Reorder system for use with an electronic printing press

• US 6,246,993 B1
• Filed: 10/29/1997
• Issued: 06/12/2001
• Est. Priority Date: 10/29/1997
• Status: Expired due to Term

• Current Assignee: RR Donnelley & Sons Company
• Original Assignee: RR Donnelley & Sons Company
• Inventors: Gill, Robert W., Kitzmiller, Roger, Warmus, James L., Dreyer, Mark G.
• Primary Examiner(s): Cosimano, Edward R.
• Application Number:
  US08/959,994
• Time in Patent Office: 1,322 Days
• Field of Search: 53/52, 531/47, 534/43, 534/47, 535/40, 270/1.01, 364/148.01, 364/468.01, 364/468.03, 364/468.05, 364/468.06, 364/468.15, 364/468.16, 364/468.17, 705/8, 705/9, 705/401, 705/402, 705/410, 700/28, 700/95, 700/99, 700/100, 700/108, 700/110
• US Class Current: 705/7.26
• CPC Class Codes: G06F 40/10 Text processing natural language analysis G06F40/20; semantic analysis G06F40/30; processing or translation of natural language G06F40/40
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06316 Sequencing of tasks or work

Abstract

A method of, and system for, selectively reordering the reprinting of books on one or more electronic presses are disclosed. In one embodiment, sensors and a processor are utilized to reorder books fouled by an auxiliary device. In another embodiment, a sensor, and a global processor in communication with first and second local processors respectively associated with first and second printing presses are utilized to reorder books on one of the first and second printing presses selected to minimize processing time and/or to maximize postal rate discounts. In another embodiment, a sensor and a press processor are utilized to reorder errored books by inserting a book back into a stream of books being printed if re-printing the book with the stream entitles the errored book to a predefined postal discount.

Claims

1. For use with an auxiliary device located downstream from a first printing press printing a stream of books with fixed and variable data, the auxiliary device being adapted to perform a process on books printed by the first printing press, a reorder system comprising:

a first sensor located downstream of the auxiliary device to monitor books output by the auxiliary device; and

a local processor associated with the auxiliary device, the local processor being in communication with the first sensor and being adapted to recognize an errored book based at least in part on an output of the first sensor; and

,

a global processor in communication with the local processor, the global processor being responsive to a communication from the local processor identifying the errored book to cause the errored book to be reprinted with fixed and variable data after at least one other book in the stream of books has been printed by the first printing press.

2. A system as defined in claim 1 wherein the local processor identifies a missing book by comparing the output of the first sensor to a list of expected books.

3. A system as defined in claim 1 further comprising a log identifying the variable data and the fixed data to be used to reprint the errored book.

4. A system as defined in claim 1 wherein the auxiliary device comprises one of the group comprising:

a folding device, a trimming device, a weighing device, a binding device, a gluing device, a dot wacker, a tip-on, a card feeder, a strapper, and a mechanical co-mailer.

5. A system as defined in claim 1 further comprising a press processor associated with the first printing press for controlling the operation thereof.

6. A system as defined in claim 5 wherein the global processor is in communication with the press processor for causing the first printing press to reprint the errored book in response to signals received by the global processor from the local processor.

7. A system as defined in claim 1 further comprising a second sensor located upstream of the auxiliary device.

8. A system as defined in claim 7 wherein the local processor identifies a missing book by comparing the output of the first sensor with an output of the second sensor.

9. A system as defined in claim 7 wherein the first and second sensors comprise barcode readers.

10. A system as defined in claim 7 wherein the first and second sensors comprise electronic eyes on a positive position device.

11. A system as defined in claim 7 wherein the first and second sensors comprise part of an optical recognition system.

12. A system as defined in claim 1 further comprising a second printing press, the global processor being in selective communication with a first press processor associated with the first printing press and with a second press processor associated with the second printing press, wherein the global processor selectively causes the errored book to be reprinted on one of the first and second printing presses.

13. A system as defined in claim 12 wherein the global processor selects the one of the first and second printing presses to minimize processing time.

14. A system as defined in claim 12 wherein the global processor selects the one of the first and second printing presses to maximize a postal rate discount.

15. A system as defined in claim 14 wherein the global processor selects the one of the first and second printing presses by comparing postal information for the errored book to postal information of a book to be printed by the first printing press.

16. A system as defined in claim 15 wherein the global processor selects the one of the first and second printing presses by comparing postal information for the errored book to postal information of a book to be printed by the second printing press.

17. A system as defined in claim 1 wherein the local processor identifies errored books in a log and, after the stream of books has been processed by the auxiliary device, the global processor causes the errored books to be reprinted in accordance with instructions input by the user.

