Patent Application
20240161059
The disclosure is directed, in general, to supply chain management systems and methods; and, in particular, to radio frequency identification (RFID) based enterprise inventory management systems and methods.
Supply chain management is utilized to manage the storage and movement of goods, including raw materials, work-in-process, and finished goods, from the point of origin to points of purchase or consumption. Reasons to accurately account for articles in an enterprise include tracking shipments from a bulk vendor, reduction of inventory for just-in-time manufacturing operations, reduction of shrinkage due to breakage and pilfering, managing claims against a manufacturer, and validating sales and other dispositions of articles. With continued growth and emphasis on efficiency of enterprises such as retail and warehousing operations, for both online commerce and physical brick-and-mortar stores, it is increasingly important to account for and track the actual inventory at each enterprise location in real time.
An enterprise can include hundreds of warehouses and retail locations, each of which may contain hundreds of thousands of articles that require tracking, and collectively require tens of millions of articles to be tracked throughout the enterprise. Historically, it was sufficient to perform inventory operations on a monthly or annual basis. Such inventory operations were often performed manually or by optically scanning barcodes, sometimes even relying on paper notebooks to tally results. The scale of many modern enterprises, however, magnifies the inefficiencies of performing frequent inventory management processes using primitive techniques.
Technologies have evolved to more precisely identify inventory items. In particular, radio frequency identification (RFID) uses electromagnetic fields to automatically identify and track tags attached to objects. An RFID tag consists of a tiny radio transponder; a radio receiver and transmitter. When triggered by an electromagnetic pulse from a nearby RFID interrogator, the tag transmits digital data, usually an identifying inventory number, back to the RFID interrogator; the number can be used to inventory goods. Periodically registering the identities and numbers of items with an enterprise, however, is insufficient to meet the demands of modern commercial enterprises, such as reduced overhead and high accuracy. Accordingly, there is a need in the art for novel enterprise inventory management systems and methods that improve the state of the art through the use of RFID technology.
To improve the state of the art, disclosed herein is an enterprise inventory management system, and methods of use thereof, utilizing novel functionalities. The system includes a centralized global inventory database subsystem for cataloging a plurality of inventory items from a plurality of remote physical locations, each of the items identified by at least a unique identification code (e.g., an Electronic Product Code (EPC)); and, a plurality of localized radio frequency identification (RFID) interrogator subsystems associated with a corresponding plurality of remote physical locations, wherein each of the localized RF interrogator subsystems is operative to read RFID tags associated with ones of the plurality of inventory items located at its associated physical location, wherein each of the RFID tags is programmed with at least a unique identification code for its associated item. Each of the localized RFID interrogator subsystems is operable to: first, receive, from the centralized global inventory database subsystem, a plurality of unique identification codes associated with a like plurality of items; second, scan the RFID tags of ones of the plurality of inventory items contained at its associated physical location; and, third, report, to the centralized global inventory database subsystem, whether any of the plurality of inventory items is present at its associated physical location.
In an exemplary embodiment, each of the localized RFID interrogator subsystems is further operable to receive an Advance Shipping Notice (ASN) from the centralized global inventory database subsystem, wherein the ASN identifies a plurality of new inventory items to be received at the physical location associated with the localized RFID interrogator subsystem; and, scan the RFID tags of all items subsequently contained in a shipment subsequently received at the associated physical location, whereby receipt of all expected items identified in the ASN can be verified.
In an exemplary embodiment, each of the localized RFID interrogator subsystems is further operable to emit an audible tone only the first time an inventory item associated with any of the unique identification codes is scanned, whereby the presence or absence of ones of the plurality of inventory items can be confirmed when all inventory items at the physical location have been scanned and no further audible tone is emitted. In such embodiments, the physical location is the sales floor of a store. In a related embodiment, each of the localized RFID interrogator subsystems is further operative to scan items contained within a second physical location; in such embodiments, the second physical location is a back stock area of said store.
In an exemplary embodiment, the global inventory database subsystem updates the physical location of ones of the plurality of items in response to the receipt of a report from a localized RFID interrogator subsystem. In a related embodiment, the global inventory database subsystem maintains at least one attribute for each of the plurality of inventory items, wherein an attribute defines a status of an associated item, and wherein each localized RFID interrogator is further operative to encode an RFID tag associated with an inventory item with the status. The status of an associated item can indicate, for example, that an inventory item is available, reserved, sold, damaged, on display, or unsalable.
