The present invention relates generally to tracking orders in production, and more particularly to techniques for applying customer-specific labels to an unprinted side of printed products.
Vendors of fine printed products traditionally manufactured printed products on offset printers by printing long runs of the same print job. Each print job required an expensive and time-consuming setup process, involving the separation of colors of the document into primary ink colors (such as Cyan, Magenta, Yellow, and Black), creation of aluminum printing plates for each ink color, and mounting and setup of the aluminum printing plates in the printing press. Traditionally, each print job corresponded to a document ordered by a single customer. Orders were tracked by print job and were simple to track because only a single print job was printed at a time, and each print job required physical setup of the printing press.
With the increasing preference of customers to shop online, at least one web-based customized printed product vendor (namely, www.vistaprint.com) now allows a customer to order small or large quantities of customer-personalized printed products. Vistaprint.com may aggregate the orders of personalized printed products from multiple customers into a single print job to achieve enhanced performance advantage by reducing or eliminating the setup time required between individual customers' print jobs. When large numbers of a customer's product is ordered, for example 250 business cards, the customer's business card design may be aggregated with hundreds of other customers' business designs into a composite print job, whereby each of the individual customers' designs are arranged and printed onto a single sheet of substrate. The print job is run to print 250 sheets. The stack of 250 printed sheets may then be cut into individual stacks of 250 business cards, each stack containing 250 identical business cards corresponding to the same customer, and each individual stack potentially corresponding to a different customer.
For orders of large quantities of small products (such as business cards or other printed products in which multiple designs may be simultaneously printed on a single substrate), customer orders may be tracked by keeping track of the position of the customer's design in the composite print design.
For orders of small quantities of larger products, such as orders of banners and posters in single-digit quantities (such as 1 or 2), order tracking becomes more difficult. One way of tracking a particular customer's order is to print an identifier such as a barcode together with the design. Because customers of fine printed products do not desire to have a barcode integrated into the design to be printed, the barcode (or other identifier) may be printed outside the printed design area. However, customers do not desire to receive a printed product that requires trimming.
Accordingly, it would be desirable to have a technique for printing and associating a barcode or other identifier unique to a customer or customer order, and allowing the barcode to stay with the product without requiring the customer to trim the product upon receipt of the product.
The present invention is directed at techniques for applying customer-specific labels to an unprinted or non-displayed side of printed products.
In an embodiment, a method for applying customer-specific labels to an unprinted side of printed products includes receiving a product design identifier corresponding to a customer's customized product design, printing the customer's customized product design in a no-trim area on a substrate, printing the product design identifier associated with the customer's customized product design on the substrate in an area outside the no-trim area, and prior to trimming away the no-trim area, scanning the identifier and printing a corresponding label containing customer order information and affixing the label to a different side of the substrate within the no-trim area of the printed design.
A more complete appreciation of this invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
Aspects of the invention include machines and methodologies for tracking customer orders of small quantities of printed products by applying customer-specific labels to an unprinted side of the ordered printed products.
It will be understood that, while the discussion herein describes applications of the invention to the printing of small quantities of customer-unique posters or banners, the invention is not so limited and is relevant to any application for tracking customer-specific orders of printed products.
The model further includes an Order Fulfillment component 104 which accepts orders from the Order Pipeline component 103 and prints and ships the orders to the customers. In an embodiment, the Order Fulfillment component 104 is a printing facility which prints the ordered items with the design specified in a customer's order.
In an embodiment, each of the Create Content component 101, the Generate Demand component 102, the Order Pipeline component 103, and Order Fulfillment component 104 is implemented at least in part using one or more computer systems, for example as illustrated and discussed in connection with
A system embodying the model of
Each of the Create Content component 101, the Generate Demand component 102, the Order Pipeline component 103, and Order Fulfillment component 104 described in
Each article of manufacture is printed in a targeted printing area of predefined dimensions. In an embodiment, the components 301 and 302 are combined with a layout component that defines the positions of each of the components within an area corresponding to a targeted printing area of a particular article of manufacture. For example, if the article of manufacture is a poster, the targeted printing area dimensions may be of a predefined size (for example, 12×18 inches, 24×36 inches, etc.). The template 300 is described in a template description 307 and is stored in a content database 202 preferably in a markup language format such as eXtensible Markup Language (XML) that can be processed by a web browser to render an image of the template on a computer display screen.