18. A system as defined in claim 17 further comprising a graphical user interface, the graphical user interface displaying data associated with the errored books and permitting a user to enter instructions specifying how the errored books are to be reprinted.

19. A system as defined in claim 18 wherein the graphical user interface permits the user to specify the printing press to reprint the errored books.

20. A system as defined in claim 18 wherein the graphical user interface permits the user to group the errored books into discrete jobs.

21. A system as defined in claim 20 wherein the processor is adapted to process as a separate job any errored books not grouped into a discrete job by the user.

22. For use with a weight measuring device located downstream from a first printing press printing a stream of books, the weight measuring device being adapted to weigh books printed by the first printing press, a reorder system comprising:

a first sensor located upstream of the weight measuring device to monitor books entering the weight measuring device;

a processor in communication with the first sensor for identifying each book input into the weight measuring device, the processor being adapted to calculate an expected weight range for the identified book, and to cause the identified book to be automatically reprinted with fixed and variable data if a measured weight of the identified book developed by the weight measuring device falls outside the expected weight range.

23. A system as defined in claim 22 further comprising a log identifying the variable data and the fixed data to be used to reprint the identified book.

24. A system as defined in claim 22 wherein the expected weight is developed by summing the expected weights of at least two factors in the group comprising:

a total paper weight for the identified book, a cover weight for a cover of the identified book, an insert weight for an insert to the identified books, an envelope weight for an envelope associated with the identified book, and a kit weight for a kit associated with the identified book.

25. A system as defined in claim 24 wherein the expected weight is further developed by adding in a weight tolerance for each of the as least two factors.

26. A system as defined in claim 25 wherein the processor comprises a global process and a local processor, the local processor being associated with the weight measuring device.

27. A system as defined in claim 26 further comprising a press processor associated with the first printing press for controlling the operation thereof.

28. A system as defined in claim 27 wherein the global processor is in communication with the press processor for causing the first printing press to reprint the identified book in response to signals received by the global processor from the local processor.

29. A system as defined in claim 26 further comprising a second printing press, the global processor being in selective communication with a first press processor associated with the first printing press and with a second press processor associated with the second printing press, wherein the global processor selectively causes the identified book to be reprinted on one of the first and second printing presses.

30. A system as defined in claim 29 wherein the global processor selects the one of the first and second printing presses to minimize processing time.

31. A system as defined in claim 29 wherein the global processor selects the one of the first and second printing presses to maximize a postal rate discount.

32. A system as defined in claim 31 wherein the global processor selects the one of the first and second printing presses by comparing postal information for the identified book to postal information of a book to be printed by the first printing press.

33. A system as defined in claim 32 wherein the global processor selects the one of the first and second printing presses by comparing the postal information for the identified book to postal information for a book to be printed by the second printing press.

34. For use with a first and a second printing press, a first press processor being associated with the first printing press and a second press processor being associated with the second printing press, a reorder system comprising:

a global processor in selective communication with each of the first and second press processors; and

a sensor located downstream of the first printing press for monitoring books output by the first printing press, the sensor being in communication with the first press processor whereby the first press processor can detect errored books and wherein, the first press processor notifies the global processor of the errored book and the global processor causes one of the first and second presses to reprint the errored book.

35. A system as defined in claim 34 wherein the global processor selects the corresponding one of the first and second printing presses to minimize processing time.

36. A system as defined in claim 34 wherein the errored book comprises fixed and variable data, and further comprising a log identifying the variable data to be used to reprint the errored book.

37. A system as defined in claim 34 wherein the global processor causes one of the first and second printing presses to reprint the errored book within a stream of books already being printed.

38. A system as defined in claim 34 wherein the sensor comprises a barcode reader.

39. A system as defined in claim 34 wherein the sensor comprises electronic eyes on a positive position device.

40. A system as defined in claim 34 wherein the sensor comprises part of an optical recognition system.

41. A system as defined in claim 34 wherein the global processor selects the corresponding one of the first and second printing presses to maximize a postal rate discount.

42. A system as defined in claim 41 wherein the global processor selects the one of the first and second printing presses by comparing postal information for the errored book to postal information of a book to be printed by the first printing press.

43. A system as defined in claim 42 wherein the global processor selects the one of the first and second printing presses by comparing the postal information for the errored book to postal information of a book to be printed by the second printing press.

44. A system as defined in claim 34 wherein the global processor identifies errored books in a log and, after the first and second presses have finished printing, causes at least one of the first and second printing presses to reprint the errored books in accordance with instructions input by the user.

