Patent Application
20180121866
The present invention relates to inventory management systems used to track the quantity of items taken or replaced from the inventory. More specifically, the present invention relates to an inventory management system which can be used to wirelessly record multiple inventory items using one or more button modules, and the associated functionality.
There are many methods for tracking who takes, returns or restocks items in a store room warehouse or final point of use, in order to maintain a record of the on-hand quantity, and to monitor that quantity in order to place orders to replenish stock. A typical system comprises a computer with a database storing information about each item, and means for users to interact with that database, to maintain a computer based numerical representation of what is actually physically on the shelves. The maintenance of that information in the computer, which is referred to as a perpetual inventory system, is a common process today. In order to maintain the perpetual inventory, early systems required a user interacting with the inventory, to also interact with a nearby computer terminal, either before or after visiting the location of the material they are taking, and input information about what they did.
For busy stock rooms, and particularly large warehouses, having a fixed terminal entry requiring multiple users to remember or note down what they did at multiple item locations, and return to a fixed location to enter data into a computer terminal, is at best inconvenient, and at worst will be a process that users are unlikely to consistently follow. The same is true of a supervisor's maintenance functions, such as assigning or de-assigning an item to a location, entering the maximum and minimum levels required, and performing routine check functions such as a physical inventory count (a.k.a. cycle counting). All these operations would be more conveniently done at the location where the item is located on a shelf or in a bin, physically remote from any fixed computer terminal(s).
There are a number of ways in which this problem has been solved when the item locations are remote from a computer terminal. One has been to provide portable intelligent bar code scanners that communicate with the base computer and where information can be entered on the scanner screens. More recently portable tablet computers or mobile devices have been employed. For applications in a warehouse environment, such systems are successfully used by people who are specifically trained for that function, and where the investment of purchasing equipment for a small number of full-time trained people is worthwhile.
Inventory management at the final point of use however is more challenging. This may be in a manufacturing plant, an office, a clinic, a hospital or anywhere where supplies are consumed during the work-day. In these cases, the people taking the products usually need quick and easy access to supplies in their work area, and having many other duties, do not want to be burdened with lengthy procedures to get at the products they need. More importantly it is impractical with a large and changing staff to keep them trained on using complex equipment like bar code terminals. In spite of that, ideally it would be beneficial to accurately maintain exact inventory levels at these points of use. When justifiable, this can be achieved with relative simplicity for the user by locked automated dispensing cabinets that only dispense one item at a time, after a user has logged into a computer interlace that is embedded in the cabinet, allowing identification of a specific item taken, and who took it. This kind of equipment is useful for expensive items, or items such as narcotics that require regulatory control, but is too expensive for many low cost supplies.
The next level of control is to require a user to log into a secure cabinet and select the items and quantities they will be taking from a list, and give them access to compartments that contain Multiple quantities of those items, or even multiple items. The user can of course take more than they said they were taking, but if the product is not something that might be of use to that person outside of their work, most users are motivated to make sure that the product is accurately counted to ensure re-order, and hence future availability when needed, These cabinet solutions are still prohibitively expensive for low cost or bulky items. More frequently such items are simply stored in bins or on shelving or in drawers. In these circumstances, if the restock process requires someone to check product levels on a regular basis, that checking is costly in labor, and stock-outs can be frequent.
Various systems have been devised to enable easier tracking of stock levels in an open system. As suggested earlier, systems that require bar code scanning that might be effective in a warehouse, are not effective at the point of use because they require training, and the extra time required to perform that scanning is a time burden on users who have many other responsibilities. Having a stack of re-order cards in each item bin allows a user to place the card in a re-order box for someone to pick up, if the user sees the bin is getting low on stock. Other systems include Kanban, where there are two bins for every product, and when one is empty, it is place in a location where materials staff pick them up and replenish them, or they are placed on a RFID reading tray and an RFID tag on the empty bin is read, which then electronically orders a replacement bin. The Kanban system can be effective where there is room for two bins for every product, but is inefficient, costly for expensive product, and impractical for a product that is bulky and which would require the extra storage of the two-bin Kanban system. Ideally in these circumstances we would like an open system (thus avoiding the cost of a locked cabinet), but where the exact inventory is maintained. Maintaining this perpetual inventory record, allows the computer system to re-order the product in sufficient time to prevent a stock-out, but without the need to carry a large amount of excess inventory.
