Patent Application
20060271234
1. Field of the Invention
The present invention relates generally to a management system and, more specifically, to the management and processing of pallets and containers through a facility.
2. Background Description
The delivery of mail such as letters, catalogs, advertisements, parcels and a host of other articles have increased exponentially over the years. These mail pieces are known to be critical to commerce and the underlying economy. It is thus critical to commerce and the underlying economy to provide efficient delivery of such mail in both a cost effective and time efficient manner. This includes, for example, managing and processing the flow of mail through facilities. By efficiently managing and processing the flow of mail and other pallets through postal facilities, the delivery of mail and other articles can be provided in an orderly and effective manner.
In current postal facilities, such as, for example, a Processing and Distribution Center (PDC), the managing and processing includes, for example, receiving, temporarily storing, and transporting pallets and containers that contain mail. More specifically, a PDC receives pallets and containers at its loading dock. The PDC personnel transport these pallets to internal staging areas and mark them with a processing date. When the processing date arrives, the personnel transport the pallets to a preparation area, which prepares the pallets for automated mail processing. Personnel then move the mail through several sorting operations, such as, for example, automated sorting machines, which in turn, sort the mail to a delivery route sequence.
Different postal facilities use different methods for pallet management. Typically, PDC personnel manually manage the flow of pallets through the PDC. Personnel physically label each pallet, manually assign staging locations, and rely on human memory and searching to locate pallets that must be processed for that day. Manual methods are also used to schedule, track, and account for all pallets in the system. These manual methods are often ad hoc, and can result in problems including pallets arriving late or arriving in less-than-optimal sequence for sorting and/or sequencing of mail pieces. This and similar problems associated with current manual methods compound with an increasing volume of pallets.
The introduction of automated sorting systems such as, for example, the Flats Sorting Sequencer (FSS), has provided a substantial increase in the volume of pallets handled in the PDC. Historically, a substantial portion of flats mail has not been processed through the PDC's because it was either crossed-dock (e.g., a truck to track transfer without sorting) or delivered directly to a delivery unit. However, such flats mail that historically did not visit the PDC will now be directed to the PDC for sorting in the FSS. Since flats mail generally arrives at the PDC in palletized form, the FSS thus ensures that pallet traffic in a typical PDC can be expected to increase by at least 50%. And, as described above, this increased volume can, and likely will, overwhelm the current manual methods of pallet management and processing.
Accordingly, there is a need for more efficient managing and processing of pallets and other containers at postal facilities.
According to a first aspect of the invention, there is a system comprising a device generating at least one of a storage assignment and a movement schedule for each of a plurality of items based on item information and scheduling processes and an interface for displaying the generated storage assignments and movement schedules.
According to a second aspect of the invention, there is a computer program product comprising a computer useable medium having a computer readable program, wherein the computer readable program when executed on a computer causes the computer to generate at least one of a storage assignment and a movement schedule for each of a plurality of items based on item information and scheduling processes.
According to a third aspect of the invention, there is a method comprising obtaining information about at least one item of a plurality of items, generating item management enhanced information for each of the plurality of items based on the obtained information, and managing the storage and movement of the plurality of items based at least partly on the item management enhanced information.
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
The invention is directed to a management system and method for managing pallets in a facility. More specifically, the invention relates to a management system and method for managing the processing and flow of pallets through a facility. Although the invention is described with respect to postal facilities and pallets of mail, it is understood that other applications such as warehousing and storage applications are also contemplated for use with the invention. Also, the invention is not limited to pallets, but can be implemented for other items, such as, for example, containers, cartons, trays, individual objects, etc.
In embodiments, the invention comprises a system and method that integrates various systems to provide an overview of existing pallets and rolling stock, expected pallets and rolling stock, and sortation equipment capacity and predicted throughput. In one aspect, the invention utilizes existing databases to efficiently identify staging area assignments, schedule internal material deliveries, automatically calculate internal plant routing of materials, notify when internal delivery commitments can not be met, and incorporate internal delivery verification, to name a few features. This information can then be used to perform numerous tasks such as, for example, storing, tracking, and managing pallets on the dock and throughout the sortation process, predicting workload, generating and monitoring sortation schedules. Additionally, embodiments of the invention automatically provide staging assignments for incoming pallets, provide staging areas within the existing facility footprint, schedule and track pallets from the dock to the point of consumption, assist in scheduling and tracking of sorting operations, alert personnel when priorities and schedules cannot be met, and generate alternate processing recommendations in the event of exception conditions such as sortation system failures and pallet cancellation. The invention, when utilized, is further designed to reduce manual handling of pallets and meet overall delivery commitments.
