Paperless warehouse management system

• US 6,339,764 B1
• Filed: 12/10/1999
• Issued: 01/15/2002
• Est. Priority Date: 12/10/1998
• Status: Expired due to Fees

• Current Assignee: Retrotech, Inc. (Remia CV)
• Original Assignee: Woodson Incorporated
• Inventors: Getchell, David L., Singer, Chester H., Livesay, Mark F.
• Primary Examiner(s): CHILCOT, RICHARD E
• Application Number:
  US09/458,812
• Time in Patent Office: 767 Days
• Field of Search: 705/22, 705/28, 705/29, 255/385
• US Class Current: 705/28
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials

Abstract

The present invention consists of a Hewlett-Packard Unix-based server, client PCs, client RF (radio-frequency) terminals, and various other peripherals, running warehouse management software developed specifically for high-volume bakeries. Personnel, which include auditors, parkers, checkers, shippers and receivers, are equipped with real-time hand-held RF data terminals. The terminals display information, accept keyed entries, and scan bar codes on production lines, racks, warehouse and truck locations, trucks and products. The system has one server and multiple PC'"'"'s associated with multiple production lines. The PC'"'"'s provide information of product made, batch sequences, expected count, current count and batch complete. The auditor supplies racks to the production line and identifies planned racks, marks and places them for movement by the parkers to the shippers. The auditor receives unplanned racks of products, scans the bar code and places the unplanned racks in position for movement to the checkers. The checkers move product from unplanned production racks to shipping racks, scanning the bar codes of the wheeled racks and products and entering amounts as prompted by their terminals, move the completed shipping racks to the truck loading stations, scanning the bar code of the racks and the shipping position. The shippers scan the racks in the shipping position, scan the truck ID and, as prompted by their terminals, roll the racks onto the trucks, position the racks in predetermined positions as prompted, enter the rack position in the truck and scan the rack bar code.

Claims

1. An apparatus for managing a warehouse, comprising:

a host computer server;

at least one personal computer connected to the host computer server for receiving a production schedule from the host computer server and modifying the production schedule remotely;

at least one radio-frequency (RF) terminal connected to the host computer server for receiving a production schedule from the host computer server and modifying the production schedule remotely;

at least one production line that receives the production schedule from the host computer and for producing product in response to the production schedule;

an inventory area for receiving product from the at least one production line;

a holding area for receiving product from the inventory area and arranging product into orders set by the production schedule; and

a shipping area for receiving product from the holding area and for preparing the product for shipment.

2. The apparatus of claim 1, wherein the at least one personal computer is connected to the host computer server via an Ethernet network.

3. The apparatus of claim 1, wherein the at least one RF terminal is connected to the host computer server via an Ethernet-based base radio.

4. The apparatus of claim 1, wherein at least one of the at least one RF terminals is located proximal the production line for modifying the production schedule in to response the produced product.

5. The apparatus of claim 1, wherein at least one of the at least one RF terminals is located proximal the inventory area for modifying the production schedule in response to the product received by the inventory area.

6. The apparatus of claim 1, wherein at least one of the at least one RF terminals is located proximal the holding area for modifying the production schedule in response to the product received by the holding area.

7. The apparatus of claim 1, wherein at least one of the at least one RF terminals is located proximal the shipping area for modifying the production schedule in response to the product received by the shipping area.

8. The apparatus of claim 1, wherein the holding area further comprises a first production holding area for receiving planned product from the inventory area and a second production holding area for receiving unplanned product from the inventory area.

9. The apparatus of claim 8, further comprising a picking rack for receiving unplanned product from the second production holding area.

10. The apparatus of claim 8, wherein at least one of the at least one RF terminals is located proximal the first production holding area for modifying the production schedule in response to the product received by the first production holding area.

11. The apparatus of claim 1, wherein at least one of the at least one RF terminals is located proximal the second production holding area for modifying the production schedule in response to the product received by the second production holding area.

