Automated prescription filling system/method with automated labeling and packaging system/method automated order consolidation system/method

• US 6,892,512 B2
• Filed: 08/09/2002
• Issued: 05/17/2005
• Est. Priority Date: 08/07/2002
• Status: Expired due to Term

• Current Assignee: Express Scripts Strategic Development, Inc. (The Cigna Group)
• Original Assignee: Medco Health Solutions Incorporated (The Cigna Group)
• Inventors: Leu, Chih-Jen, Rice, Dennis Wayne, Lasher, Christopher J., McErlean, James G., Monkhouse, Peter, Howell, Robert Gregory, Booler, Andrew P., Walton, Douglas W., Szesko, Michael Joseph, Hess, E. Christian, Bonkenburg, Thomas P., Shupert, P. Thomas, Bell, Michael W. G.
• Primary Examiner(s): Gerrity, Stephen F.
• Assistant Examiner(s): DESAI, HEMANT
• Application Number:
  US10/215,249
• Publication Number:
  US 20040065053A1
• Time in Patent Office: 1,012 Days
• Field of Search: 53/55, 534/95, 534/93, 534/73, 534/45, 534/11, 531/68, 534/20, 532/38, 532/37, 532/51, 532/50, 532/49, 531/314, 531/312, 535/00
• US Class Current: 53/445
• CPC Class Codes: B65B 5/103 for packaging pills or tablets
• CPC Class Codes: B65B 61/20 for adding cards, coupons or other inserts to package contents adding unpacking elements B65B61/18
• CPC Class Codes: B65C 2009/0018 Preparing the labels
• CPC Class Codes: B65C 9/0015 Preparing the labels or articles, e.g. smoothing, removing air bubbles
• CPC Class Codes: B65C 9/22 by wetting, e.g. by applying liquid glue or a liquid to a dry glue coating
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 40/08 Insurance
• CPC Class Codes: G16H 20/13 delivered from dispensers
• CPC Class Codes: G16H 70/40 relating to drugs, e.g. their side effects or intended usage
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1033 Flexible sheet to cylinder lamina
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 156/1326 Severing means or member secured thereto also bonds
• CPC Class Codes: Y10T 156/1339 Delivering cut part in sequence to serially conveyed articles
• CPC Class Codes: Y10T 156/1768 Means simultaneously conveying plural articles from a single source and serially presenting them to an assembly station
• CPC Class Codes: Y10T 156/1771 Turret or rotary drum-type conveyor
• CPC Class Codes: Y10T 156/1773 For flexible sheets

Abstract

Computer assisted systems, methods and mediums for filling one or more orders. One embodiment of the present invention is a system that includes an order consolidation station configured to receive at least one bottle containing pills individually counted and/or at least one package containing pharmaceutical products without having been designated for any of the orders when the package was created and/or at least one literature pack optionally including patient specific information. The order consolidation station is further configured to combine automatically the received bottle and/or package and/or literature pack into a container to be sent to a recipient including, for example, mail order pharmacies, wholesalers and/or central fill dealers for subsequent distribution or sale including retailer distribution or sale. The bottle is specifically designated for the order, and the order generally includes at least one prescription for the package.

Claims

1. A system for filling at least one prescription order, said system comprising at least one order consolidation station configured to:

receive from a first transport system at least one bottle containing a number of pills individually counted as determined by the at least one prescription order;

receive from a second transport system at least one package containing prepackaged pharmaceutical products;

at least one identifier detector to detect at least one identification information associated with the at least one bottle, and to detect at least another identification information associated with the at least one package;

at least one mechanism to place the at least one bottle and the at least one package into a container; and

a control system that coordinates the first and second transport systems and the at least one mechanism so that the at least one bottle and the at least one package are placed in the container when the at least one identification information associated with the bottle and the at least another identification information associated with the at least one container correspond to the at least one prescription order.

2. The system of claim 1, wherein the at least one order consolidation station is further configured to:

print at least one customized literature pack for the at least one prescription order comprising patient specific information; and

insert automatically the at least one literature pack into the container.

3. The system according to claim 2, wherein the at least one identifier detector determines whether the at least one bottle, the at least one package, the at least one customized literature pack, and the container belong to the at least one prescription order.