In embodiments, the server 10 generates storage assignments, movement schedules, and sortation schedules for all pallets in the facility based on existing information and information received when pallets arrive at the dock. Facility personnel view these assignments and schedules via interfaces, such as computers 20 and PDAs 25, while handling the pallets within the facility. Facility personnel also communicate data to the server 10 via interfaces, whereby the data is used as input for the generated assignments and schedules for each pallet in the facility. In embodiments, the interface may comprise the server.
In the illustrative implementation depicted in
Still referring to
The Second Zone (2) may include intra-facility movement of pallets, such as, for example, moving pallets from the staging area 35 to a preparation area 40. In embodiments, facility personnel use an interface (e.g., PDA 25) to view server-generated schedules that notify when a particular pallet is to be moved, where it is currently located, and where to move it to.
The Third Zone (3) may include processing, such as, for example, where pallets are consumed by sorting machines (e.g., FSS 44 and APPS 46) such that the pieces of mail of a pallet are sorted for delivery. In embodiments, facility personnel use an interface (e.g., PDA 25) to view server-generated schedules that notify when to process an pallet and where to find that pallet.
Thus, in the implementation of the invention shown in
The server 10 may be any type of server and comprises software that provides a highly configurable interface that is usable to access and process data from multiple remote databases 15. In embodiments, these databases may include well known databases utilized by the U.S. Postal Service such as, for example, Integrated Data System (IDS), PostalOne, Facility Access and Shipment Tracking system (FAST), and Drop Shipment Appointment System (DSAS). The data accessed from the databases 15 may include expected pallet delivery information, individual pallet characteristics, sortation information, process status, historical throughput information, and sort volume predictions, amongst others. It should be recognized by those of skill in the art that the server 10 can equally interface and manage data of other databases.
As further shown in
In implementations, facility personnel use the PDA 25 to scan, or record in other manners, information of incoming pallets, and send this information to the server 10. Facility personnel also use the PDA 25 to send intra facility pallet movement data and pallet consumption data to the server 10. In return, the server 10 generates storage assignments, schedules, inventory, and alert information that can be accessed by the facility personnel via interfaces, such as computers 20 and PDAs 25.
In embodiments, the server 10 utilizes various data from the databases 15 and interfaces (e.g., computers 20 and PDAs 25) to generate storage assignments and schedules of all of the pallets within the facility. The various data may include, for example: expected pallet delivery date and time, characteristics of pallets (e.g., flats, parcels, first class, priority, etc.), inventory and location of pallets within the facility, available pallet storage space within the facility, target processing deadlines for each pallet, sortation information, processing machine status (e.g., normal, behind schedule, inoperative for maintenance, etc.), historical throughput information for each processing machine, pre-programmed sort plans of processing machines, and sort volume predictions, among others. The DMS is dynamic in that the server-generated storage assignments and schedules may change as the various data changes. Thus, the DMS provides a constantly-updating overview of the handling and management of all of the pallets throughout a facility.
The steps depicted in the flow diagram of
In step 310, an item is received. In embodiments, dock receipt personnel receive delivered incoming pallets, such as, for example, from delivery trucks.
In step 320, item information is retrieved. For example, dock receipt personnel use an interface to retrieve information from each incoming pallet. In embodiments, the interface is a PDA 25 comprising a barcode scanner that reads a barcode on each incoming pallet. In alternative embodiments, the interface could be other devices, such as a computer 20, and information may be retrieved without the use of barcodes, such as, for example, by manual input, RFID, etc. The retrieved information may be, for example, the type of mail a pallet contains (e.g., flats, parcels, etc.), the class of mail it contains (e.g., first class, priority, etc.), and the target processing deadline (e.g., date and time) of the mail it contains. In this manner, in embodiments, the PDA 25 also serves as an interface that accepts input data regarding the actual receipt of pallets into the facility.
In step 330, the retrieved information is communicated, such as, for example, to the server 10. In embodiments, the interface (e.g., PDA 25) communicates the retrieved information to the server 10 in any known way, including, for example, wireless transmission, docking station, local area network (LAN), Internet, Ethernet, etc.
In step 340, results are generated, such as, for example, placement of incoming pallets at a location or movement of pallets. In embodiments, the server 10 uses the retrieved information in conjunction with the other data, such as, for example, from the databases 15, and possibly from other interfaces, to generate a storage assignment and schedule for the incoming pallet. In this manner, each incoming pallet is inducted into the overall management and handling system of the DMS.
