Abstract:
There is provided herein methods and systems for fulfilling customer orders by mail in a timely and cost-effective manner. Items to be included in the order are custom-selected based on characteristics such as weight and/or size to minimize postage cost. Customer orders too large to take advantage of discounted postal rates are parsed into multiple mailings, each mailing taking advantage of reduced postal rates, the multiple mailings together fulfilling the customer order.  
     Customer order data processing may be remotely handled at any convenient location. Custom item selection and packaging is handled in a fast, highly-automated manner by a computer-controlled, assembly-line machine. The customer is automatically notified on each mailing if the order has been packaged and mailed in multiple mailings.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates generally to package handling and mailing and more particularly to the custom selection and packaging of items to fulfill customer orders through cost- effective mailing.  
         BACKGROUND OF THE INVENTION  
         [0002]    Today many commercial items are delivered to customers through the United States and/or other national mail systems. A very small list of exemplary commercial items includes magazines, CD&#39;s and DVD&#39;s, clothing, and others. The postal rates applied to these items are, in contrast to first class rates, lower commercial rates. These commercial rates vary substantially depending on the weight and size of the mailing.  
           [0003]    Different systems are known for controlling the cost of postage with respect to characteristics of commercial items. U.S. Pat. Nos. 4,639,873 and 5,177,687, both to Baggarly et al., show insertion machines with postage categorization wherein necessary items are inserted into a mailing on an assembly-line basis, the items selected determined by indicia printed on a master control item. The weight of these necessary items is known as are the weights of optional items. Selected optional items are inserted into the mailing only if doing so will not increase the postage rate. U.S. Pat. No. 4,959,795 to Christensen et al. shows a system similar to that of Baggarly et al. with the inclusion of chargeback capability to apportion and charge back the costs of added mail insertions, including additional postage, to appropriate parties.  
           [0004]    U.S. Pat. No. 6,135,292 to Pettner shows a system wherein the thicknesses of items to be mailed are measured and the items are presorted based on thickness to take advantage of postal discounts.  
           [0005]    Many other systems are known for creating mailings, each responsive to some perceived need of the inventor. For example, U.S. Pat. No. 5,659,481 describes an electro-mechanical system for inserting enclosures into mailed statements. U.S. Pat. No. 5,918,220 to Sansone et al. shows a system for producing a mail piece at a remote location so as to give the appearance to the recipient of locally generated mail. U.S. Pat. No. 5,774,885 to Delfer, III shows a system for combining multiple individual statements into a single mailing envelop.  
           [0006]    While many different systems are known for creating mailings and particularly for minimizing the postage associated with mailings by activities such as weight control, thickness/size control and/or presorts, no system is known to the present inventors for managing the creation and mailing of a customer-submitted order in an automated, cost-effective manner. In contrast to the systems of Baggarly et al., responses to customer orders must by definition include every item selected by the customers. No item can be optionally omitted. In contrast to Christensen et al. described above, it is desirable to complete such customer orders without incurring unnecessary postage costs. In fact, there may be no third-party to apportion additional mailing costs back to as taught by Christensen et al.  
           [0007]    There thus exists a need for systems and methods for fulfilling customer orders which enable the entire order to be fulfilled in a timely and cost-effective manner.  
         SUMMARY OF THE INVENTION  
         [0008]    There is provided herein methods and systems for fulfilling customer orders by mail in a timely and cost-effective manner. Items to be included in the order are custom-selected based on characteristics such as weight and/or size to minimize postage cost. In accordance with a key feature of the invention, customer orders can be parsed into multiple mailings, each mailing taking advantage of reduced postal rates, the multiple mailings together fulfilling the customer order.  
           [0009]    In accordance with other features of the invention, customer order data processing may be remotely handled at any convenient location. Custom item selection and packaging is handled in a fast, highly-automated manner by a computer-controlled machine. The system further includes the ability to efficiently and automatically notify the customer that the order has been packaged and mailed in multiple mailings.  
           [0010]    In accordance with one embodiment of the invention there are provided methods and systems for selecting and packaging items for mailing, a method comprising the steps of: receiving a customer order specifying a plurality of items for shipping by mail; retrieving a selected characteristic for each of the plurality of items; determining, based on the selected characteristic, if a single package containing the plurality of items will exceed a desired postal rate; if the single package will not exceed the desired postal rate, packaging the plurality of items in a single package; if the single package will exceed the desired postal rate, dividing, based on the selected characteristic, the customer order into multiple sub-orders, each sub-order including a subset of the plurality of items selected so that the sub-order will be at the desired postal rate, printing a mailer including a control indicia on the mailer, automatically selecting, based on the control indicia, items for inclusion in each sub-order, and packaging each of the sub-orders individually so that the customer order comprises multiple packages; and mailing the single or multiple packages to the customer.  
