Integrated warehouse management system

• US 20060025883A1
• Filed: 07/30/2004
• Published: 02/02/2006
• Est. Priority Date: 07/30/2004
• Status: Abandoned Application

• Current Assignee: United Parcel Service Of America Incorporated (United Parcel Service Incorporated)
• Original Assignee: United Parcel Service Of America Incorporated (United Parcel Service Incorporated)
• Inventors: Reeves, Rob
• Application Number:
  US10/903,883
• Publication Number:
  US 20060025883A1
• Time in Patent Office: Days
• US Class Current: 700/216
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management

Abstract

The present invention is generally directed to an improved order fulfillment system that provides a convenient and inexpensive way of ensuring the accuracy of items being packed at a packing location, that captures order-related detail data on a carton level, and that provides a way of determining an accurate carton value which can be used for such things as computing an appropriate COD or insurance value for each carton to be shipped to a consignee. The invention further includes aspects related to the integration of such carton level detail data with carton tracking data that corresponds to the movement of each carton through a transportation network.

Claims

1. A method of fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into one or more cartons and shipped from said packing facility to a consignee, said method comprising the steps of:

receiving at a computer an order number associated with said order;

retrieving order information data associated with said order number, said order information data including a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a carton identifier with a carton, said carton to be used in the transporting of at least some of the ordered goods listed on said order;

receiving at said computer at least one item identifier, each said at least one item identifier associated with an item to be placed in said carton;

validating each said at least one item identifier against said order information data to determine whether said item corresponds to an ordered good that should be placed in said carton; and

for each said item determined to be valid, recording said item identifier in association with said carton identifier to provide an indication that said item was placed in said carton.

2. The method of claim 1, wherein said validating step comprises determining whether each said item is of a type listed on said order.

3. The method of claim 2, wherein, if said item is of a type listed on said order, said validating step further comprises determining whether placement of said item in said carton would cause the number of items of said type that have been packed to exceed the number of items of said type that are listed on said order.

4. The method of claim 1, further comprising the step of generating a signal indicating that said item should not be placed in said carton if said validating step determines that said item is not valid.

5. The method of claim 1, further comprising the step of displaying said order information data to an operator who is positioned to place said items into said carton.

6. The method of claim 1, further comprising the step of receiving at said computer a carton-complete signal indicating that no more items are to be placed in said carton.

7. The method of claim 6, further comprising the step of printing a carton label to be affixed to said carton, said carton label comprising said carton identifier.

8. The method of claim 7, wherein said carton identifier is encoded on said carton label in the form of a bar code.

9. The method of claim 6, wherein said carton-complete signal further indicates that said current order is to be closed.

10. The method of claim 6, wherein said carton-complete signal further indicates that said current order is to remain open so that one or more of said ordered goods remaining on said order can be packed into a next carton.

11. The method of claim 6, further comprising the steps of:

accessing cost data related to each of the items within said carton, said cost data comprising a monetary value associated with each said item; and

associating a carton value with said carton, said carton value at least partially based on a summation of the monetary values associated with each of the items within said carton.

12. The method of claim 11, wherein said carton value further includes an amount charged by a carrier to ship said carton to said consignee.

13. The method of claim 11, wherein said carton value is used to determine an amount that is charged to said consignee upon delivery of said carton.

14. The method of claim 11, wherein said carton value is used to determine an insurance value for said carton.

15. The method of claim 14, wherein said insurance value is determined only if said carton value exceeds a certain threshold.

16. The method of claim 1, further comprising the step of storing in association with said carton identifier an indication of at least one of (a) who packed said items in said carton and (b) when said items were packed in said carton.

17. A method of fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into at least two cartons and shipped from said packing facility to a consignee, said method comprising the steps of:

receiving at a computer an order number associated with said order;

retrieving order information data associated with said order number, said order information data comprising a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a first carton identifier with a first carton, said first carton to be used in the transporting of at least some of the items listed on said order;

receiving at said computer an item identifier for each said item to be placed in said first carton;

validating each said item to be placed in said first carton against said order information data to insure that each said item corresponds to an ordered good that should be placed in said first carton;

for each said item to be placed in said first carton that is determined to be valid, recording said item identifier in association with said first carton identifier;

receiving at said computer a carton-complete signal indicating that no more items are to be placed in said first carton, said carton-complete signal further indicating that said current order is to remain open so that one or more of said ordered goods remaining on said order can be packed into a second carton;

associating a second carton identifier with said second carton, said second carton to be used in the transporting of at least some of said remaining items listed on said order;

receiving at said computer an item identifier for each said item to be placed in said second carton;

validating each said item to be placed in said second carton against said order information data to insure that each said item corresponds to an ordered good that should be placed in said second carton; and

for each said item to be placed in said second carton that is determined to be valid, recording said item identifier in association with said second carton identifier.