In step 350, the generated results are accessed by personnel. In embodiments, dock receipt personnel utilize an interface (e.g., PDA 25) to access (e.g., view) the storage assignment (e.g., assigned location within the facility to place the pallet) for an incoming pallet. In embodiments, the storage assignment (and all other server-generated data) is accessible by the interface from a central data storage location (described below).
In step 360, the item is moved to an assigned location. For example, in embodiments, the dock receipt personnel deliver (e.g., physically move) the pallet to the assigned location.
In step 370, information regarding the moved item is communicated to the server 10 or other processor. For example, in embodiments, personnel use the interface (e.g., PDA 25) to communicate delivery of the pallet to the assigned location by, for example, scanning a barcode associated with the assigned location and communicating this data to the server 10. This information is entered into the DMS to allow future retrieval of the pallet, when necessary.
The DMS, via the server 10, is capable or performing various operations with the available data. In embodiments, the operations include data translation, staging assignment, scheduling assignment, data storage, and conflict resolution. In an illustrative example, the server 10 performs data translation that operates to translate user input from the various databases 15 and interfaces (e.g., computer 20, PDA 25) to machine language that is usable by the server 10, as is well known to those of skill in the art. Thus, for example, step 3410 may include the operation of data translation such that the server 10 may utilize the various data.
In step 3420, the server 10 generates storage assignments and schedules for pallets in the facility. This may be accomplished, for example, with the data from step 3410. For example, the server 10 performs staging assignment that operates to assign each incoming pallet (e.g., pallet) to a physical location in the facility (e.g., a particular shelf in the staging area 35), based upon DMS data such as, for example, available pallet storage space within the facility, anticipated future incoming pallets, characteristics of the pallet, time needed to process the pallet, schedules of other pallets, deadline for processing the pallet, status of machines needed to process the pallet, pre-programmed sort plans of machines, etc. Based upon such data, the server 10 determines an optimum location for the pallet within the facility and assigns the pallet to that location. For example, if a pallet of high priority is received at dock 30 and needs to be processed by the APPS within three hours, then the server 10 may, via the staging assignment, assign the pallet to an available storage location that is closest to the APPS. Conversely, if a pallet of low priority arrives that need not be processed for two days, then the server 10 may, via the staging assignment, assign the pallet to an available storage location that is somewhat far away from the intended processing machine.
In step 3430; the server 10 communicates the generated assignments and schedules to a central data storage location. In embodiments, the server 10 operates to store all of the data, assigned locations, schedules, etc. For example, the server 10 stores the information at a central location (e.g., computer memory or database) for later recall by the server 10 and/or interfaces, such as the computer 20 and PDAs 25.
In embodiments, the DMS is not limited to generating results (e.g., performing steps 3410; 3420; and 3430) only when pallets arrive at the dock receipt 30. Results may be generated at any time, as defined by the user. For example, the steps may be performed on a routine time interval, such as every five minutes, although other times are contemplated by the invention. Also, a user may use an interface (e.g.; computer 20) to initiate the performance of the results generation steps.
Furthermore, the results generation steps are not limited to generating storage assignments for incoming pallets. The steps may involve other operations, such as scheduling and conflict resolution, to be described herein. In this way, the DMS creates an updated storage and scheduling solution for every pallet in the facility each time the steps are performed.
As depicted in
As shown in
As seen from
It will be appreciated by those skilled in the art that the DMS is a dynamic system that is constantly updating based upon changing data, and the act of assigning a pallet to a particular storage location may affect the management and handling of other pallets of the facility. For example, when a pallet is assigned to a location, then that location is no longer available for other pallets. This new data (e.g., one less storage location) may affect the results of subsequent operations of staging assignment, scheduling assignment, and conflict resolution (described herein).
The steps depicted in the flow diagram of
In step 410, data is accessed by an interface, such as PDA 25. In embodiments, an interface is used to access information from the central data storage location. The interface may be, for example, computers 20 and/or PDAs 25. In embodiments, the information is a delivery schedule that contains information regarding when to move a particular pallet from one location (e.g., a shelf in the staging area 35) to another location (e.g., a preparation area 40). Transmission may be initiated by the server 10, such that the information is pushed from the server 10 of the central data storage location to the interface. Alternatively, transmission may be initiated by the interface, such that the information is pulled from the server 10 or the central data storage location to the interface.
In embodiments the delivery schedule is generated by the server 10 by way of operation of a scheduling assignment solution that resides on the server 10. For example, the server 10, via scheduling assignment, uses various data as input and produces schedules of the movements of pallets throughout various locations of the facility based primarily upon an overall time deadline for each pallet. Each pallet has a deadline (e.g., date and time) to be processed and sent out of the facility for delivery, such that the units of mail contained in the pallet can be delivered according to schedule. Based on the various data (e.g., type and/or class of mail in the pallet, location of the pallet in facility, availability of sorting machines, schedule of other pallets, pre-programmed sort plans of machines, etc.), the server 10, via scheduling assignment, applies customized rules (described below) to provide schedules for the flow of pallets through the facility to meet time deadlines and optimize available resources. In other words, the server 10 derives an optimal time and location for all the various stops that a pallet will make throughout the facility.