45. A system as defined in claim 44 further comprising a graphical user interface, the graphical user interface displaying data associated with the errored books and permitting a user to enter instructions specifying how the errored books are to be reprinted.

46. A system as defined in claim 45 wherein the graphical user interface permits the user to specify the printing press to reprint the errored books.

47. A system as defined in claim 45 wherein the graphical user interface permits the user to group the errored books into discrete jobs.

48. A system as defined in claim 47 wherein the global processor is adapted to process as a separate job any errored books not grouped into a discrete job by the user.

49. A reorder system for use in a printing facility having first and second printing presses, each of the first and second printing presses being adapted to print books including both variable and fixed data, the reorder system comprising:

a first sensor located to monitor books output by the first printing press; and

a first press processor associated with the first printing press and being in communication with the first sensor to recognize errored books, the first press processor being adapted to control a printing order of books in a stream of books to be printed by the first printing press in a given job, wherein, upon recognizing an errored book, the first press processor causes the first printing press to insert the errored book into the stream of books to be printed after at least one other book has been printed if re-printing the errored book with the stream will entitle the errored book to at least a first predefined postal discount.

50. A system as defined in claim 49 further comprising a global processor in selective communication with the first press processor, wherein, if the first press processor determines that re-printing the errored book with the stream will not entitle the errored book to at least the first predefined postal discount, the first press processor identifies the errored book to the global processor.

51. A system as defined in claim 50 wherein the global processor instructs a second press processor associated with the second printing press to cause the second printing press to re-print the errored book if re-printing the book on the second printing press will entitle the errored book to at least a second predefined postal discount.

52. A system as defined in claim 51 wherein the first and second postal discounts are identical.

53. A system as defined in claim 51 wherein the first and second postal discounts are different.

54. A system as defined in claim 49 further comprising a second sensor located to monitor books output by the second printing press, and a second press processor associated with the second printing press and being in communication with the second sensor to recognize errored books, the second press processor being adapted to control a printing order of books in a stream of books to be printed by the second printing press in a given job, wherein, upon recognizing an errored book, the second press processor causes the second printing press to insert the errored book into the stream of books to be printed if re-printing the errored book with the stream will entitle the errored book to at least a second predefined postal discount.

55. A system as defined in claim 54 further comprising a global processor in selective communication with the first and second press processors, wherein, if the first press processor determines that re-printing an errored book with the stream associated with the first printing press will not entitle the errored book to at least the first predefined postal discount, the first press processor identifies the errored book to the global processor, and, wherein, if the second press processor determines that reprinting an errored book with the stream associated with the second printing press will not entitle the errored book to at least the second predefined postal discount, the second press processor identifies the errored book to the global processor.

56. A system as defined in claim 55 wherein the global processor is adapted to develop a new job to re-print errored books received from the first and second press processors.

57. A system as defined in claim 55 wherein the global processor is adapted to selectively re-assign errored books received from the first and second printing presses to one of the first and second printing presses for reprinting to optimize a postal discount.

58. A system as defined in claim 57 wherein the postal discount is optimized for a re-assigned errored book.

59. A system as defined in claim 57 wherein the postal discount is optimized for a job as a whole.

60. A system as defined in claim 57 wherein the global processor calculates the postal discounts to which each bundle of books printed by the first and second presses are entitled based on the number of books in each bundle, the number of reprinted books added to each bundle, and the number of errored books removed from each bundle.

61. A method for reordering an errored book detected at an auxiliary device located downstream of a first printing press printing a stream of books containing variable data and fixed data, the method comprising the steps of:

creating at least one database identifying the variable and fixed data to be included in each book in the stream of books;

recording an identifier of each book exiting the auxiliary device;

comparing the identifier of the books exiting the auxiliary device to the at least one database to recognize an errored book; and

,

ordering one of the group comprising the first printing press and a second printing press to reprint an errored book by using the identifier of the errored book to access the at least one database and providing the fixed and variable data needed to reprint the errored book to the selected one of the first and second printing presses.

62. A method as defined in claim 61 further comprising the step of selecting the one of the first and second printing presses for reprinting the errored book by matching the errored book to a group of books to be printed, wherein grouping the errored book with the group of books entitles the errored book to a postal discount.

63. A method as defined in claim 61 further comprising the step of selecting the one of the first and second printing presses for reprinting the errored book by matching the errored book to a group of books to be printed, wherein grouping the errored book with the group of books entitles the group of books to a postal discount.