4. The system of claim 1, further comprising:

a package storage device having an array of locations and configured to store the at least one package into one of the array of locations; and

a package dispenser configured to identify the one of the array of locations, obtain the at least one package from the one of the array of locations and provide the at least one package to the second transport system.

5. The system of claim 4, wherein the package dispenser further includes a package label printer to print at least one label for the at least one package, wherein the label is printed with patient specific information.

6. The system of claim 5, wherein the package dispenser further includes a labeler to affix a label on the at least one package.

7. The system of claim 5, wherein the package dispenser further includes an error detection system configured to detect the label affixed on the at least one package and reject the at least one package if an error is detected.

8. The system of claim 1, further comprising:

a package storage device having an array of locations and configured to store a plurality of packages into the array of locations and store the at least one package into one of the array of locations; and

a package dispenser configured to identify the one of the array of locations, obtain the at least one package from the one of the array of locations and provide the at least one package to the second transport system.

9. The system of claim 1, further comprising:

a bottle storage device having an array of locations and configured to store the at least one bottle into one of the array of locations; and

a bottle dispenser configured to identify the one of the array of locations and dispense the at least one bottle from the one of the array of the locations.

10. The system of claim 9, further comprising a metal detector configured to detect a metallic substance in the at least one bottle, wherein the bottle is transported to a quality assurance area if a metallic substance is detected.

11. The system of claim 9, wherein the bottle dispenser comprises a bottle buffer configured to receive the at least one bottle belonging to the one of at least one prescription order, wherein the bottle buffer is disposed and configured to release the received at least one bottle to the first transport system.

12. The system of claim 1, further comprising a packager configured to open the container to receive the at least one bottle and at least one package.

13. The system of claim 12, wherein the packager comprises:

a printer configured to print an address or internal control information, and affix the address or the internal control information on the container.

14. The system of claim 12, wherein the packager comprises a bagger system, and wherein said container comprises a bag.

15. The system of claim 14, wherein the bagger system comprises:

a printer configured to print an address or internal control information, and affix the address or the internal control information on the bag.

16. The system of claim 1, wherein the at least one prescription order consolidation station is further configured to:

print at least one customized literature pack for the at least one prescription order comprising patient specific information; and

insert automatically the at least one literature pack for the at least one bottle and the at least one package into the container.

17. A system for filling at least one prescription order, comprising:

a bottle handling station configured to store and dispense at least one bottle containing a number of pills as determined by the at least one prescription order;

a package handling station configured to store and dispense at least one package containing prepackaged pharmaceutical products; and

an order consolidation station configured to receive the at least one bottle from a first transport system and receive the at least one package containing prepackaged pharmaceuticals from a second transport system;

at least one identifier detector to detect at least one identification information associated with the at least one bottle, and to detect at least one other identification information associated with the at least one package;

at least one mechanism to place the at least one bottle and the at least one package into a container; and

a control system that coordinates the first and second transport systems and the at least one mechanism so that the at least one bottle and the at least one package are placed into the container when the at least one identification information associated with the at least one bottle and the at least one other identifier information associated with the at least one package correspond to the at least one prescription order.

18. The system of claim 17, further comprising:

a literature handling station configured to print and store at least one literature pack containing patient specific information for the at least one prescription order, wherein the order consolidation station receives the at least one literature pack and inserts the at least one literature pack into the container.

19. The system according to claim 18, wherein the at least one identifier detector determines whether the at least one bottle, the at least one package, the at least one literature pack, and the container belong to a same prescription order.

20. The system of claim 17, wherein the package handling station comprises:

a package storage device having an array of locations and configured to store the at least one package into one of the array of locations; and

a package dispenser configured to identify the one of the array of locations, and obtain the at least one package from the one of the array of locations and provide the at least one package to the second transport system.

21. The system of claim 20, wherein the package dispenser further includes a package label printer to print at least one label for the at least one package, wherein the label is printed with patient specific information.

22. The system of claim 21, wherein the package dispenser further includes a device to affix the at least one label on the at least one package.

23. The system of claim 21, wherein the package dispenser further includes an error detection system configured to detect the label affixed on the at least one package and reject the at least one package and the label if an error is detected.

24. The system of claim 17, wherein the bottle handling station comprises:

a bottle storage device having an array of locations and configured to store the at least one bottle into one of the array of locations; and

a bottle dispenser configured to identify the one of the array of locations and dispense the at least one bottle from the one of the array of the locations.