In embodiments, the above-mentioned customized rules may include, for example, known internal processing rates of facility machines and routing rules for pallets in the facility. Internal processing rates may include, for example, that a preparation area can process sixteen pallets per hour, or that a processing machine (e.g., FSS, APPS, etc.) can sort ten thousand flats per hour. Such processing rate information is utilized in the scheduling assignment to effectuate efficient scheduling and planning because it facilitates “as needed” or “just in time” movement of pallets within the facility. In other words, if a machine can handle sixteen pallets per hour, then it is more efficient to delivery the pallets as needed rather than delivering fifty all at one time.
In embodiments, routing rules include logical decisions that affect how a pallet is routed throughout the facility. For example, a routing rule may require that pallets containing flats be delivered to the FSS 44 because the FSS 44 sorts flats. Another routing rule may require that containers of parcels be delivered to the APPS 46. There may also be routing rules regarding the class of mail: pallets containing express mail get processed first, then pallets containing priority, then first class, etc. Additionally there may be routing rules regarding the availability of machines. For example, a routing rule may dictate that if machine “A” is unavailable (e.g., broken, overloaded, etc.) then route the pallet to machine “B”. Such routing rules are utilized in the scheduling assignment to determine the routing and scheduling of pallets through the facility.
In embodiments, the customized rules (e.g., internal processing rates, routing rules, etc.) are communicated to the server by an interface. For example, personnel may use the computer 20 to manually input the customized rules to the server 10. Alternatively, some or all of the customized rules may be derived by a computer coded program that derives the customized rules from historical data of the facility and then communicates the rules to the server 10.
In an illustrative embodiment, the server also performs conflict resolution that operates to monitor the pallets and processes of the facility and determine when a delivery deadline of a pallet cannot be met. For example, the server 10, via conflict resolution, monitors the schedules generated during scheduling assignment and the actual locations of pallets in the facility. With such data, the server 10 can determine scheduling problems in either a reactive or proactive manner. A reactive determination is when the server 10 detects that a pallet has not arrived at a scheduled location within the facility on time. A proactive determination is when the server 10 uses forward looking calculations to determine that, based upon the time required for intermediate steps, it is impossible to meet a certain deadline. In embodiments, when the server 10 determines a problem, whether reactively or proactively, it creates an alert. The alert is transmitted from the server 10 to an interface (e.g., computer 20, PDA 25, etc.) to notify personnel of the problem. At this point the personnel can take various actions, such as: do nothing because the problem is minor; cause the server 10 to generate a new optimized schedule based upon the new data; manually resolve the problem by hand processing, etc. Thus, the server 10 constantly monitors the system and alerts the personnel to problems.
Still referring to
In step 430, the item is moved from its current location to a new location. For example, this may include physically moving a pallet from the staging area 35 to the delivery point, such as, for example, a prep area 40, FSS 44, or APPS 46.
In step 440, information regarding the move is communicated. In embodiments, upon delivery of the pallet to its new location within the facility, the interface (e.g., the PDA 25) is used to communicate new location of the pallet to the server 10. For example, the PDA 25 may be used to scan a barcode of the delivery point where the pallet is delivered to, and this new location for the pallet is communicated to the server 10.
Thus, in embodiments, the computers 20 and/or PDAs 25 act as an interface for inputting data regarding intermediate deliveries within the facility. For example, the PDA 25 may be used to input information regarding material arrival to, and exit from, docks, staging areas, preparation areas, delivery points, and dispatch areas. This information may be manually typed, scanned via barcode, communicated via RFID, etc.
Furthermore, in embodiments, a user may monitor all aspects of the management of the facility (e.g., dock receipt, staging, material movement, sorting) via the Supervisor Application (SA) on the computer 20. For example, personnel may use the SA to setup and configure the system. For example, a user may input the customized-rules and/or other rules that affect the assignment of staging areas, when and where material is moved, sort plans, and thresholds for alerts. Additionally, the user may manually enter data that is not contained in the databases 15. Also, personnel may display and print reports that show overall system performance and health. Furthermore, personnel may use the system to aid in planning and revising schedules, and may receive alerts that warn when action is needed to meet a schedule commitment.