64. A method for reordering an errored book detected at an auxiliary device located downstream of a first printing press printing a stream of books containing variable data and fixed data, the method comprising the steps of:

creating at least one database identifying the variable and fixed data to be included in each book in the stream of books;

recording an identifier of each book entering the auxiliary device;

recording the identifier of each book exiting the auxiliary device;

comparing the identifiers of the books entering the auxiliary device with the identifiers of the books exiting the auxiliary device to recognize an errored book; and

,

ordering one of the group comprising the first printing press and a second printing press to reprint an errored book after at least one other book in the stream has been printed by using the identifier of the errored book to access the at least one database and providing the fixed and variable data needed to reprint the errored book to the selected one of the first and second printing presses.

65. A method as defined in claim 64 further comprising the step of selecting the one of the first and second printing presses for reprinting the errored book by matching the errored book to a group of books to be printed, wherein grouping the errored book with the group of books entitles the errored book to a postal discount.

66. A method as defined in claim 64 further comprising the step of selecting the one of the first and second printing presses for reprinting the errored book by matching the errored book to a group of books to be printed, wherein grouping the errored book with the group of books entitles the group of books to a postal discount.

67. A method for reordering a book printed by a first printing press printing a stream of books, the method comprising the steps of:

identifying a book in the stream of books to be reordered;

determining whether reprinting the book on the first printing press without re-sorting the stream of books will entitle the reprinted book to a predefined postal discount;

automatically reprinting the book on the first printing press only if the reprinted book will be entitled to at least the predefined postal discount.

68. A method for reordering a book printed by a first printing press printing a stream of books, the method comprising the steps of:

identifying a book in the stream of books to be reordered;

if reprinting the book on the first printing press without re-sorting the stream of books will not entitle the reprinted book to at least a predefined postal discount, determining if reprinting the book on a second printing press printing a second stream of books without re-sorting the second stream will entitle the reprinted book to at least a second predefined postal discount; and

reprinting the book on the second printing press if the reprinted book will be entitled to at least the second predefined postal discount.

69. A method for reordering a book printed by a first printing press printing a first stream of books, the method comprising the step of:

identifying a book in the first stream of books to be reordered;

determining a first postal discount that the reprinted book will be entitled to if reprinted on the first printing press if the first stream of books is not re-sorted;

determining a second postal discount that the reprinted book will be entitled to if reprinted on a second printing press printing a second stream of books if the second stream of books is not re-sorted;

comparing the first postal discount to the second postal discount; and

,

selecting one of the first or second printing presses for reprinting the book based on the comparison between the first and second postal discounts.

70. For use with a first printing press having a first press controller and a second printing press having a second press controller, each of the first and second printing presses printing a stream of books containing fixed and variable data, a reorder system comprising:

a storage device including a global reorder table, the global reorder table including a list of sub-jobs to be printed by the first and second printing presses, each of the sub-jobs being associated with a group of books to be delivered within a predefined postal area; and

a global processor coupled to the storage device, the global processor being in communication with the first and second press controllers to update the global reorder table to indicate completion of the sub-jobs by the first and second printing presses, the global processor being further adapted to assign an errored book identified by the first or second press controllers to a sub-job which has not yet been completed in order to optimize a postal discount.

71. A system as defined in claim 70 wherein the predefined postal areas comprise carrier routes.

72. A system as defined in claim 70 wherein the predefined postal areas comprise areas defined by five digit zip codes.

73. A system as defined in claim 70 wherein the predefined postal areas comprise areas defined by first three digits of zip codes.

74. A system as defined in claim 70 wherein the predefined postal areas comprise states.

75. A system as defined in claim 70 further comprising an auxiliary finishing device having an associated device controller, the device controller being coupled to the storage device to identify errored books in a table for subsequent reprinting.

76. A system as defined in claim 70 further comprising an auxiliary finishing device having an associated device controller, the device controller identifying errored books to the global reorder processor, the global processor being further adapted to assign errored books identified by the device controller to a new sub-job which has not yet been completed in order to maximize a postal discount.

77. A system as defined in claim 70 wherein the postal discount is optimized with respect to the errored book.

78. A system as defined in claim 70 wherein the global reorder table includes a book count for each sub-job identifying the number of books associated with each sub-job, and wherein the global processor updates the book count of the new sub-job to reflect the addition of a book and updates the book count of the sub-job wherein the errored book originated to reflect the subtraction of a book.

79. A system as defined in claim 78 wherein the global processor calculates postal discounts for each of the sub-jobs based on the updated book counts.

80. A system as defined in claim 70 wherein the global reorder processor selects the new sub-job by searching the global reorder table for a sub-job containing books addressed to the same postal area as the errored book.