Locked cabinet systems have been developed that make a pair of buttons available at each inventory location to indicate the taking or returning of an item. The Take or Return button is pushed once for each item taken. This assumes that the user will take the trouble to comply, and since the process is so simple and takes so little time, this is usually achieved. It also assumes that the user is only taking one or two items, and does not have to press the button a large number of times, which can be time consuming and potentially inaccurate. Because there is a device at each location, the cost of such a device needs to be kept very low. Consequently, other functions which require being physically present at the location of the product, such as inventory verification counting (a.k.a. cycle-counting), restocking and destocking, still need access to a computer terminal that is usually remote, for data entry.
The invention relates to a system that comprises wireless-connected button modules, one button module semi-permanently located at each item shelf location, able to transmit and receive wireless signals to and from a central console, that central console comprising at least a processor, database and user interface. To make the installation of a large number of these button modules on shelving practical, they are powered by batteries, and communicate to the central console using very low power wireless signals. Each button module has at least two buttons, one for removing stock, one for adding. For selected, authorized users, it is desirable to change the mode of operation of the button module in order to perform other functions, other than the Take and Return of stock, and where the function of the Take button becomes that of decreasing any number to be adjusted, and the Return button becomes that of increasing any number to be adjusted. Access to these administration functions can be provided by a third administration button, or by holding down the Take and Return button simultaneously for a period of time, which action can be detected by the button module firmware, allowing it to detect a desire by the user to change the mode of operation. For the purposes of this application the workflows assume a separate third administration button. The button module also includes either a small alphanumeric display or preferably a bitmap display allowing alphanumeric text of any size with numbers shown much larger than text and the ability to also display status icons where appropriate. Each button module may also have an LED alert light, a piezo beeper, and the ability to interact with a user via an NFC or RFID chip.
Since the buttons are intended for use on open shelving in a small stock room, if it is required that items are tracked to a specific user, then only one user can be logged into the central console at a time. Where users do not need to log in, the button modules can track the quantity on hand taken by multiple users simultaneously, but in the device described here will not be able to determine who is using the module. Other invention applications describe the button module as containing an NFC chip, which could be used for individual identification if the user was using an NFC communication device or badge read and recognized at each button module. The remaining description assumes the situation where the product is being identified to a single user at a time.
In normal, everyday use, the name of the product and other identifying information related to the item, may be shown on the button module display, and typically also a numeric display of the quantity on hand that the computer has in its memory. A new user may use the displayed information to determine the correct product, but typically a user is visually identifying the product they wish to take by looking at the product itself on the shelf, and then doing no more than pressing the Take or Return button at that shelf location to record their action. A user with administrative privileges, however may either casually, or as part of a routine cycle count, observe the display of on hand quantity, and compare that to the amount on the shelf, and if there is a discrepancy they may put the button module into cycle count mode and adjust the number using the Take and Return buttons in a different mode, as buttons that simply increase or decrease the computer value of inventory on hand, without recording an issue or return of product. Access to this administrative function of cycle counting is reached by pressing the administration button a certain number of times in rapid succession, the number of presses determining the administration function to be selected.
Another administration function is for the restocking or destocking of items, allowing the administration user to enter the number of items that they are restocking at the button module without having to pre-enter the number at a computer terminal remote from the item location. In this case the display can show the number of times the button has been pushed, representing the amount being restocked, allowing the administration user to confirm they have entered the right quantity. Further the display allows the button to operate in typematic mode, so that if the button is held down, then after a short delay to distinguish the held finger from a single button push, the number scrolls rapidly up (or down). For large numbers, this lets the user get close to the number then adjust the number to be exact with individual up or down button pushes. In other cases, it is convenient to provide an administration function that allows instant ordering. If for example the button module shows that there are ten items on hand but an administration user sees there are only a few left on the shelf, they have two options. One is to correct the count and let the normal ordering system order the item. However, a regular ordering system may only re-order once a week. So an alternative is to provide an administration function for immediate reorder. This would for example, allow the computer system to place the order immediately or at the end of the day, causing the distributor to expedite replacement items overnight.
The actions described are based on observations at the button module. Functions of cycle-counting and restocking are frequent and usually executed on a routine basis, but there are still advantages to the features of this invention. When the items from a large purchase order are received, the restock administration user can use the main central console to flash the lights on each button module which will need restocking. The central console can also cause the quantity of each item to be restocked to be displayed on the respective button module screens. In this way the user simply has to walk around the stock room, check that the displayed number is correct, adjust it up or down if it is not, press the administration button to have the number recorded in the central console, at which point the flashing LED light on that button module is switched off, and continue this process until all the LED lights are out. The beeper can also be energized. Sound is more difficult to locate physically, and multiple sounds particularly difficult, and so is redundant when there is a flashing light. However, when most of the items have been restocked and there are only one or two items left, the enabling of a beep signal for the remaining one or two items, even if they are hard to locate audibly, can alert the user to the fact that there are one or two flashing LED modules that they missed, and the need to look for them.
