CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application
is a continuation-in-part of U.S. patent application Ser. No. 10/643,197, filed
Aug. 18, 2003, which is a continuation-in-part of U.S. patent application Ser.
No. 09/734,360, filed Dec. 1, 2000, now U.S. Pat. No. 6,650,225, which are
hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The present invention generally concerns material handling
systems, and more specifically, but not exclusively concerns an integrated
material handling systems with image display capabilities.
[0003] To
manage and control inventories, companies have been adopting automated light
directed inventory systems so as to reduce paperwork and increase efficiency. In
a usual light directed inventory system, pick/put to light (PTL) devices are
used to direct an operator's attention to a particular bin, shelf location, or
carousel in a warehouse. For instance, a light on the PTL device may illuminate
so that the operator knows which storage location needs to be serviced. Once at
the desired storage location, the operator can add (put), remove (pick) or count
the required items at the storage location.
[0004] Although PTL devices
have increased supply chain efficiency, there is always the risk that items may
be moved or bins can be rearranged so that the operator removes or adds the
wrong item. Since typical PTL devices at the most only display the desired
quantities of items, the operator can never be sure that the right item handled.
These and other types of handling errors can sometimes create dire circumstance,
especially in the medical industry. For example, if an employee of a
pharmaceutical company or hospital retrieves the wrong medication, a patient's
health may be placed in jeopardy.
[0005] Cost is always a concern for
any type of inventory system. Even though the PTL device systems improve
efficiency, the initial purchase price and maintenance costs associated the PTL
devices may offset any economic advantage gained by their installation. Typical
light directed inventory systems require a PTL device to be positioned at every
storage location so that an operator is able to identify the storage location.
Even in a modestly sized warehouse, the number of PTL devices needed to service
each location can become quite large. In addition, some storage locations are
not suitable to have PTL devices mounted close by.
[0006] To save cost,
some customers implement PTL systems in a piecemeal fashion such that some older
automated systems remain in use that need still need to interface with the new
PTL system. For example, a company may still continue to use a proprietary
inventory tracking system that is specifically tailored to their particular
needs, but the system needs to obtain servicing information about individual
servicing locations and/or items. Retrofitting the older system to the newer PTL
system through software changes can be difficult, if not nearly impossible, both
technically and economically speaking. For instance, the original programmers
for the system may no longer be available to implement the required changes.
[0007] Retrofitting PTL devices to current paper based or some automatic
systems can be problematic. For instance, the Food and Drug Administration (FDA)
requires that the barcode on packaging of products as well as the bin location
barcodes be scanned each time a drug or other medical product is handled so as
to reduce the chance of the wrong product being selected. Also, for safety, it
is sometimes required that the personnel scan a barcode on the packaging as well
as a second product identification barcode, located near the bin or on a
checklist, to confirm that the correct product was being handled. Typically, a
paper barcode that identifies the location is affixed to each storage bin or
storage location. These barcode labels can be damaged through everyday handling,
and as a result, need to be replaced. Location identification barcode labels by
their very nature need to be placed at or near the location that they identify.
Occasionally, barcode labels are placed at locations that make the labels
difficult to read, such as when labels are wrapped around irregularly shaped
poles. The nature of the location can make identification of the location
through a barcode a very daunting task. For example, the sites in which barcode
labels can be affixed are limited, which can lead to barcode labels being
located at locations that are less ideal for scanning, such as areas where the
barcode can become easily covered with dirt. These undesirable conditions can
lead to missed readings, which in turn hurts overall operational efficiency. As
should be realized, storage locations can be fixed or dynamic. Sometimes storage
bins are moved along an assembly line or carousel, or are normally fixed in
position, but moved periodically. If the bin is moved, or the warehouse is
rearranged, the paper barcode that identifies the location becomes obsolete and
has to be replaced with a new one. As a result, this can create many logistical
problems and creates room for error.
[0008] Besides tracking location,
other difficulties occur with barcode systems. Warehouse personnel experience
many difficulties when gathering and updating warehouse information.
Instructions on where and when to scan barcodes is limited so that mistakes are
often made. Aiming of the barcode scanner can present some difficulty, and this
miss aiming of the barcode scanner occasionally results in the scanning of the
wrong barcode. Personnel can also scan barcodes out of sequence, which can lead
to errors as well as reduce overall efficiency. As an example, a worker might
repeatedly scan the location barcode with the wrong belief that they are
scanning a product or some other type of barcode, which is actually located
elsewhere.