The stored content 202 (i.e., template description files 307 and associated components 301, 302) may be provisioned to a server 230 hosting a website. In one embodiment, as illustrated in
As illustrated, in this embodiment, the image of the printed poster has been updated to show how the poster will appear as the final product. In an embodiment, the user-inserted text in the text entry boxes 421-424 is returned to the server for conversion to an image and returned to the client computer for display in the user's browser. Alternatively, the user-entered text could be rendered directly by the design tool(s) 235 executing in the client browser.
In an embodiment, the design tool(s) 235 made available to the user via the customer's browser may allow the customer flexibility in positioning the text and graphic components of the engraving design. For example, the design tool(s) 235 made available to the user may allow the user to change the font of the text or move the text and/or graphic components of the design around within the targeted engraving area of the article. Since in the exemplary embodiment each of the text and graphic components that make up the design template are separate <XML>-defined components, user edits to any of the components is easily performed and the final composite design (i.e., <XML> document defining the customer's engraving design) is easily updated.
Once the user is satisfied with the design, the user may be presented with a checkout process, for example as begun in
Returning to
A “gang” is a grouping of individual customer's printed product designs that can all be printed together by the printing system to simultaneously print multiple different customer products in a single print job. The process of choosing which individual customer's printed product designs are part of a particular gang is called “ganging.” Ganging leads to efficiencies on equipment with high setup costs and low run costs. It spreads the setup cost of a print-and-cut job across many orders.
Gangs are generated by the ganging system 260 by filling up gang templates 207. In an embodiment, a gang template is a postscript file such as a .pdf file defining a plurality of pre-positioned empty cells that can be filled with individual postscript files (.pdf) such as individual customer designs 206. Gang templates are stored in non-transitory computer memory 265. The layout of a gang will depend on the type and size of the products to be printed.
For example, in an embodiment, the products to be printed in a composite print job are posters, which may come in various sizes (e.g., 24×18 inches, 24×36 inches, A1, and A2. In an embodiment, and with reference to
The cells 601 in a gang template 600 are filled according to an automated ganging algorithm, executed within the ganging system 260. The ganging system 260 selects a gang template 600 appropriate to a particular product (e.g., a 24×36 poster) and instantiates a gang template 207 corresponding to the correct product (e.g., a gang for 24×36 inch posters) to create a gang file 208. The ganging system 260 selects individual customer design items scheduled for production and begins filling corresponding cells of the associated gang 208 with the corresponding individual customer design files 206, as illustrated in
A gang file 208 is preferably filled to capacity (by filling each cell 801 with individual customer designs (.pdf) 206 of the same type of product) or may only partially fill the gang templates for other reasons (such as meeting critical shipping deadlines when insufficient orders exist to fill an associated gang template). In either case, when the ganging system 260 determines that all items that will be ganged together have been added to the associated gang file 208, the associated gang file 208 is saved. The result is a composite print file 207 to be printed by the printing system 280 onto a large substrate that is subsequently submitted to a cutting system 284 to separate the printed substrate into the individual printed documents corresponding to the individual customer's printed products. In this way, multiple different items that may be associated with multiple different orders and may contain multiple different content and may be simultaneously manufactured.
If the ordered quantity of finished products associated with an item document is more than one, then additional instances of the rendered item graphics PostScript file 611 may be placed in additional cells of the gang template 600 to manufacture the ordered quantity of products. Alternatively, or in addition, additional gang sheets may be printed and cut to manufacture the desired ordered quantity of any given item.
As previously described in conjunction with
The gang file 208 is sent to the printing system 280 (e.g., a printer or a printing press such as an offset press) and printed onto a substrate (such as, but not limited to, a sheet or roll of paper or vinyl) to produce a printed gang sheet 285. The printed gang sheet 285 is then conveyed along a conveyor to a cutting system 284 which cuts the printed gang sheet into individual finished products 286 (e.g., individual printed posters corresponding to individual customers' ordered posters printed with corresponding customer designs). The finished products 286 are sorted by a sorting system 290 into individual customer orders (which may include quantities of 1 or more of the same poster with the individual customer's design and/or additional ordered products). Additional post-print processing, such as affixation of labels or binning an item while waiting for additional items belonging to the order may be performed. The filled orders 291 are then passed by a scanner 292, which reads the barcode on the finished product(s), associates the finished product(s) with the customer, order, and shipping address, and instructs a labeler 294 to generate a label with the customer's shipping address. A packaging system 295 (automated or human) packages the customer's ordered products into the labeled package, and the products are ready to ship or deliver to the respective customers.