The foregoing has broadly outlined the essential and optional features of the various embodiments that will be described in detail hereinafter; the essential and certain optional features form the subject matter of the appended claims. Those skilled in the art should recognize that the principles of the specifically-disclosed systems and methods can be utilized as a basis for similar or functionally-equivalent systems and methods that may be within the scope of the appended claims.
For a complete understanding of the present disclosure, reference is now made to the following detailed description taken in conjunction with the accompanying drawings, in which:
Unless otherwise indicated, corresponding numerals and symbols in the different figures generally refer to corresponding parts or functions.
Radio frequency identification (RFID) systems utilize RFID reader/writer devices, also known as RFID interrogators, and RFID tags. Such systems can be used to locate and identify items to which the tags are attached; they are particularly useful in product-related industries for tracking inventory items through manufacture, distribution and sale. An RFID tag can be affixed to an individual product, its package, or a container for multiple products or packages.
An RFID tag typically includes an antenna section, a radio section, a power-management section, and frequently a non-volatile memory. Some RFID tags include an energy storage device, such as a battery. Tags for products for sale, however, are typically powered solely by the RF signal they receive; such tags do not include an energy storage device (e.g., a battery), but are passive tags.
RFID inventory management techniques utilize an RFID interrogator to inventory one or more items having RFID tags, where inventorying involves at least singulating a tag and receiving a unique identifier from the tag. “Singulated” is defined as an RFID interrogator singling-out one tag, potentially from among multiple tags. “Identifier” is defined as a number identifying the tag or the item to which the tag is attached, such as a tag identifier (TID) or an electronic product code (EPC). In typical systems, an RFID interrogator transmits a modulated RF command, receives a tag reply, and transmits an RF acknowledgement signal responsive to the tag reply. A tag that senses the interrogating RF wave responds by transmitting back another RF wave; the tag either generates the transmitted RF wave or reflects back a portion of the interrogating RF wave in a process known as backscatter. The reflected-back RF wave can encode data stored in the tag, such as the EPC. The response is decoded by the RFID interrogator, and can thereby identify, count, or otherwise interacted with the associated item; the decoded data can denote a serial number, a price, a date, a time, a destination, an encrypted message, an electronic signature, or any other attribute or status or combinations thereof. The systems and methods described hereinafter make use of such data to improve the operation and use of enterprise inventory management systems.
Turning now to
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The novel methods for enterprise inventory management will be described with reference to the global inventory database subsystem 110 and RFID interrogator subsystem 120 illustrated in
To fully understand the novel inventory management methods, and advantages thereof, disclosed herein, it is important to understand the basics of item-level inventory practices throughout the distribution chain. Conventionally, shipping verification for items is performed employing just a sampling process and is often performed by a manual count of shipped items. Such practices require substantial manpower and time; it is not an efficient utilization of human resources. While a stock keeping unit (“SKU”) associated with each item can identify many attributes (e.g., manufacturer, description, material, size, color, etc.), it does not uniquely identify an item; each item can be uniquely identified, however, through use of an electronic product code (“EPC”), which is a union of an SKU and a serial number. The adoption and use of EPCs has provided the basis for many new and useful methods to intelligently manage the inventory of small to global enterprises.
In a warehouse (also referred to as a “distribution center”), an inventory management system must perform many functions, including receiving, inbound auditing, pick processing, pack auditing, and shipping verification. Upon receiving a shipment, inbound auditing can confirm whether all expected items are contained in the shipment. An RFID interrogator can read an RFID tag on each container, or RFID tags of each item in a container, to be checked against an advance shipping notice (“ASN”); any discrepancies between what is received and the ASN can be reported to the inventory management system.
An inventory management system manages all orders from a vendor/supplier. An order is placed on a supplier, for example, for a particular number of articles with a certain mix of styles, sizes and colors. There may be a large number, perhaps millions, or articles of different sizes, colors, brands, etc., in a warehouse at any point in time. Staff selectively select items in a pick process, conventionally from a paper pick list, and load the items on a transport mechanism (e.g., a conveyor belt) for delivery to another part of the warehouse for pack auditing, which was performed in conventional practice without RFID item-level tracking.
