This disclosure relates to an inventory management and scheduling tool (IMS tool) operating within an environment where product inventory is transported to different locations. The IMS tool includes technical improvements for tracking inventory within the environment, scheduling transport of the inventory within the environment, and providing modifications to a transfer schedule that incorporates deviations into predetermined manufacture and/or packaging workflows for the product. The IMS tool may further generate and utilize unique data structures to implement the features described herein to provide a technical improvement in the operation of a computing device implementing the inventory management. The IMS tool further includes detection and alerting features, as described in more detail herein. The IMS tool may be comprised of a combination of software, hardware, and/or circuitry for implementing the features described herein.
Apparatuses, systems, and methods are described that take advantage of the technological improvements offered by an inventory management and scheduling (IMS) tool. The IMS tool may be utilized within an environmental setting that includes, for example, a product manufacturing factory, or a product storing warehouse setting. The IMS tool may also be applied across different settings such as a manufacturing plant, product warehouse, food service facility, medical facility, or other setting that relies on tracking items to different locations within a known space.
The IMS tool utilizes a combination of predetermined product tracking workflows and product tracking data structures to more efficiently track products through a set of known workflows. The predetermined product tracking workflows may describe known manufacturing steps, as well as any corresponding manufacturing machines, that are used to bring a product from raw form to finished product. The predetermined product tracking workflows may also include known packaging steps, as well as any corresponding retrieval or packaging machines, and intervening steps and machines, to retrieve a product from a storage location and package the product for safe shipping. The predetermined product tracking workflows may also be modified to incorporate deviation processes, where the deviation processes may be selected from a collection of known deviation processes that apply to the type of predetermined product workflow.
The technological improvements include faster processing times, as well as conservation of computer resources (e.g., hardware and/or processing resources), which are achieved through the reduced reliance on bulky and resource draining hardware sensors. For example, the IMS tool utilizes existing tracking devices within an environment (e.g., manufacturing plant or storage warehouse) and specialized product tracking data structures (e.g., product count registers) to track products as they are picked up and dropped off at different stations according to a predetermined product tracking workflow. The actual tracking may be of a storage bin holding a number of products. So unlike other tracking systems, the IMS tool offers technological improvements that do not necessarily require barcode scanning or radio-frequency identification (RFID) sensor scanning to track items through a process within a space.
This system further provides an easy and efficient solution for modifying the predetermined product tracking workflow by inserting deviations, and/or removing existing processes. The IMS tool may further assign a product pick up or drop off ticket to a specific transporter (e.g., forklift and/or driver of the forklift) based on attributes of the transporter. The IMS tool may further be configured to detect maintenance issues within the environment and issue specifically tailored alert tracker announcements such as an announcement to notify individuals within the area utilizing the IMS tool of a quality or process issue. In some situations, these alert tracker announcements may be directed to specific personnel.
In this way, the IMS tool improves the computer capabilities of the devices involved to more efficiently (e.g., improved speed, less data handling, less resource utilization, better information flow, requires less user interaction) and accurately manage and track products moving within an environment.
The building further includes a computer device 110 and a database 111 accessible by the computer device 110. The computer device 110 may include the hardware, software, and/or circuitry for executing the IMS tool. The database 111 may include information referenced by the IMS tool. This information may include user profiles, building conditions, and/or predetermined product tracking workflows. A predetermined product tracking workflow identifies the specific steps, and machines, that are involved in manufacturing, or packaging, a specific product. For example, the predetermined product tracking workflow corresponding to the manufacturing of the fastener nut includes a description of the process for putting material through each of the former machine 121, then through the tapper machine 122, and finally though the deflection machine 123 (as well as any stops between the scale 126 and/or washer 125) to obtain the finished fastener nut product. The predetermined product tracking workflow may also be available in various degrees of granularity to provide, for example, the specific steps, and machines, that are involved in any of the individual steps.
The building 120 further includes various building components 150 that may be utilized by the IMS tool. These include one or more video cameras, one or more microphones, one or more speakers, one or more motion sensors, one or more displays, and/or one or more sensors (e.g., radio frequency (RF) sensors).