Customers of printed products prefer to receive a finished product rather than a product that requires some user effort to complete. When identifiers such as barcodes 621 are printed on the front side of a poster or banner and sent to the customer with the identifier still imprinted thereon, the customer may be less satisfied than if the identifier were affixed on the back or some other non-displayed side of the printed product. In the case of printed posters, it is seemingly more desirable to place the identifiers on the back side of the poster where viewers of the poster do not see the identifier. However, in a printing system which prints on one side only, or which takes additional operator steps to print the back side, other solutions are desired to remove the identifier from the front side and to attach an identifier to the back side.
In accordance with aspects of the invention, at least one scanner 282 and at least one subsequent labeler 283 are placed along a conveyor system between the printing system 280 and cutting system 284. The scanner(s) 282 read the identifiers 621, 622, 623, 624, 625 on the newly printed gang sheet and passes the read information to the Fulfillment Center server 240. The Fulfillment Center server 240 instructs the labeler to print each identifier read by the scanner 282 onto a corresponding label and signals the labeler to affix the label to an area on the underside of the gang sheet corresponding to the back side of the corresponding customer's printed poster as the printed gang sheet is conveyed past the labeler 283.
The printed gang sheets may further be printed with one or more bullseye indicator(s) 603 in predetermined locations on the gang sheet 285 outside the no-trim area. The bullseye indicator(s) 603 are detected by optical positioning detectors 760R, 760L. Detection of the bullseye indicator(s) 603 triggers actuation of the labeler tamper 752, which applies the printed label 711 to the underside of the printed gang sheet 285 in a predetermined position.
As a printed gang sheet 285 exits the printing system, it is conveyed by the conveyor 720 past the barcode scanners 740R, 740L and optical bulleye detector(s) 760R, 760L. A controller (not shown) controls the conveyor and hence the movement of the printed gang sheet 285 past the scanners 740R, 740L and optical bullseye detection system 760R, 760L. When the scanners 740R, 740L detect a barcode 621-625, they read the barcode ID and transmit it to the Fulfillment Center server 240, which then instructs the labeler 750R, 750L corresponding to the scanner to print the barcode onto a label 711 using label printer 754. When the optical bullseye detection system detects a bullseye indicator 603, it sends a signal to the labeler 750L, 750R, which triggers actuation of the labeler tamper 752, which applies the printed label 711 to the underside of the printed gang sheet 285 at a position corresponding to the backside of the corresponding printed poster area on the printed gang sheet (i.e., within the no-trim area of the corresponding gang cell 601).
In this way, unsightly product identifiers which are specific to a customer and the customer's product design and order, are removed from the front (displayed portion) of the printed product and affixed to a non-displayed area (e.g., the back side) of the printed product.
Computer 910 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 910 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CDROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 910. Computer storage media typically embodies computer readable instructions, data structures, program modules or other data.
The system memory 930 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 931 and random access memory (RAM) 932. A basic input/output system 933 (BIOS), containing the basic routines that help to transfer information between elements within computer 910, such as during start-up, is typically stored in ROM 931. RAM 932 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 920. By way of example, and not limitation,
The computer 910 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only,
The drives and their associated computer storage media discussed above and illustrated in
The computer 910 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 980. The remote computer 980 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 910, although only a memory storage device 981 has been illustrated in
When used in a LAN networking environment, the computer 910 is connected to the LAN 971 through a network interface or adapter 970. When used in a WAN networking environment, the computer 910 typically includes a modem 972 or other means for establishing communications over the WAN 973, such as the Internet. The modem 972, which may be internal or external, may be connected to the system bus 921 via the user input interface 960, or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 910, or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation,
The system and techniques just described have several advantages. First, multiple articles of manufacture may be engraved in a single engraving job, resulting in savings of time and operator attention for loading and unloading articles of manufacture into the engraving station for engraving. Second, the articles can be engraved through transparent packaging so that the articles need not be removed from their packaging prior to engraving, saving time, cost, and materials.
Those of skill in the art will appreciate that the invented method and apparatus described and illustrated herein may be implemented in software, firmware or hardware, or any suitable combination thereof. Thus, those of skill in the art will appreciate that the methods and systems described herein may be implemented by one or more processors executing computer-readable instructions being stored for execution on one or more computer-readable media. Alternative embodiments are contemplated, however, and are within the spirit and scope of the invention.
Although this preferred embodiment of the present invention has been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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