[0009] Systems have been proposed in which product
identification barcodes are displayed on televisions for identifying televisions
model or serial number for after market servicing purposes. While other systems
have been proposed that display product identification barcodes for bulk items
at point of service (POS) checkout terminals. However, none of these systems
address the unique problems associated inventory tracking for warehousing or
manufacturing environments. For example, none of these systems recognize the
problems associated with location related barcodes or the logistics involved in
tracking and updating barcodes for multiple locations. Moreover, none of these
systems consider the practical difficulties involved in scanning multiple
barcodes or environmental conditions that can affect scanning and lead to
errors.
[0010] Thus, there remains a need for improvement in this field.
SUMMARY
[0011] One form of the present invention concerns a
technique in which a pick/put to display device is provided with an image
display and an indicator light. The indicator light is illuminated to alert an
operator of a service to be performed on an item at a storage location. A
service instruction for the item is displayed on the image display, and an image
of the item is displayed on the image display.
[0012] Another form
concerns a technique for reducing the number of pick/put to display devices
needed for a storage area. A pick/put to display device with an image display is
positioned between a first storage location and a second storage location. A
first arrow pointing toward the first storage location and a first instruction
for servicing the first storage location are displayed on the image display. A
second arrow pointing toward the second storage location and a second
instruction for servicing the second storage location are displayed on the image
display.
[0013] A further form concerns a technique in which an operator
is alerted of a service to be performed on an item at a storage location with a
pick/put to device that has an image display. Instructions concerning the item
at the storage location are displayed on the image display. An image concerning
the item at the storage location is displayed on the image display.
[0014] A further form concerns a system that includes a pick/put to
display device that is positioned proximal a storage location. The pick/put to
display device includes a processor that is operable to download an instruction
and an image that concern an item associated with the storage location. Memory
is operatively coupled to the processor, and an indicator light is operatively
coupled to the processor to alert an operator of a servicing task for the item
at the storage location. An image display is operatively coupled to the
processor to display the instruction and the image concerning the item at the
storage location.
[0015] In another form, a system includes a first
storage location configured to store a first item and a second storage location
configured to store a second item. A pick/put to display device is positioned
between the first storage location and the second storage location to handle
service instructions for both the first storage location and the second storage
location. The pick/put to display device has an image display configured to
display a first arrow that points toward the first storage location and a second
arrow that points to the second storage location.
[0016] A further form
concerns a technique in which a pick/put to display device is provided that
includes an alert device and a display. The pick/put to display device is
located proximal to at least a first inventory location and a second inventory
location. Attention is drawn to the pick/put to display device by activating the
alert device. A first location barcode is displayed on the display that
identifies the first inventory location, and a second location barcode is
displayed on the display that identifies the second inventory location.
[0017] Another form relates to a technique in which a pick/put to
display device is provided that includes an alert device and a display.
Attention is drawn to the pick/put to display device by activating the alert
device. A first barcode is displayed on the display of the pick/put to display
device, and input is received with the pick/put to display device. A second
barcode is displayed on the display of the pick/put to display device after
receiving the input.
[0018] Still yet a further form concerns an
apparatus that includes a pick/put to display device located proximal to at
least one storage location. The pick/put to display device includes a processor
and an alert device operatively coupled to the processor. The alert device is
configured to draw attention to the pick/put to display device. An image display
is operatively coupled to the processor, and the image display is operable to
display at least one barcode related to the storage location. A server is
operatively coupled to the pick/put to display device, and the server is
operable to update the barcode by transmitting the update to the pick/put to
display device.
[0019] A further form relates to a system that includes
a storage system. The storage system includes at least a first storage location
and a second storage location. A pick/put to display device is positioned
proximal the first storage location and the second storage location. The
pick/put to display device includes means for drawing attention to the pick/put
to display device and means for displaying a first barcode related to the first
storage location and a second barcode related to the second storage location.
[0020] Other forms, embodiments, objects, features, advantages, and
aspects of the present invention shall become apparent from the detailed
drawings and description contained herein.
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