           [0011]    In accordance with another embodiment of the invention there are provided methods and systems for selecting and packaging items for mailing, comprising the steps of: receiving a customer order specifying a plurality of items for shipping by mail; determining, based on a selected characteristic for each of the plurality of items, if a single package containing the plurality of items will exceed a desired postal rate; if the single package will not exceed the desired postal rate, packaging the plurality of items in a single package; if the single package will exceed the desired postal rate, dividing, based on the selected characteristic, the customer order into multiple sub-orders, each sub-order including a subset of the plurality of items selected so that the sub-order will be at the desired postal rate, packaging each of the sub-orders individually so that the customer order comprises multiple packages; and mailing the single or multiple packages to the customer.  
           [0012]    In accordance with another embodiment of the invention there are provided methods and systems for selecting and packaging items for mailing, comprising the steps of: receiving a customer order specifying a plurality of items for shipping by mail; determining, based on a selected characteristic or each of the plurality of items, if a single package containing the plurality of items will exceed a desired postal rate; if the single package will not exceed the desired postal rate, printing a single mailer including a control indicia for operating a machine to place the plurality of items into a single package; if the single package will exceed the desired postal rate, printing a plurality of mailers, each of the plurality of mailers including a control indicia for operating a machine to place a selected subset of the plurality of items into a package, the multiple packages associated with the plurality of mailers together fulfilling the customer order. 
       
    
    
     DESCRIPTION OF THE DRAWING FIGURES  
       [0013]    These and other objects, features and advantages of the invention will be apparent from a consideration of the detailed description of the invention below when read in consideration of the drawing figures, in which:  
         [0014]    [0014]FIG. 1 is a block diagram showing the various parties associated with the present invention and their various communications channels;  
         [0015]    [0015]FIG. 2 is a block diagram showing the details of the data processing center of FIG. 1;  
         [0016]    [0016]FIG. 3 is a table showing exemplary postal rate data stored in the database of FIG. 2;  
         [0017]    [0017]FIG. 4 is a table showing exemplary customer order data stored in the database of FIG. 2;  
         [0018]    [0018]FIG. 5 is a table showing exemplary item characteristics data stored in the database of FIG. 2;  
         [0019]    [0019]FIG. 6 is a block diagram showing the details of the fulfillment center of FIG. 1;  
         [0020]    [0020]FIG. 7 is a block diagram showing the mailer of FIG. 6 before packaging;  
         [0021]    [0021]FIG. 8 is a block diagram showing the mailer of FIG. 6 after packaging;  
         [0022]    [0022]FIG. 9 is a flow chart showing an overview of an order fulfillment process in accordance with the present invention;  
         [0023]    [0023]FIG. 10 is a flow chart showing the customer order obtainment process from FIG. 9;  
         [0024]    [0024]FIG. 11 is a flow chart showing customer order data processing;  
         [0025]    [0025]FIG. 12 is a flow chart showing the order fulfillment process of FIG. 9; and  
         [0026]    [0026]FIG. 13 is a flow chart showing the package calculation process of FIG. 12. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]    With reference now to FIG. 1, there is shown a system  20  including a customer  22 , a merchant  24 , a data processing center  26  and a fulfillment center  28  interconnected through a network  30  such as the Internet. Merchant  24  comprises, for example, a financial services institution or any other institution that communicates regularly with customers such as customer  22 . Customer  22  comprises a conventional customer of merchant  24 . Data processing center  26  and fulfillment center  28  are as described in detail below.  
         [0028]    The various parties in FIG. 1 are connected to communicate electronically with one another through the Internet  30 . Additionally, customer  22  and merchant  24  communicate by mail, as do the customer and fulfillment center  28 , in the manner described below.  
         [0029]    With reference now to FIG. 2, data processing center  26  is seen to include a conventional computer  32  connected to a conventional user interface  34 , a database  36  and to network  30 . References to like elements are by same reference numbers. Computer  32  can be any conventional computer, for example a personal computer, server or a mainframe computer, running the processes described below. Database  36  comprises any conventional data storage containing the data as described herein and software for performing the steps described below. In particular, database  36  contains postal rate data and customer order data as described with respect to FIGS. 3 and 4 below. Likewise, user interface  34  comprises any conventional user interface, for example including a keyboard, display, and compact disc (cd) and/or digital video disc (dvd) and/or other data input/output device(s).  
         [0030]    With reference now to FIG. 3, postage rate table  40  contained in database  36  is seen to include postage rates based on mail package characteristics. For example, the table is seen to include postage rates based on package weight and postage rates based on package thickness. Other characteristics affecting postage rates will be known to those skilled in the art.  
