transfer has been successfully made, the system, in step  512 , electronically notifies the quality assurance representative of the successful transfer.  
     [0034] Because the system of the present invention provides a global repository for a variety of color-related information, entries in the system are subsequently valuable as reference materials for future color match requests. Referring now to FIG. 6, there is disclosed a flow chart describing one embodiment for searching stored CMR or other product design programs to determine the need for a new CMR. In step  600 , the system receives a user request to search for a stored CMR program. In step  602 , the system displays a plurality of search code fields relating to searchable information in each CMR. In a preferred embodiment, examples of searchable fields include: customer name; type of program; CTQ values;  Δ L,  Δ a, and  Δ b values (color related quantities); spectral values; end use; product line; etc.  
     [0035] In step  604 , the system receives any submitted search criteria and, in step  606 , conducts a search of all stored CMR and other product design programs. In step  608 , the system displays a listing of all programs which met the received criteria. In step  610 , the system receives, a user request to view the details of a particular program displayed in the listing of step  608 . In response, the system, in step  612 , displays a detailed description of the selected program. Any information which was attached to the program during pendency is also available at this time.  
     [0036] By providing a uniform process for providing globalized color matching capabilities, the system of the present invention, substantially solves the problems involved with conventional color matching system. Because all color matching programs in every location must be introduced in accordance with the above system, added consistency results. In addition to consistency, the above-described invention further provides for a uniform system of record for all color match requests that is subsequently searchable as a reference tool. Consequently, future developers may search the system to determine if similar work had been done in the past. Further, because of the computer-based nature of the inventive system, transitions between stages are streamlined through electronic notifications and file attachments. This effectively reduces the turnaround time previously required to match a color upon customer request.  
     [0037] While the foregoing description includes many details and specificities, it is to be understood that these have been included for purposes of explanation only, and are not to be interpreted as limitations of the present invention. Many modifications to the embodiments described above can be made without departing from the spirit and scope of the invention, as is intended to be encompassed by the following claims and their legal equivalents.