18. A system for fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into two or more cartons and shipped from said packing facility to a consignee, said system comprising:

an order number capture device for capturing an order number associated with said order;

an order information storage device for storing data associated with said order;

an item capture device for capturing an item identifier associated with each item to be placed into one of said cartons; and

a computer system including one or more computers, said computer system configured for;

receiving said order number from said order number capture device;

retrieving order information data associated with said order number from said order information storage device, said order information data comprising a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a first carton identifier with a first carton, said first carton to be used in the transporting of at least some of the items listed on said order;

receiving an item identifier from said item capture device for each said item to be placed in said first carton;

validating each said item to be placed in said first carton against said order information data to insure that each said item corresponds to an ordered good that should be placed in said first carton;

for each said item to be placed in said first carton that is determined to be valid, recording said item identifier in association with said first carton identifier;

receiving a carton-complete signal indicating that no more items are to be placed in said first carton, said carton-complete signal further indicating that said current order is to remain open so that one or more of said ordered goods remaining on said order can be packed into a second carton;

associating a second carton identifier with said second carton, said second carton to be used in the transporting of at least some of said remaining items listed on said order;

receiving an item identifier from said item capture device for each said item to be placed in said second carton;

validating each said item to be placed in said second carton against said order information data to insure that each said item corresponds to an ordered good that should be placed in said second carton; and

for each said item to be placed in said second carton that is determined to be valid, recording said item identifier in association with said second carton identifier.

19. A method of fulfilling an order at a packing facility, said order comprising a list of ordered goods that are packed into one or more cartons and shipped from said packing facility to a consignee, said method comprising the steps of:

reading a carton identifier that is physically associated with one of said cartons;

accessing carton detail data associated with said carton using said carton identifier, said carton detail data comprising a list of items contained within said carton and a monetary value associated with each said item;

associating a carton value with said carton, said carton value at least partially based on a summation of the monetary values associated with each of the items within said carton;

associating a tracking identifier with said carton, said tracking identifier used for tracking the movement of said carton through a carrier'"'"'s transportation system as it is transported to said consignee;

storing said carton value and said carton identifier in association with said tracking identifier; and

providing said tracking identifier and said carton identifier to one or more authorized persons.

20. The method of claim 19, wherein said providing step comprises transmitting an email notification to said one or more authorized persons, said email notification comprising a link to tracking data associated with said tracking identifier and to carton detail data associated with said carton identifier, said carton detail data comprising a list of the items within said carton.

21. A system for fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into one or more cartons and shipped from said packing facility to a consignee, said system comprising:

a data capture device for reading a carton identifier that is physically associated with one of said cartons;

an order information storage device for storing data associated with said order; and

a computer system including one or more computers, said computer system configured for;

receiving said carton identifier from said data capture device;

retrieving from said order information storage device carton detail data associated with said carton using said carton identifier, said carton detail data comprising a list of items contained within said carton and a monetary value associated with each said item;

associating a carton value with said carton, said carton value at least partially based on a summation of the monetary values associated with each of the items within said carton;

associating a tracking identifier with said carton, said tracking identifier used for tracking the movement of said carton through a carrier'"'"'s transportation system as it is transported to said consignee;

storing said carton value and said carton identifier in association with said tracking identifier; and

providing said tracking identifier and said carton identifier to one or more authorized persons.

22. The system of claim 21, wherein said providing step comprises transmitting an email notification to said one or more authorized persons, said email notification comprising a link to tracking data associated with said tracking identifier and to carton detail data associated with said carton identifier, said carton detail data comprising a list of the items within said carton.

23. A system for fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into one or more cartons and shipped from said packing facility to a consignee, said system comprising:

an order number capture device for capturing an order number associated with said order;

an order information storage device for storing data associated with said order;

an item capture device for capturing an item identifier associated with each item to be placed into one of said cartons; and

a computer system including one or more computers, said computer system configured for;

receiving said order number from said order number capture device;

retrieving order information data associated with said order number from said order information storage device, said order information data comprising a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a carton identifier with a carton, said carton to be used in the transporting of at least some of the ordered goods listed on said order;

receiving at least one item identifier from said item capture device, each said at least one item identifier associated with an item to be placed in said carton;

validating each said item identifier against said order information data to determine whether said item corresponds to an ordered good that should be placed in said carton; and

for each said item determined to be valid, recording said item identifier in association with said carton identifier to provide an indication that said item was placed in said carton.