         [0031]    With reference now to FIG. 4, a customer order data table  42  contained in database  36  is seen to include data relating to customer orders. Each customer order entry, that is each row of data, is seen to include an order identifier, customer information such as name, address and other related information, order information including the items and quantities of items ordered and order fulfillment information including the number of mailings and items in each mailing in the manner described below.  
         [0032]    With reference now to FIG. 5, an item characteristic data table  43  contained in database  36  is seen to include characteristics relating to items to be mailed, and more particularly characteristics relevant to the postal rates of FIG. 3. Each item entry, that is each row of data, is seen to include a weight and thickness that can be used to determine postal mailing costs.  
         [0033]    With reference now to FIG. 6, fulfillment center  28  (see also FIG. 1) is seen to include an assembly line conveyor belt  46  connected to convey a mailing label  48  past a linear array of machines including a bar-code scanner  50 , a series of N hoppers  52 A-N and eventually a packaging station  54  to provide a package  56  for mailing. A control computer  58  is connected to network  30 , an order fulfillment database  60  and to each of the conveyor belt  46 , scanner  50 , hoppers  52 A-N and packaging station  56 . Control computer  58  preferably includes a conventional user interface (not shown) for administering it&#39;s operation.  
         [0034]    Control computer  58  comprises any conventional personal computer, server or mainframe computer connected to control the operation of the scanner, hoppers and packaging station as described below. Order fulfillment database  60  comprises any conventional database for storing the customer order data  42  as shown in FIG. 4 and software instructions for performing the steps described below.  
         [0035]    In the described embodiment, each of hoppers  52 A-N contains a stack of a particular compact disc (CDs) or digital video disc (DVDs) to be mailed to fulfill customer orders, as well as an electro-mechancial device for inserting the items onto mailer  48  in the manner described below. Packaging station  54  comprises a shrink-wrap packaging station for shrink-wrap packaging the selected CD and DVD items stacked on belt  46  by hoppers  52 A-N. Many such hoppers are well known in the art.  
         [0036]    Similarly, bar-code scanner  50  and heat-wrap packaging station are conventional, commercially available units well known to those of ordinary skill in the art.  
         [0037]    It will be understood that the invention is not limited to CDs and/or DVDs and the mechanisms for packaging same, but to any items which can be processed in accordance with the methods described herein below. Exemplary items in addition to those described include: brochures, books, card packs, clothing items and any other item wherein groups of the same item have similar characteristics such as size or weight and are capable of automated handling in the described manner.  
         [0038]    With reference now to FIG. 7, the front and back of mailer  48  (FIG. 6) is shown before the mailer is packaged for shipping. As shown, the front includes appropriate postage, a customer address and a notice to the customer, for example that the customer order has been shipped in multiple shipments. The back contains a bar code as further described below.  
         [0039]    [0039]FIG. 8 shows a first mailer  58 A and an N th  mailer  58 N, the mailers together comprising a single customer order packaged as a plurality of sub-orders in the manner described below. The front of each mailer includes the information described in FIG. 7 above. The barcode on the back of each mailer is covered by stacked items as described below. Each mailer is shrink-wrapped in plastic for mailing in a selected national postage system or with a private mailing service.  
         [0040]    With reference now to FIG. 9, an order fulfillment process  64  is shown at an overview level wherein initially a customer order, including order data, is obtained (step  66 ) by merchant  24  from customer  22  (FIG. 1). Subsequently the customer order is provided to data processing center  26  (FIG. 1) for processing (step  68 ) and data processing center  26  transmits the processed customer order data to fulfillment center  28  (FIG. 6) for fulfillment (step  70 ). Each of these process steps is described in further detail herein below.  
         [0041]    With reference now to FIG. 10, in the described embodiment, customer order obtainment process (step  68  of FIG. 9) is done by United States postal mail. In this described embodiment, a customer order form is mailed from merchant  24  to customer  22 , for example included in a customer bill or statement (step  72 ). Alternatively, the order form may be provided in any other acceptable manner including, for example, by facsimile, electronic file transmission, or customer order data may be collected by telephone through a live operator or automated answering service. As described above, in the present embodiment the order form enables the customer to select desired CDs and/or DVDs.  
         [0042]    The customer completes the order form (step  74 ) and returns it by mail to the merchant (step  76 ). Again, the order form may be completed and returned by many other obvious means such as facsimile or electronically, or the order data provided by telephone. The customer order data is collected by merchant  24  and transmitted (step  78 ) to data processing center  26  (FIG. 1), for example by mail, for processing as described below. With reference now to FIG. 11, the customer order data processing (step  68  of FIG. 9) is shown wherein the customer order data is read from the customer form (step  80 ), entered into computer  32  (step  82 ) and transmitted, for example over Internet  30 , to fulfillment center  28  (step  84 ). It will be understood that as a result of this data processing, table  42  (FIG. 4) has been populated with the exception of the order fulfillment information. Table  42  thusly resides in database  36  of data processing center  26  and also in order fulfillment database  60 .  