25. The system of claim 24, further comprising a metal detector configured to detect a metallic substance in the at least one bottle, wherein the bottle is transported to a quality assurance area if a metallic substance is detected.

26. The system of claim 24, wherein the bottle dispenser comprises a bottle buffer configured to receive the at least one bottle belonging to one of at least one prescription order, wherein the bottle buffer is disposed and configured to release all received at least one bottle from said bottle storage area into the container.

27. The system of claim 17, further comprising a packager configured to open the container to receive the at least one bottle and at least one package.

28. The system of claim 27, wherein the packager comprises a printer configured to print a label comprising an address or internal control information, and affix the label on the container.

29. The system of claim 27, wherein the packager comprises a bagger system, and wherein said container comprises a bag.

30. The system of claim 29, wherein the bagger system comprises:

a printer configured to print an address or internal control information, and affix the address or the internal control information on the bag.

31. A system for filling a plurality of prescription orders, comprising:

a package handling station configured to store a plurality of packages containing prepackaged pharmaceutical products;

a literature handling station configured to print and store at least one literature pack relating to one of the plurality of prescription orders and coordinate the at least one literature pack with respect to corresponding prescription orders;

a computer system configured to monitor the package handling and literature handling stations and cause the package handling station to dispense the plurality of packages in coordination with the dispensing of the plurality of literature packs by the literature handling station;

at least one identifier detector to detect at least one identification information associated with the plurality of packages and at least another identification information associated with the at least one literature pack;

at least one mechanism to place the at least one bottle and the at least one package into a container;

an order consolidation station configured to receive the packages from a first transport system and the literature packs from a second transport system; and

a control system that coordinates the first and second transport systems and the at least one mechanism so that the packages and the literature packs are placed into the container when the at least one identification information and the at least one other identification information correspond to a same prescription order.

32. The system of claim 31, further comprising:

a bottle handling station configured to store a plurality of bottles, each bottle containing a number of pills as determined by a prescription order;

wherein the computer system is further configured to monitor the bottle handling station and cause the bottle handling station to dispense the bottles in coordination with the at least one literature pack, and

wherein the order consolidation station is further configured to receive the bottles associated with the corresponding prescription order and insert the bottles with the corresponding packages and literature packs into a container.

33. The system of claim 32, wherein the control system detects an error when the bottles received by the order consolidation station do not correspond with the at least one literature pack.

34. The system of claim 32, wherein the order consolidation station is configured to:

receive the bottles and the at least one literature pack in the order sequence in which the at least one literature pack is stored with respect to the corresponding prescription orders; and

insert the bottles, packages and the at least one literature pack into the container.

35. The system of claim 34, wherein the control system detects an error when the bottles are not received by the order consolidation station in the order sequence in which the at least one literature pack is stored.

36. The system of claim 32, wherein the container comprises a bag.

37. The system according to claim 32, wherein the at least one identifier detector determines if the plurality of bottles, the plurality of packages, the at least one literature pack, and the container belong to a same prescription order.

38. The system of claim 31, wherein the control system detects an error when the packages received by the order consolidation station do not correspond with the at least one literature pack.

39. The system of claim 31, wherein the order consolidation station is configured to receive the packages and the at least one literature pack in the order sequence in which the at least one literature pack is stored with respect to the corresponding prescription orders.

40. The system of claim 39, wherein the control system detects an error when the packages are not received by the order consolidation station in the order sequence in which the at least one literature pack is stored.

41. A system for filling at least one prescription order, comprising:

a first transport means for receiving at least one bottle containing a number of pills individually counted as determined by a prescription order;

a second transport means for receiving at least one package containing prepackaged pharmaceutical products;

at least one identifier detector to detect at least one identification information associated with the at least one bottle, and to detect at least one other identification information associated with the at least one package;

at least one mechanism to place the at least one bottle into a container; and

an order consolidation means for receiving the at least one bottle from said first transport means and receiving the at least one package containing prepackaged pharmaceutical products from said second transport means; and

a control system that coordinates the first and second transport means and the at least one mechanism so that the at least one bottle and the at least one package are placed into a container when the at least one identification information and the at least one other identification information correspond to the at least one prescription order.