As described, the IMS tool may be executed on the computer device 110. The computer device 110 may be a type of central command computer for overseeing the operation of the IMS tool as it tracks product delivered to different stations within the building 120. In addition or alternatively, the IMS tool may be running, at least in part, as a web-based application 142 on a remote enterprise system 140 through a network 130. The enterprise system 140 may include an enterprise server computer 141 that allows a user remote access to the IMS tool after providing proper authentication for accessing the IMS tool remotely. The network 130 may be representative of one or more private, and/or public, networks defined over any predetermined and possibly dynamic internet protocol (IP) address ranges. According to some embodiments, the IMS tool may be implemented across a mesh network of decentralized computing devices.
The GUIs 205 and the I/O interface circuitry 206 may include touch sensitive displays, voice or facial recognition inputs, buttons, switches, speakers and other user interface elements. Additional examples of the I/O interface circuitry 206 includes microphones, video and still image cameras, headset and microphone input/output jacks, Universal Serial Bus (USB) connectors, memory card slots, and other types of inputs. The I/O interface circuitry 206 may further include magnetic or optical media interfaces (e.g., a CDROM or DVD drive), serial and parallel bus interfaces, and keyboard and mouse interfaces. The I/O interface circuitry 206 may further include sensors such as RF sensors that are part of the computer architecture 200, or separate devices that are in communication with the computer architecture 200.
The communication interfaces 208 may include wireless transmitters and receivers (“transceivers”) 210 and any antennas 212 used by the circuitry of the transceivers 210. The transceivers 210 and antennas 212 may support WiFi network communications, for instance, under any version of IEEE 802.11, e.g., 802.11n or 802.11ac, or other wireless protocols such as Bluetooth, Wi-Fi, WLAN, cellular (4G, LTE/A). The communication interfaces 208 may also include serial interfaces, such as universal serial bus (USB), serial ATA, IEEE 1394, lighting port, I2C, slimBus, or other serial interfaces. The communication interfaces 208 may also include wireline transceivers 214 to support wired communication protocols. The wireline transceivers 214 may provide physical layer interfaces for any of a wide range of communication protocols, such as any type of Ethernet, Gigabit Ethernet, optical networking protocols, data over cable service interface specification (DOCSIS), digital subscriber line (DSL), Synchronous Optical Network (SONET), or other protocol. The communication interfaces 208 may communicate with remote computing devices via a network, such as the network 130.
The computer architecture 200 also includes, or in other embodiments communicates with, a production database management system (enterprise PDMS) 230. The PDMS 230 may be included as part of the enterprise system 140 illustrated in
The system circuitry 202 may be representative of any combination of hardware, software, firmware, application programming interface, or other circuitry for implementing the features of the IMS tool described herein. For example, the system circuitry 202 may be implemented with one or more systems on a chip (SoC), application specific integrated circuits (ASIC), microprocessors, discrete analog and digital circuits, and other circuitry. The system circuitry 202 may implement any desired functionality of the IMS tool. As just one example, the system circuitry 202 may include one or more instruction processor 216 and memory 220.
The memory 220 stores, for example, control instructions 223 for executing the features of the IMS tool, as well as an operating system 221. In one implementation, the processor 216 executes the control instructions 223 and the operating system 221 to carry out any desired functionality for the IMS tool. For example, the control instructions 223 for the IMS tool includes a ERP portion 224, an IMS portion 225, a deviation management portion 226, and an alert tracker portion 227. Each component of the control instructions 223 may include the instructional logic for implementing the associated features of the IMS tool. The memory 220 also includes control parameters 222 that provide and specify configuration and operating options for the control instructions 223, operating system 221, and other functionality of the computer architecture 200.
So the first stage register shows seven (7) bins are initially stored in the WIP pile 124. The remaining second stage register, third stage register, and fourth stage register show there are no products that have been processed to those stations. Throughout the implementation of the workflow, the values for the different stage registers will increase and decrease to reflect a number of bins at the respective station. However, at all times during the workflow, the stage register count value should add up to the total number of bins that are known to have been introduced into the workflow, which in this scenario is seven (7) bins.