It will be appreciated by the skilled artisan that the DMS is a dynamic system that is constantly updating based upon changing data, and the results of scheduling assignment and/or conflict resolution may have an impact on other parts of the facility. For example, if a pallet is moved from location “A” in the staging area 35 to location “B” in a preparation area 40, then the server 10 can ascertain that there is now an open storage location at area “A” and may determine that an anticipated incoming pallet may be placed in this location upon receipt of that incoming pallet at the dock 30. As another example, if the server 10 ascertains, via scheduling assignment and conflict resolution, that the FSS 44 is behind schedule by a certain amount of time, then the sever 10 may dictate that no more pallets be moved to the preparation area of that FSS 44 until the backlog is cleared, or that pallets be routed to other machines that can handle the workload.
The steps depicted in the flow diagram of
In step 510, data is accessed from the server 10 or central data storage location by the interface, for example. The interface may be, for example, computers 20 and/or PDAs 25. In embodiments, the information is a processing schedule that contains information regarding when to process a particular pallet in a particular machine (e.g., FSS 44, APPS 46, etc.). Transmission of the information may be initiated by the server 10, such that the information is pushed from the server 10 or the central data storage location to the interface. Alternatively, transmission may be initiated by the interface, such that the information is pulled from the server 10 or the central data storage location to the interface.
In step 520, item information is retrieved by the interface. For example, personnel use a PDA 25 to scan a barcode associated with either the pallet or the current storage location of the pallet. Step 520 may include communicating this data to the server 10 and viewing the assigned processing information for the pallet on the interface (e.g., PDA 25). For example, upon scanning a pallet barcode, the processing information may automatically be displayed on the PDA 25 by way of communication between the server 10 and the PDA 25.
In step 530, the item or pallet is processed. For example, this may include consuming the contents of the pallet in a processing machine. This may include depositing the parcels that are contained in a pallet into the APPS 46, such that the parcels are sorted and the pallet is now empty.
In step 540, information regarding the processing of the item is communicated. In embodiments, upon processing of the pallet, the interface (e.g., the PDA 25) is used to communicate the processing of the pallet to the server 10. For example, the PDA 25 may be used to scan a barcode of the processing machine in which the pallet is processed, and this information is communicated to the server 10. Alternatively, the processing machine (e.g., APPS 46) may include a device, such as a barcode scanner, that is capable of retrieving pallet information. For example, the processing machine may automatically capture and communicate the pallet information to the server (either directly or indirectly via a database), without the need for scanning with a PDA 25. In this manner, whether the information is captured by a PDA 25 or the processing machine, the DMS knows that the pallet is empty and no longer needs to be accounted for.
It will be appreciated by those skilled in the art that the DMS is a dynamic system that is constantly updating based upon changing data, and the act of processing one pallet may have an impact on the management and handling of other pallets of the facility. For example, when a pallet is processed, then the data that is used by all of the operations of the server 10 changes because the storage location that the pallet occupied is now vacant and the processing machine no longer has that pallet in its queue. This new data (e.g., an open storage location and a freed-up machine) may affect the results of subsequent operations of staging assignment, scheduling assignment, and conflict resolution, etc.
Thus, in embodiments, the invention presents significant advantages to the overall management of systems in a facility. For example, by implementing the invention, the system captures the barcode or other information of any pallet, container, etc., that arrives at a dock or other location, and correlates it to pertinent data in the database, thus allowing the system to display to personnel, via interfaces such as PDAs 25 and computers 20, assigned staging area locations, schedules of dock deliveries, and alerts for priority or late pallets that should be delivered directly to other areas (e.g., processing), etc.
Furthermore, the invention provides improved handling and management of pallets, containers, or other items or objects, in a facility by providing personnel with the exact location to look for a needed pallet, container, object, etc. For example, the invention tracks the location of every pallet from staging area to delivery point, thereby reducing the number of lost pallets. Additionally, the invention allows personnel to view anticipated and real-time updated schedules that show when and where pallets need to be delivered, so that personnel can plan ahead accordingly. Also, through the use of historic information, the system can alert personnel when an internal delivery commitment could be in jeopardy.
The invention provides benefits of efficient management and processing of inventory through utilization of data. For example, the invention accomplishes this by assigning pallets to known locations, scheduling pallet deliveries, providing easy operator access to pallet information, and providing visibility to all pallets, and monitoring pallets as they move through the processing facility.
While the invention has been described in terms of embodiments, those skilled in the art will recognize that the invention can be practiced with modifications and in the spirit and scope of the appended claims.
This application claims priority to U.S. Provisional Patent Application No. 60/685,485, filed on May 31, 2005, the disclosure of which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60685485 | May 2005 | US |