If an RFID interrogator is used to track and identify items, a pick order, as distinguished from a pack order, can be downloaded into the RFID interrogator from the inventory management system. For example, a large number of jackets, maybe thousands, may be selectively picked, and will be packed, perhaps 20 jackets per container, and transported by truck to various warehouses around the country. The pack auditing process audits the accuracy of the pick process.
An RFID tag of a pack (or container) can be scanned with an RFID interrogator and identification of all the items that should be placed in the pack can be downloaded from the inventory management system. The RFID interrogator can then be used to scan all the items on the transport mechanism to determine if there are any missing or incorrect items; the missing items can then be withdrawn from inventory to complete the order.
A pack allocation can identify the particular items and quantities in a pack. A container should thus contain a certain number and type of each item. As the container is packed, the assortment is verified, such as how many of a particular size, color, etc., are in the container. An audit can then be performed against a manifest, such as what types and quantities should be in the container. Recalling that an RFID interrogator reads an electronic product code, a label on the container can be taken to identify the SKUs and item serial numbers in the container, and even to know what particular items are in the container by EPC number. The data for each container can then be uploaded to the inventory management system. The result is one EPC of any article in a container can be employed with the inventory management system to identify the remaining articles in the container. The container is then sealed for shipment to a retail outlet or the next location on the distribution chain.
The containers can next be transported to shipping verification. The number of containers that are to be included in a shipment is known by the inventory management system, including the individual EPCs or identifiers of the items that are in each container. The inventory management system can identify which particular container(s) should be on a truck for each ASN. An ASN can be used as a shipping verification that indicates that a particular ASN includes a certain number of containers, and identifiers therefor. The containers themselves may/may not include RFID tags and ASNs, as compared to the items therein. As the containers pass through a portal, it may only be necessary to read one of the RFID tags of the items in each container because the items in each container are associated with each other and the corresponding container.
As the containers are loaded onto a truck, the number of containers for the shipment and the items therein can be verified with another RFID interrogator. The inventory management system needs to only read at least one RFID tag of an item in each container, and it can now identify all the items therein. The association of the items with a container alleviates the need to read all of the RFID tags of the items in a container, which could be very time consuming for containers holding many items. An item to container association is constructed by the inventory management system, and the ASN to container association can also be provided by the inventory management system.
The foregoing inventory process steps of receiving, inbound auditing, pick verification, pack auditing and shipping verification, can be performed whether RFID interrogators are used or not; the accuracy of each process, however, is typically increased from 75-90% to 90% or better when using RFID item-level inventory management systems and processes as described herein, typically resulting in a reduction (e.g., 30%) of claims against manufacturers, a reduction (e.g., 50%) of mis-shipments to retail organizations, and a reduction (e.g., 10-20%) of inventory loss and shrinkage.
Another inventory management process is omnichannel packing, which is typically executed in a warehouse/distribution center of a retail enterprise. When a customer places an order, which may be an online order, the retail enterprise may prefer that the customer pick up the order in one of its numerous physical stores, which thereby exposes the customer to further sales opportunities, or that the item be first shipped with other items to a retail store or distribution center proximate the purchaser, and then shipped from there to the purchaser. Whereas the retail enterprise already regularly ships new inventory to each physical store, it can save certain shipping expenses by adding the particular item to a scheduled shipment to a physical store proximate the customer's location. In such cases, an omnichannel pick process is employed wherein, during the pick process at the warehouse, the particular item is designated with a “reserve” status and is packed and isolated, typically in a plastic bag or other container, and provided with a customer identification tag; the reserved item is then included with the next general inventory shipment to the physical store proximate the customer's location.
When a shipment is received at a retail location, the containers are unloaded, and the RFID tags are again scanned utilizing an RFID interrogator; the RFID identities can be reconciled against an ASN. If the RFID tag of a particular item identifies it as “reserved”, or it is identified on the ASN as such, it is set aside for customer pick-up or further shipment rather than being added to the general inventory. A challenge for RFID inventory management systems can be deciphering between existing items and new items in a shipment. To address that problem, the unique RFID identifiers for existing items can be downloaded to the RFID interrogator from the inventory management system; when the interrogator scans items, it can provide an audible alert for each RFID tag that is read, ignoring those of the existing items. When the audible alerts cease, the store personnel can be relatively assured that all new items have been scanned; the identities of those items can then be reconciled against an ASN, either by the RFID interrogator device or a server of the inventory management system. If the receiving operation identifies unexpected items (i.e., not including in the ASN), or fails to identify expected items, they can be indicated in a delivery accuracy report sent to the inventory management system.