12. The apparatus of claim 9, wherein at least one of the at least one RF terminals is located proximal the picking rack for modifying the production schedule in response to the product received by the picking rack.

13. The apparatus of claim 1, further comprising at least one sensor mounted on the at least one production line for counting product produced by the at least one production line.

14. The apparatus of claim 13, wherein the at least one personal computer is located proximal the at least one sensor for modifying the production schedule in response to the production count made by the sensor.

15. The apparatus of claim 1, further comprising a receiving area for receiving product that is produced external to the at least one production line and for sending received product to the inventory area.

16. The apparatus of claim 15, wherein at least one of the at least one RF terminals is located proximal the receiving area for modifying the production schedule in response to the product received by the receiving area.

17. The apparatus of claim 1, further comprising a scanner on the at least one RF terminal for scanning bar codes on the product for modifying the production schedule.

18. A warehouse management system, comprising:

providing a production schedule from a host computer server to at least one production line;

receiving the production schedule from the host computer server with at least one personal computer connected to the host computer server;

receiving the production schedule from the host computer server with at least one radio frequency (RF) terminal connected to the host computer server;

producing product with the at least one production line in response to the received production schedule;

moving the product from the at least one production line to an inventory area;

marking the product as either planned product or unplanned product;

moving the planned product from the inventory area to a first production holding area;

moving the planned product from the first production holding area to a shipping area;

moving the unplanned product from the inventory area to a second production holding area;

moving the unplanned product from the second production holding area to a picking rack;

moving the unplanned product from the picking rack to the shipping area; and

preparing the planned and the unplanned product in the shipping area for shipment.

19. The system of claim 18, wherein the moving the product from the at least one production line to an inventory area and marking the product further comprises providing a first auditor for moving and marking the product.

20. The system of claim 18, wherein the moving the planned product from the inventory area to a first production holding area further comprises providing a second auditor for moving the product.

21. The system of claim 18, wherein the moving the unplanned product from the inventory area to a second production holding area further comprises providing a third auditor for moving the product.

22. The system of claim 18, wherein the moving the planned product from the first production holding area to a shipping area further comprises providing a first parker for moving the planned product.

23. The system of claim 18, wherein the moving the planned product from the second holding area to a picking rack further comprises providing a checker for moving the unplanned product.

24. The system of claim 18, wherein the moving the unplanned product from the picking rack to the shipping area further comprises providing a second parker for moving the unplanned product.

25. The system of claim 18, wherein the preparing the planned and the unplanned product in the shipping area for shipment further comprises providing a shipper for preparing the planned and the unplanned product.

26. The system of claim 18, further comprising receiving the product from a source other than the at least one production line in a receiving area, and moving the product from the receiving area to the inventory area.

27. The system of claim 26, wherein the receiving the product and moving the product further comprises a receiver for receiving the product and moving the product.

28. The system of claim 18, further comprising:

mounting at least one sensor on the at least one production line;

counting the produced product with the sensor;

providing the at least one personal computer proximal the at least one sensor;

transmitting the count from the sensor to the at least one personal computer;

transmitting the count from the at least one personal computer to the host computer server; and

modifying the production schedule in response to the count received by the host computer server.

29. The system of claim 19, further comprising providing the first auditor with an RF terminal for scanning the product and modifying the production schedule.

30. The system of claim 20, further comprising providing the second auditor with an RF terminal for scanning the product and modifying the production schedule.

31. The system of claim 21, further comprising providing the third auditor with an RF terminal for scanning the product and modifying the production schedule.

32. The system of claim 22, further comprising providing the first parker with an RF terminal for scanning the product and modifying the production schedule.

33. The system of claim 23, further comprising providing the checker with an RF terminal for scanning the product and modifying the production schedule.

34. The system of claim 24, further comprising providing the second parker with an RF terminal for scanning the product and modifying the production schedule.

35. The system of claim 25, further comprising providing the shipper with an RF terminal for scanning the product and modifying the production schedule.

36. The system of claim 27, further comprising providing the receiver with an RF terminal for scanning the product and modifying the production schedule.