A predetermined workflow may take bins from stage 1, to stage 2, to stage 3, and end at stage 4. According to some embodiments, in addition to the predetermined workflow, the bins may be put through an initial scale and wash step prior to entering the predetermined workflow where bins of product are washed and scaled by the washer 125 and scale 126. The bins may also be put through a subsequent scale and wash step after existing the predetermined workflow where bins of product are washed and scaled by the washer 125 and scale 126.
Further, according to some embodiments deviations steps may be inserted between any of the steps of the predetermined workflow. For example,
At 401, the IMS tool initially generates a transport order to pick up and transport a first bin from stage 1 (e.g., WIP pile 124) to stage 2 (e.g., staging area 131). This transport order may be transmitted to any, or all, available forklifts to be claimed.
At 402, a forklift claims a work ticket corresponding to the transport order, and picks up the first bin from the WIP pile 124. When the forklift picks up the first bin from the WIP pile 124, a driver on the forklift may input a “claim” command to confirm the pickup. For example,
At 403, the forklift drops off the first bin at stage 2. When dropping off the first bin at stage 2, the IMS tool increases the register count for the second stage register 12.
Subsequent steps 404 to 406 are exemplary of a deviation stage that may be ordered. As the deviation stage is ordered, the IMS tool decreases the register count for the second stage register 12 when a transport order is claimed for transporting the first bin from stage 2 to the deviation stage.
At 404, the first bin enters a deviation stage when it is transported to the scale 126. At the scale 126, the first bin is scanned and weighed. The IMS tool determines a product count for the first bin based on the weight obtained from the scale 126 (e.g., the product count is obtained by dividing the weight of the bin (after removing the weight of the bin itself) with a known weight for a single product). When the first bin is dropped off at the scale 126, thus representing entering the deviation stage, the IMS tool increases a register count for a deviation register 16.
At 405, the first bin enters another deviation stage when it is further transported to the washer 125, where the product in the first bin is washed by the washer 125.
At 406, the first bin is further transported back to the scale 126, where the first bin is scanned and weighed again. The IMS tool compares the post-wash product count to the pre-wash product count to detect any lost product. When the first bin is claimed from the scale 126, thus representing exiting the deviation stage, the IMS tool decreases a register count for the deviation register 16.
At 407, the first bin is transported out of the deviation stage and back into the workflow by being dropped off at stage 3 (e.g., “running” at deflection machine 123). At stage 3, the product within the bin may be processed (e.g, deflected by the deflection machine 123). In addition, upon receiving confirmation that the first bin has been dropped off at stage 3, the IMS tool recognizes stage 3 now has one more bin, and a register count of the third stage register 13 is increased accordingly.
At 408, when a second bin is waiting for pickup from stage 3, the IMS tool is prompted to generate a subsequent transport order to pick up the second bin from stage 3, where the second bin contains product that has finished being processed through the third station. The subsequent transport order includes instructions to drop off the second bin at stage 4 (e.g., “done” finished product pile 300).
At 409, a forklift claiming a subsequent work ticket corresponding to the subsequent transport order will pick up the second bin from stage 3. Upon receiving confirmation that the second bin has been picked up from stage 3, the IMS tool recognizes stage 3 now has one less bin, and a register count of the third stage register 13 is decreased accordingly.
At 410, the forklift drops off the second bin at stage 4. Upon receiving confirmation that the second bin has been dropped off at stage 4, the IMS tool recognizes stage 4 now has one more bin, and a register count of the fourth stage register 14 is increased accordingly.
The IMS tool may track delivery times for each driver of the forklifts, and store this information into the driver's profile. The IMS tool may further track whether a transport was successful or unsuccessful (e.g., picked up on time within a predetermined window of time, delivered on time within a predetermined window of time from pick up confirmation, dropped off at correct destination), and store this information into the driver's profile.
The process described by flow diagram 400 may be repeated for each bin that is scheduled to work through the workflow.
Referring back to
In the representative illustration of building 120 shown in
At 801, the IMS tool generates a transport order for pick up and transport of the first bin from the deflection machine 123 located at the third station. The transport order ticket may be initiated from a user input command. In addition or alternatively, the transport order ticket may be initiated according to a timing schedule accessed by the IMS tool that identifies when the first bin is ready for pick up after being processed by the deflection machine 123.