Referring now to
In a second example, if an inventory of a sales floor is to be performed, an expected list of items can be downloaded from the global inventory database subsystem 110 to the RFID interrogator subsystem 120, and all items on the sales floor can be scanned. A display on a handheld RFID interrogator can display the number of expected items and the number of those that have been counted; the inventor process is considered complete when all expected items have been counted or when no further audible tones are emitted. If the count is less than the number of expected items, then it is known that the items not identified are not on the sales floor (an item may have been stolen or improperly moved to back stock); if additional items were identified, they may have been returned and not properly added to inventory or may have been improperly moved from back stock to the sales floor. The physical location and/or attributes/statuses for all scanned items can then be updated in the global inventory database subsystem 110; in addition, an RFID interrogator may update the tag of an item to change an attribute or status, such as changing the status of a returned item from “sold” to “available”, or to update the physical location where the item should be located.
In another example, a “pick list” can be generated by the inventory management system; the list can identify, for example, items to be moved from back stock based on business rules, such as what quantity of each size of an item is to be maintained on a sales floor. To make in-store replenishment work properly, a reference shelf capacity, or planogram, is employed, and the inventory management system maintains information on the real-time display quantity per item. If the sales floor stock falls below the shelf capacity, in-store replenishment is triggered, and the article is automatically put on the in-store pick list. For this process, a pick list, with the unique identities of items in back stock to be moved, can be downloaded to a handheld RFID interrogator for use by a sales associate in locating the items in the back stock for moving to the sales floor, according to the process illustrated in
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In the embodiment illustrated in
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One or more performance metrics for the global inventory database subsystem 110 are generated based on the receipt of the data from the simulated RFID interrogator subsystem (step 740). In response to the one or more performance metrics, the generation rate of data by the first instance of the simulated RFID interrogator subsystem can be altered, or additional instances of the simulated RFID interrogator subsystem can be instantiated, to generate additional data, until a performance metric of the global inventory database system reaches a predefined value (step 750). The method can further include the step 745 wherein, in response to the performance metrics, the computing resources associated with the global inventory database subsystem are modified. The method can also include a step 760, wherein a report is generated of the one or more performance metrics correlated to data received from one or more instances of the simulated RFID interrogator subsystem.
For global enterprises which often have hundreds of manufacturing facilities, warehouses, distribution centers, and/or retail stores, it is important to properly plan and optimize an inventory management system prior to implementation. The system and method described can facilitate doing so. Each instance of a simulated RFID interrogator subsystem can generate data representative of expected data from one or more real-world physical facilities. For example, the expected data can be a function of the size of each of the one or more real-world physical facilities; e.g., the number of inventory items for a particular physical location is typically a function of the square footage. The expected data can also be a function of the time zone where each of the one or more real-world physical facilities is located, thus allowing for the system to anticipate and accommodate different data rates based on different working hours. Similarly, a performance metric can, for example, represent an instantaneous value or an average value associated with a predefined temporal period; the temporal period might be used as a control for a maximum data throughput or an average value over a period of hours, days or weeks, thus accommodating different policies for performing inventory procedures. For example, based on the anticipated data for an enterprise exceeding a predefined value, the computing resources associated with the global inventory database subsystem can be modified (e.g., increased) or the inventory policies of the enterprise can be altered to reduce the peak data rate (e.g., by having different physical locations perform inventory operations on different days or at different times).
The foregoing has described various embodiments of enterprise inventory management systems and methods of operation thereof; and, in particular, to systems utilizing RFID interrogators. The disclosed systems and methods are provided to illustrate the essential and optional features and functions, and those skilled in the art may conceive of alternatives or modifications that do not depart from the principles of the invention as encompassed by the appended claims, and that such alternatives or modifications may be functionally equivalent.
This application is a Continuation of U.S. application Ser. No. 15/929,807, entitled “RFID Enterprise Inventory Management Systems And Methods”, filed May 22, 2020, which claims the benefit of U.S. Provisional Application No. 62/851,456, entitled “Inventory Management System and Method of Operating the Same,” filed May 22, 2019, which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62851456 | May 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15929807 | May 2020 | US |
| Child | 18449217 | US |
