Surgical instrument tray shipping tote identification system and methods of using same

• US 7,227,469 B2
• Filed: 11/22/2004
• Issued: 06/05/2007
• Est. Priority Date: 11/22/2004
• Status: Active Grant

• Current Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Original Assignee: SDGI Holdings Incorporated (Medtronic Plc)
• Inventors: Nycz, Jeffrey H., Varner, Robert, Tethrake, Steven M.
• Primary Examiner(s): Hofsass; Jeffery
• Assistant Examiner(s): Lu; Shirley
• Application Number:
  US10/993,487
• Publication Number:
  US 20060109105A1
• Time in Patent Office: 925 Days
• Field of Search: 340/676, 340/571.2, 128/604, 235/375, 235/385
• US Class Current: 340/572.1
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G08B 13/2462 Asset location systems combined with EAS inventory, tracking, logistic G06Q10/00; entrance control systems G07C9/00

Abstract

A surgical instrument tray shipping tote identification system is provided. During transit to or from a medical facility, processing center, distribution center or other location, multiple surgical instruments trays are placed in an instrument tray shipping tote. Each instrument tray includes at least one RFID transponder tag storing identification information about that tray. The shipping tote has a bar coded shipping label affixed to one surface generated at the point of origin. When the tote arrives at the distribution center, it is placed on a conveyor system that includes a reading station having an RFID transceiver and a bar code reader. Information read from the RFID transponder tags and the bar code label is transmitted by a controller to an external database to check for any off-nominal status indicators. Once this check is performed, an indication is sent back to the controller and an appropriate indicator on the identification system is activated.

Claims

1. An apparatus for identifying surgical instrument trays and surgical instrument tray shipping totes, comprising:

a chassis;

a conveyor system defining a path of travel supported by the; and

a reader station attached to the chassis by a frame and comprising an RFID transceiver, a bar code reader, a control circuit and an indicator, wherein the bar code reader is configured to read a bar coded shipping label on an instrument tray shipping tote, the RFID transceiver is configured to read information from an RFID tag associated with instrument tray in the tote, and the control circuit is configured to perform a comparison between information read from the bar coded shipping label and the RFID tag with stored information and to activate the indicator in response to this comparison.

2. The apparatus of claim 1, wherein the conveyor system is selected from a conveyor belt or a plurality of conveyor rollers.

3. The apparatus of claim 1, wherein the RFID transceiver comprises at least one RF antenna configured to generate a RF field and to receive signals emitted from RFID transponder tags within the field.

4. The apparatus of claim 1, further comprising a data bus for communicating data from the RFID transceiver and the bar code reader to a computer system.

5. The apparatus of claim 4, wherein the data bus comprises a wireless data channel.

6. The apparatus of claim 4, wherein the data bus comprises a wired data channel.

7. The apparatus of claim 4, wherein the indicator comprises an indicator selected from the group consisting of a visual indicator, an audible indicator a printed indicator message, and mixtures thereof.

8. The apparatus according to claim 1, wherein the controller comprises means for activating the indicator based on a determined that at least one predetermined condition has been satisfied.

9. The apparatus according to claim 8, wherein the determination comprises comparing information obtained by the RFID reader and the bar code reader with previously stored information.

10. A method for identifying surgical instrument trays and surgical instrument tray shipping totes comprising:

placing a surgical instrument tray shipping tote containing one or more surgical instrument trays on a conveyor system;

activating an RFID reader to read information from at least one RFID transponder tag associated with each of the one or more surgical instrument trays contained in the shipping tote;

activating a bar code reader to read information from a bar-coded shipping label affixed to a surface of the shipping tote;

comparing the information read by the RFID reader and the bar code reader with previously stored information; and

activating an indicator based on the step of comparing.

11. The method according to claim 10, the step of activating an RFID reader comprising generating an RFID field over a portion of the conveyor system with one or more RF antennae so as to automatically energize any RFID transponder tags passing within the portion of the conveyor system and reading information from the energized RFID transponder tags.

12. The method according to claim 10, the step of activating a bar code reader comprising activating a bar code reader positioned above the surface of the shipping tote to which the bar-coded shipping label is affixed.

13. The method according to claim 10, the step of comparing comprising sending the information read by the RFID reader and the bar code reader to a computer system, comparing the information with information stored in a database, and receiving a signal from the computer system indicative of a result of the comparison.

14. The method according to claim 13, the step of sending comprising sending the information over a physical data channel.

15. The method according to claim 13, the step of sending comprising sending the information over a wireless data channel.

16. The method according to claim 13, the step of activating an indicator based on the step of comparing comprising activating an indicator corresponding to the result.

17. The method according to claim 13, the step of activating an indicator comprising activating an indicator chosen from the group consisting of a visual indicator, an audio indicator, an printed indicator and mixtures thereof.

18. A method of identifying surgical instrument kits comprising:

affixing a bar-coded shipping label to a surface of a surgical instrument shipping tote containing one or more surgical instrument kits each surgical instrument kit comprising at least one RFID transponder tag;

placing the surgical instrument shipping tote on a conveyor system;

operating the conveyor system to move the shipping tote past an RFID transceiver and a bar code reader at a reading station;

obtaining first identification information from the RFID reader when the tote enters the reading station;

obtaining second identification information from the bar code reader corresponding to the shipping tote and its contents;

comparing the obtained first and second identification information with previously stored information; and

activating an indicator based on the results of the comparison.

19. The method according to claim 18, the step of obtaining first identification information comprising energizing each RFID transponder tag contained in the tote with an RFID transceiver with one or more RF antennae and receiving a signal from each energized tag containing the first identification information.

20. The method according to claim 18, the step of obtaining second identification information comprising illuminating the bar-coded label with a bar code scanner and obtaining a signal including the second identification information.

21. The method according to claim 18, the step of comparing comprising communicating the first and second identification information to a computer system through a communications channel, comparing the first and second identification information with information stored at the computer system, and receiving a signal from the computer system over the communications channel indicative of the results of the comparison.

22. The method according to claim 21, the step of communicating the first and second identification information through a communications channel comprising communicating the information through a physical communications channel.

23. The method according to claim 21, the step of communicating the first and second identification information through a communications channel comprising communicating the information through a wireless communications channel.

24. The method according to claim 21, the step of activating an indicator based on the results of the comparison comprising activating an indicator chosen from the group consisting of a visual indicator, an audio indicator, an printed indicator and mixtures thereof.

25. A method for identifying the status of a surgical instrument kit shipping tote and surgical instrument kits residing therein with a surgical instrument shipping kit and surgical instrument kit shipping tote identification system comprising:

scanning a bar coded shipping label comprising encoded information associated with a surgical instrument shipping tote with a hand held bar code scanner;

transferring the encoded information received by bar code scanner to a data processor over a communication link of the identification system to matched with surgical instrument kits associated with that encoded information;

receiving a response from the data processor indicating that the encoded information has been received;

conveying the shipping tote to an RFID reader station along a conveyor path of the identification system;

reading information from at least one RFID transponder tag associated with at least one surgical instrument kit contained within the shipping tote;

transferring the information read from the at least one RFID transponder tag to the data processor;

receiving a signal indicative of a processing status of the current shipping tote; and

displaying a visual cue indicative of the processing status of the current shipping tote.

26. The method according to claim 25, wherein the information read from the at least one RFID transponder tag comprises identification information for the surgical instrument kit that the tag is associated with.

27. The method according to claim 25, wherein said processing status comprises a status selected from the group consisting of normal processing, expedited processing, and exception/error processing.