24. The system of claim 23, wherein said validating step comprises determining whether each said item is of a type listed on said order.

25. The system of claim 24, wherein, if said item is of a type listed on said order, said validating step further comprises determining whether placement of said item in said carton would cause the number of items of said type that have been packed to exceed the number of items of said type that are listed on said order.

26. The system of claim 23, wherein said computer system is further configured for generating a signal indicating that said item should not be placed in said carton if it is determined in said validating step that said item is not valid.

27. The system of claim 23, wherein said system further comprises a display device, and said computer system is further configured for displaying said order information data on said display device for an operator who is positioned to place said items into said carton.

28. The system of claim 23, wherein said computer system is further configured for receiving a carton-complete signal indicating that no more items are to be placed in said carton.

29. The system of claim 28, wherein said system further comprises a printer device, and said computer system is further configured for printing a carton label to be affixed to said carton, said carton label comprising said carton identifier.

30. The system of claim 28, wherein said carton-complete signal further indicates that said current order is to be closed.

31. The system of claim 28, wherein said carton-complete signal further indicates that said current order is to remain open so that one or more of said ordered goods listed on said order can be packed into a next carton.

32. The system of claim 28, wherein said computer system is further configured for:

accessing cost data related to each of the items within said carton, said cost data comprising a monetary value associated with each said item; and

associating a carton value with said carton, said carton value at least partially based on a summation of the monetary values associated with each of the items within said carton.

33. The system of claim 32, wherein said carton value further includes an amount charged by a carrier to ship said carton to said consignee.

34. The system of claim 32, wherein said carton value is used to determine an amount that is charged to said consignee upon delivery of said carton.

35. The system of claim 32, wherein said carton value is used to determine an insurance value for said carton.

36. A method of fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into one or more cartons and shipped from said packing facility to a consignee, said method comprising the steps of:

receiving at a computer an order number associated with said order;

retrieving order information data associated with said order number, said order information data comprising a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a carton identifier with a carton, said carton to be used in the transporting of at least some of the ordered goods listed on said order;

receiving at said computer at least one item identifier, each said at least one item identifier associated with an item to be placed in said carton;

validating each said at least one item identifier against said order information data to determine whether said item corresponds to an ordered good that should be placed in said carton;

for each said item determined to be valid, recording said item identifier in association with said carton identifier to provide an indication that said item was placed in said carton;

receiving at said computer a carton-complete signal indicating that no more items are to be placed in said carton;

associating a tracking identifier with said carton, said tracking identifier used for tracking the movement of said carton through a carrier'"'"'s transportation system;

storing said tracking identifier in association with said carton identifier; and

providing said tracking identifier and said carton identifier to at least one authorized person.

37. The method of claim 36, wherein said providing step comprises transmitting an email notification to said at least one authorized person, said email notification comprising a link to tracking data associated with said tracking identifier and to carton detail data associated with said carton identifier, said carton detail data comprising a list of the items within said carton.

38. A system for fulfilling an order at a packing facility, said order comprising a list of ordered goods that are to be packed into one or more cartons and shipped from said packing facility to a consignee, said system comprising:

an order number capture device for capturing an order number associated with said order;

an order information storage device for storing data associated with said order;

an item capture device for capturing an item identifier associated with each item to be placed into one of said cartons; and

a computer system including one or more computers, said computer system configured for;

receiving said order number from said order number capture device;

retrieving order information data associated with said order number from said order information storage device, said order information data comprising a list of said ordered goods that are to be transported from said packing facility to said consignee;

associating a carton identifier with a carton, said carton to be used in the transporting of at least some of the ordered goods listed on said order;

receiving at least one item identifier from said item capture device, each said at least one item identifier associated with an item to be placed in said carton;

validating each said item identifier against said order information data to determine whether said item corresponds to an ordered good that should be placed in said carton;

for each said item determined to be valid, recording said item identifier in association with said carton identifier to provide an indication that said item was placed in said carton;

associating a tracking identifier with said carton, said tracking identifier used for tracking the movement of said carton through a carrier'"'"'s transportation system;

storing said tracking identifier in association with said carton identifier; and

providing said tracking identifier and said carton identifier to at least one authorized person.

39. The system of claim 38, wherein said providing step comprises transmitting an email notification to said at least one authorized person, said email notification comprising a link to tracking data associated with said tracking identifier and to carton detail data associated with said carton identifier, said carton detail data comprising a list of the items within said carton.