         [0043]    With reference now to FIG. 12, order fulfillment process  84  is shown wherein initially there is calculated the number of packages necessary to fulfill a customer order (step  90 ). With reference now to FIG. 13, package calculation process  90  is seen to include receiving the electronic customer order data from data processing center  26 . As noted above, the customer order data includes at least the order information contained in table  42  of FIG. 4, i.e. the customer information and items ordered, less the fulfillment data still to be calculated. This data is stored in fulfillment center database  60  (step  92 ) with the described processing performed by control computer  58 .  
         [0044]    Continuing with reference to FIG. 13, subsequently, the list of ordered items is retrieved from the customer order data and the pertinent mail characteristics for each ordered item are retrieved from table  43  (step  94 ). The pertinent postal data is retrieved from table  40 , and the total items in the customer order are considered to determine if a single package would exceed the desired postal rates (step  96 ). For example, assuming that CDs and DVDs are being mailed, it is likely that the determining characteristic for postage would be weight. Thus, the weight of each ordered item is retrieved and the total weight calculated to see if it exceeds the maximum weight for the desired postal class and rate. For items where thickness or other size measurements or other characteristics are determinative of postal rates, the determinative characteristic(s) would be retrieved for each item and totaled.  
         [0045]    If a single package can be assembled and mailed at the desired postal rate (step  98 ), then those steps are performed (step  100 , returning to step  106  of FIG. 12). If a single package cannot be assembled and mailed at the desired postal rate (step  98 ), then the number of packages including the exact item contents of each package is determined (step  102 ), and the package is assembled and mailed (step  104 , returning to step  106  of FIG. 12). Many different methods will be readily apparent for determining how to assemble groups of items within the desired postal rate. For example, a sub-order of items may simply be selected in order from a list until the maximum characteristic, i.e. weight, is reached, then a new sub-order started. Other more complex methods may be used to group items by the appropriate characteristic. Still other more complex methods may be used to group items both by a first characteristic relevant to postal rates and a second characteristic not relevant to postal rates but otherwise relevant to fulfilling the customer order, for example a second characteristic based on grouping similar types of items.  
         [0046]    With reference back to FIG. 12, once the total number of packages/mailings is determined to fulfill a customer order (FIG. 13), that data is stored in database  60  in the field shown in table  42  (FIG. 4) and the necessary number of mailers  48  (see FIG. 7) are printed (step  106 ). Each mailer  48  includes, on its back, a bar code, the bar code keyed to the order fulfillment information in database  60 , each bar code thus describing the exact item selection to be packaged for its particular mailing. On its front, each mailer  48  includes the customer name and address, postage, and if the customer order is to be fulfilled in multiple packages, a notice to the customer indicating same.  
         [0047]    Continuing with respect to FIG. 12, each printed mailer is placed on assembly line  46  (FIG. 5) with the barcode up so as to be readable by scanner  50  (step  108 ). Scanner  50  scans the barcode on mailer  48  so as to identify the order fulfillment data (step  110 ) including the exact items to be packaged with that mailer (step  112 ). As the mailer proceeds down assembly line  46  (step  114 ), responsive to the barcode scanning, control computer  58  operates the appropriate hoppers  52 A-N to stack the selected items for that mailing directly onto the mailer (step  116 ). As the mailer and stacked items reach packing station  54 , they are shrink-wrapped in plastic in a conventional manner leaving the customer address, postage and any customer notice exposed on the face of the mailer (step  118 ). As described above, FIG. 8 shows multiple packages, stacked and wrapped, the group  58 A-N comprising a single customer order. As described above, a notice is included on the front of the mailer informing the customer that the order will arrive in multiple packages.  
         [0048]    Finally, the assembled packages are mailed in a selected public or private postal system (step  120 ).  
         [0049]    In an alternate embodiment of the invention, the packing calculation process shown in FIG. 13 is performed by computer  32  in data processing center  26  and the order fulfillment data determined, stored in table  42  and transmitted to order fulfillment database  60  in fulfillment center  28 . In this alternate embodiment control computer  58  retrieves the pre-calculated order fulfillment data from order fulfillment database  60  and the process otherwise proceeds as described above.  
         [0050]    There has thus been provided methods and systems for automated and cost-effective processing of customer orders requiring fulfillment with multiple, customer-selected items. The invention provides, in a customized manner for each customer order, item selection for multiple packages to take advantage of lowest commercial postal rates. The invention further provides for the automatic and fast packing and wrapping of each package in an assembly-line type environment. When multiple packages are used to fulfill a single&#39; customer order, notice of the multiple mailings is provided to the customer on each mailing.