During each individual restock process, the display at the button module can show the amount that was ordered, and the administration restocker can check that is the quantity received and make any adjustment. Preferably, in this restock mode, the current quantity on hand is displayed first, available for correction. In this way before restocking the user can perform a cycle count, then push the admin button again, which will then cause the restock quantity to be displayed. In that way the system conveniently combines a cycle count with the restock function. A supplemental restock process is also described. This is for items that may not be associated with an electronic purchase order, and so the user simply needs to put the module into a restock mode where they can add a quantity of stock, and record it as restocking (not returning previously issued stock).
In large inventory situations it can be laborious to cycle count every item, and so it is desirable to do selective counts. This selection can be based on items that have been accessed since the last cycle count, or expensive items, or where the stock out would be critical. Such lists can be tracked and selected at a central console, and then, in the same way as was used for the restock process, the LED on the buttons to be counted can be flashed, and when the cycle counting is almost complete, the beeper can be energized on the remaining buttons to make sure all have been addressed.
In one variation a method for recording multiple inventory items by one or more users generally comprises providing a button module with at least two buttons, and a controllable alphanumeric or bit map display, where the power for the button module is from built in batteries and providing bi-directional communication means to a central console comprising a user interface, processor and database that may be local or in the cloud or both. The method further comprises displaying on a home screen alphanumeric text related to a physical inventory item adjacent to the location where the button module is placed, displaying one or more numbers on the screen relating to that item, detecting the pressing of either of the two buttons on the home screen and sending the number of times each has been pushed back to the central console, detecting the pressing of a third button at the module, and determining how many times it was pressed over a short period of time, and utilizing the number of presses of the third button within a short period of time to allow the central data base and user interface to modify what is displayed on the button module screen to perform different functions, each function uniquely corresponding to the number of times that third button was pushed during that short period of time.
In another variation, the Method for recording multiple inventory items may generally comprise displaying a count upon a display screen of a module, wherein the count corresponds to a number of a physical inventory items adjacent to a location of the module, detecting a first input from a user upon a first user interface of the module, wherein the first input is indicative of a change in the count displayed upon the display screen, transmitting the first input from the module to a central console located remotely from the module, detecting for a second input from the user upon a second user interface of the module, wherein the second input corresponds to a particular function depending upon a number of times the second user interface is actuated by the user, transmitting the second input from the module to the central console such that the central console processes both the first input and the second, and modifying the count displayed upon the display screen via a modifying signal received by the module from the central console.
Two buttons 5 and 6 are provided, and in this application are labelled in large letters “Return” and “Take” respectively, since that is the most common function in an inventory application, But plus and minus signs are also shown for use in other administrative functions where the words Take and Return might be ambiguous. Alternatively, other symbols such as an up-arrow and down-arrow or other analogous signs may be used instead. A third button 7 is provided for administrative functions, and may be typically made smaller and less obvious than the main function buttons. Access to administrative functions could also be provided by holding down the Take and Return buttons simultaneously, but this functionality is less convenient. In the central console software, users may be restricted or excluded from accessing one or more of the administrative functions accessed through this administration function. If a user has one or more access privileges, and as described here where there are more than one admin functions, the desired function is accessed by pushing the button 7 a number of times in reasonably rapid succession. Each admin function is associated with a specific number of button pushes. Once in the administration function, a single push of the administration button accepts the function that has been performed, or if it is a multi-step function, moves on to the next step. At any point during execution of a function in the administration mode, pressing, and holding the administration button 7 will cancel the changes made, and return the user to the regular home screen.
Other variations of navigating through an administration feature may of course be utilized. Moreover, the devices described herein are not limited to the use of physical buttons or the like but such buttons are presented as examples. Other variations may include alternative mechanisms for actuating or activating features, e.g., touch-sensitive icons, capacitive sensing, etc.
All that a user, who has logged into the central console, has to do to record the Take (or Return) of an item is to press the Take or Return button, and the result of this action is shown in
The button modules are put in cycle-count mode 92 initially, so that the user, sees the current on hand quantity of nine in this example 91, and the units 43, and so with no further action, the user can immediately use the Take 6 or Return 5 buttons as shown in
The applications of the disclosed invention discussed above are not limited to any particular industries, but may include any number of industries and applications. Modification of the above-described methods and devices for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the arts are intended to be within the scope of this disclosure. Moreover, various combinations of aspects between examples are also contemplated and are considered to be within the scope of this disclosure as well.