81. A system as defined in claim 80 wherein, in the event multiple sub-jobs are identified by searching the global reorder table, the global processor selects the new sub-job by comparing the book counts of the multiple sub-jobs.

82. A system as defined in claim 70 wherein the global processor is adapted to terminate a sub-job being processed by one of the first and second printing presses and to assign the unprinted books in the terminated sub-job to one or more new sub-jobs containing books addressed to the same postal area as the terminated sub-job if, upon receiving an errored book from one of the first and second press controllers, the global processor determines that the book count of the sub-job associated with the errored book has fallen below a predetermined value and that sub-jobs containing books addressed to the same postal area remain unprinted.

83. A system as defined in claim 82 wherein the predetermined value comprises a minimum number of books that must be contained in a bundle of books for the bundle of books to be entitled to a postal discount.

84. A system as defined in claim 70 wherein the postal discount is optimized with respect to a job defined by a group of the sub-jobs.

85. A system as defined in claim 84 wherein the group comprises all of the sub-jobs.

86. For use with an auxiliary device located downstream from a first printing press printing a stream of books, the auxiliary device being adapted to perform a process on books printed by the first printing press, a reorder system comprising:

a first sensor located downstream of the auxiliary device to monitor books output by the auxiliary device; and

a processor in communication with the first sensor, the processor being adapted to recognize an errored book based at least in part on an output of the first sensor, to identify the errored book in a log, and, after the stream of books has been processed by the auxiliary device, to cause the errored books in the log to be reprinted in accordance with instructions input by the user.

87. A system as defined in claim 86 wherein the processor identifies a missing book by comparing an output of the first sensor to a list of expected books.

88. A system as defined in claim 86 wherein the auxiliary device comprises one of the group comprising:

a folding device, a trimming device, a weighing device, a binding device, a gluing device, a dot wacker, a tip-on, a card feeder, a strapper, and a mechanical co-mailer.

89. A system as defined in claim 86 further comprising a second sensor located upstream of the auxiliary device.

90. A system as defined in claim 89 wherein the processor identifies a missing book by comparing outputs of the first and second sensors.

91. A system as defined in claim 86 further comprising a graphical user interface, the graphical user interface displaying data associated with the errored books and permitting a user to enter instructions specifying how the errored books are to be reprinted.

92. A system as defined in claim 91 wherein the graphical user interface permits the user to specify the printing press to reprint the errored books.

93. A system as defined in claim 91 wherein the graphical user interface permits the user to group the errored books into discrete jobs.

94. A system as defined in claim 93 wherein the processor is adapted to process as a separate job any errored books not grouped into a discrete job by the user.

95. For use with a weight measuring device located downstream from a first printing press printing a stream of books, the weight measuring device being adapted to weigh books printed by the first printing press, a reorder system comprising:

a press processor associated with the first printing press for controlling the operation thereof;

a first sensor located upstream of the weight measuring device;

a local processor in communication with the first sensor for identifying each book input into the weight measuring device, the local processor being adapted to calculate an expected weight range for the identified book, and to determined that the identified book is errored if the measured weight of the identified book developed by the weight measuring device falls outside the expected weight range; and

a global processor in communication with the local processor, the global processor being in communication with the press processor to cause the first printing press to reprint the identified book in response to a signal received by the global processor from the local processor.

96. For use with a weight measuring device located downstream from a first printing press printing a stream of books, the weight measuring device being adapted to weigh books printed by the first printing press, a reorder system comprising:

a first press processor associated with the first printing press for controlling the operation thereof;

a second press processor associated with a second printing press for controlling the operation thereof,

a first sensor located upstream of the weight measuring device;

a local processor in communication with the first sensor for identifying each book input into the weight measuring device, the local processor being adapted to calculate an expected weight range for the identified book, and to determined that the identified book is errored if the measured weight of the identified book developed by the weight measuring device falls outside the expected weight range; and

a global processor in communication with the local processor, the global processor being in selective communication with the first press processor and with the second press processor to selectively cause the identified book to be reprinted on one of the first and second printing presses if the local processor determines that the identified book is errored.

97. A system as defined in claim 96 wherein the global processor selects the one of the first and second printing presses to minimize processing time.

98. A system as defined in claim 96 wherein the global processor selects the one of the first and second printing presses to maximize a postal rate discount.

99. A system as defined in claim 98 wherein the global processor selects the one of the first and second printing presses by comparing postal information for the identified book to postal information of a book to be printed by the first printing press.

100. A system as defined in claim 99 wherein the global processor selects the one of the first and second printing presses by comparing the postal information for the identified book to postal information for a book to be printed by the second printing press.