42. The system of claim 41, wherein the order consolidation means is further configured to receive at least one literature pack containing patient specific information relating to the at least one order and combine the at least one literature pack with the at least one bottle and the at least one package.

43. The system of claim 41, further comprising:

a package storage means, having an array of locations, for storing the at least one package into one of the array of locations; and

a package dispense means for identifying the one of the array of locations, obtaining the at least one package from the one of the array of locations and providing the at least one package to the order consolidation means.

44. The system of claim 43, wherein the package dispense means includes a package label printer to print at least one label for the at least one package, wherein the label is printed with patient specific information.

45. The system of claim 44, the package dispense means further includes a device to affix the at least one label on the at least one package.

46. The system of claim 44, wherein the package dispense means further includes an error detection system configured to detect the label affixed on the at least one package and reject the at least one package and the label if an error is detected.

47. The system of claim 41, further comprising:

a bottle storage means, having an array of locations, for storing the at least one bottle into one of the array of locations; and

a bottle dispense means for identifying the one of the array of locations and dispensing the at least one bottle from the one of the array of the locations.

48. The system of claim 47, further comprising

a metal detector means for detecting the presence of a metallic substance in the at least one bottle, and for rejecting the at least one bottle if a metallic substance is detected therein.

49. The system of claim 47, wherein the bottle dispense means comprises:

a bottle buffer means for receiving the at least one bottle belonging to the one of at least one prescription order, wherein the bottle buffer means is disposed and configured to release all received at least one bottle.

50. The system of claim 41, wherein the system further comprises

a bagger means for opening the container to receive the at least one bottle and the at least one package into the container.

51. The system of claim 50, wherein the packager means comprises:

a printer means for printing an address or internal control information, wherein the bagger means is further configured for affixing the address or the internal control information on the container.

52. The system of claim 41, wherein the container comprises a bag.

53. A system for filling at least one prescription order, comprising:

a bottle handling means for storing and dispensing at least one bottle containing a number of pills as determined by the at least one prescription order;

a package handling means for storing and dispensing at least one package containing prepackaged pharmaceutical products;

at least one identifier detector to detect at least one identification information associated with each of the at least one bottle, and to detect at least one other identification information associated with each of the at least one package;

an order consolidation means for receiving the at least one bottle from a first transport system and receiving the at least one package from a second transport system; and

at least one mechanism for inserting the at least one bottle and the at least one package into a container when the at least one identification information and the at least one other identification information are detected corresponding to a common prescription order.

54. The system of claim 53, further comprising:

a literature handling means for printing and storing at least one literature pack containing patient specific information for the at least one prescription order,

wherein the order consolidation means receives the at least one literature pack and inserts the at least one literature pack into the container.

55. The system of claim 53, wherein the container comprises a bag.

56. A system for filling a plurality of prescription orders, comprising:

package handling means for storing a plurality of packages having at least one identification information and containing prepackaged pharmaceutical products;

literature handling means for printing and storing at least one literature pack relating to one of the plurality of prescription orders and coordinating the at least one literature pack with respect to corresponding prescription orders, the at least one literature pack having another identification information associated therewith;

a computer system configured to monitor the package handling and literature handling means and control the package handling means to dispense the plurality of packages in coordination with the dispensing of the at least one literature pack by the literature handling means; and

order consolidation means for receiving at least one prepackaged pharmaceutical product from a first transport system and at least one literature pack from a second transport system, said order consolidation means comprising a control system that enables at least one mechanism to place the at least one prepackaged pharmaceutical product having identification information corresponding to a particular prescription order and the at least one literature pack having another identification information corresponding to the same particular prescription order into at least one container corresponding to the same prescription order.

57. The system of claim 56, further comprising:

bottle handling means for storing a plurality of bottles each containing a number of pills as determined by a prescription order,

wherein the computer system is further configured to monitor the bottle handling means and cause the bottle handling means to dispense the bottles in coordination with the at least one literature pack, and

wherein the order consolidation means is further configured to receive the bottles associated with the prescription order and combine the bottles associated with the prescription order with the packages and literature packs.

58. The of claim 57, wherein the order consolidation means is configured to receive the bottles and the at least one literature pack in a same order sequence in which the at least one literature pack is stored with respect to the corresponding prescription orders and combine the bottles associated with the corresponding prescription orders with the combined packages and the at least one literature pack.