At 802, the IMS tool determines a pool of available transport options. To determine the pool of available transport options, the IMS tool may determine an operational status of forklifts within the building 120, determine a location of the forklifts in relation to the deflection machine 123, or obtain other attributes of the forklifts. Then, the IMS tool may determine the pool of available transport options to be forklifts determined to be in an operational status, forklifts that are not currently transporting a bin, forklifts that are within a predetermined distance from the deflection machine 123 located at the third station, or a combination thereof. In addition or alternatively, other considerations may be taken by the IMS tool when determining the pool of available transport options.
At 803, the IMS tool selects, from the pool of available transport options, a transport option based on a predicted performance of the selected transport option. The predicted performance of the transport option may consider one or more of the following attributes: forklift's distance from the deflection machine 123, forklift's capability to handle the bin (e.g., is the forklift rated to carry the weight of the bin), or a past performance of the forklift driver. For example, the IMS tool may select the first forklift that is closest to the deflection machine 123. The IMS tool may further select the forklift that is closest to the deflection machine 123 that is rated to carry the weight of the bin. The IMS tool may further consider attributes of the respective forklift driver, and select the forklift having a driver with the highest past performance score. The driver's performance score may consider the driver's timeliness in delivering bins, as well as a ratio of successful transports versus unsuccessful transports. Drivers having greater timeliness and a greater ratio of successful transports versus unsuccessful transports will be given higher performance scores.
At 804, the IMS tool assigns the transport order ticket to the selected transport option. This may include transmitting the transport order ticket to a tablet computer attached to the selected forklift for the respective driver to view.
At 805, the IMS tool transmits a recommended route to the selected transport option. For example, the IMS tool may consider traffic within the building 120, and determine a recommended route that is predicted to result in the shorted travel time for the transport option to accomplish their task.
At 901, the IMS tool detects a maintenance event. The maintenance event may be initiated by a user input that directly alerts the IMS tool of an issue (e.g., malfunctioning machine). The maintenance event may also be initiated by an automatic detection of a maintenance event by the IMS tool itself. For example, the IMS tool may identify a scheduled maintenance check for the deflection machine 123, and determine this to be a maintenance event. The IMS tool may also monitor certain machines within the building 120, and when an issue with the monitored machine is detected, the IMS tool may determine this to be a maintenance event.
At 902, the IMS tool determines a pool of available personnel for addressing the maintenance issue event. To determine the pool of available personnel, the IMS tool may determine a status of personnel (e.g., currently working, on vacation, paid time off), determine attributes of personnel (e.g., work skills, education, certifications, work history), or obtain other attributes of the personnel. Then, the IMS tool may determine the pool of available personnel to be personnel that are currently present in the building, personnel that have addressed the same or similar maintenance issue previously, personnel having requisite authority to address the maintenance issue, or a combination thereof. In addition or alternatively, other considerations may be taken by the IMS tool when determining the pool of available personnel.
At 903, the IMS tool selects, from the pool of available personnel, a personnel based on a predicted performance of the selected personnel. The predicted performance of the personnel may consider one or more of the following attributes: personnel's past performance of successfully fixing similar maintenance issue previously, personnel's level of education or work certification, or other attribute related to a personnel's ability to perform a solution to the maintenance issue. For example, the IMS tool may select the personnel that has experience in successfully fixing the same, or similar, maintenance issue previously.
At 904, the IMS tool assigns the alert tracker ticket to the selected personnel.
At 905, the IMS tool transmits the alert tracker ticket to an electronic account or mobile computing device associated with the personnel. This may include an email, phone number, or internal messenger service associated with the selected personnel.
At 906, the IMS tool may optionally transmit a general alert tracker. The general alert tracker may be transmitted to the available pool of personnel to obtain backup options for addressing the maintenance issue in case the selected personnel cannot.
Various implementations have been specifically described. However, other implementations that include a fewer, or greater, number of features for each of the apparatuses, methods, or other embodiments described herein are also possible.