59. The system of claim 58, wherein the control system detects an error when the order consolidation means does not receive the bottles in the order sequence in which the at least one literature pack is stored.

60. The system of claim 56, wherein the order consolidation means is configured to receive the packages and the at least one literature pack in a same order sequence in which the at least one literature pack is stored with respect to the corresponding prescription orders.

61. The system of claim 60, wherein the control system detects an error when the order consolidation means does not receive the packages in the order sequence in which the at least one literature pack is stored.

62. A system for filling a plurality of prescription orders, comprising:

a belt mechanism including a plurality of locations each of which is capable of carrying a pack of printed material corresponding with a prescription order;

a bottle storage table including a plurality of tubes to store at least one bottle belonging to the prescription order;

a first conveyor located to receive the at least one bottle from the bottle storage table and move the at least one bottle;

means for receiving and holding the at least one bottle prior to placing the bottle into a container;

a plurality of shelf locations, wherein each shelf location contains at least one package;

a first robot mechanism having an end effector to obtain the at least one package and a means to release the at least one package;

a second conveyor having a moving surface to move the at least one package received from the first robot mechanism;

a second robot mechanism having an end effector to pick up the at least one package;

a packager to open and hold the container; and

a control system configured to coordinate the activities of;

a) the belt mechanism to convey at least one pack of printed material and discharge the at least one pack into the container, b) the means for receiving and holding to obtain and dispose the at least one bottle into the container, and c) the second robot mechanism to obtain and dispose the at least one package into the container.

63. A system for filling at least one prescription order, comprising at least one order consolidation station configured to:

receive from a first transport system at least one literature pack comprising patient specific information associated with a prescription order;

receive from a second transport system at least one package containing prepackaged pharmaceutical products associated with the prescription order;

detect at least one identification information associated with each of the at least one literature pack, and to detect at least another identification information associated with each of the at least one package;

place the at least one package into a container; and

coordinate the first and second transport systems and the at least one mechanism so that the at least one literature pack and the at least one package are placed in a container when the at least one identification information associated with the at least one literature pack and the at least another identification information associated with the at least one package correspond to the at least one prescription order, to thereby fill the at least one prescription order.

64. The system of claim 63, wherein the at least one order consolidation station is further configured to receive at least one bottle containing a number of counted pills corresponding to the prescription order, and combine the at least one literature pack with the at least one bottle and the at least one package.

65. The system of claim 64, further comprising:

a bottle storage device having an array of locations and configured to store the at least one bottle into one of the array of locations; and

a bottle dispenser configured to identify the one of the array of locations and dispense the at least one bottle from the one of the array of the locations.

66. The system of claim 65, further comprising

a metal detector configured to detect a metallic substance in the at least one bottle, wherein the bottle is transported to a quality assurance area if a metallic substance is detected.

67. The system of claim 65, further comprising

a bottle buffer configured to receive the at least one bottle belonging to the one of at least one prescription order, wherein the bottle buffer is disposed and configured to release the received at least one bottle from said storage device.

68. The system of claim 63, further comprising:

a package storage device having an array of locations and configured to store the at least one package into one of the array of locations; and

a package dispenser configured to identify the one of the array of locations, obtain the at least one package from the one of the array of locations and provide the at least one package to the order consolidation station.

69. The system of claim 68, wherein the package dispenser further includes a package label printer to print at least one label for the at least one package, wherein the label is printed with patient specific information.

70. The system of claim 69, wherein the package dispenser further includes a labeler to affix the at least one label on the at least one package.

71. The system of claim 69, wherein the control system comprises an error detection system configured to detect the label affixed on the at least one package and reject the at least one package and the label if an error is detected.

72. The system of claim 63, further comprising:

a package storage device having an array of locations and configured to store a plurality of packages into the array of locations and store the at least one package into one of the array of locations; and

a package dispenser configured to identify the one of the array of locations, obtain the at least one package from the one of the array of locations and provide the at least one package to the order consolidation station.

73. The system of claim 63, further comprising a packager configured to open a container to receive the at least one literature pack and the at least one package.

74. The system of claim 73, wherein the packager comprises:

a printer configured to print an address or internal control information, and wherein the packager is further configured to affix the address or the internal control information on the container.

75. The system of claim 63, wherein the container comprises a bag.