Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND APPARATUS FOR EFFICIENT PACKAGE DELIVERY AND
STORAGE
BACKGROUND OF THE INVENTION
Field of the Invention
The invention pertains to the general field of storage and delivery of ordered
items.
More particularly, the invention pertains to an efficient method for handling
the bulk delivery
of articles from a depot into an automated article storage and retrieval
system at a centralized
article pickup location.
Description of the Related Art
The Internet has provided tremendous opportunities for the sales of products
in the
retail business. Consumers can easily go online using a computer, personal
digital assistant
(PDA), or even a cellular phone, and readily access a plethora of web sites
that offer a wide
range of products. Notwithstanding the fact that online businesses can offer
lower prices to
consumers because of lower overhead costs, consumers and retailers can be
disadvantaged by
the cost associated with shipping and handling. For example, the effective
cost of ordering a
bottle of shampoo and a toothbrush which might cost $4.00 could be $9.00 due
to the cost of
shipping and handling. As a result of the added cost of shipping and handling,
it is currently
impractical to order low cost items unless the cost of shipping and handling
can be
significantly reduced. Even for higher priced items, the shipping and handling
costs
associated with each order can be tolerable for an occasional purchase, but
are prohibitive
when added up across the frequency of purchase a consumer normally makes.
In order to reduce the cost of shipping and handling, more efficient methods
and
systems of delivery are required. In current delivery methods and systems,
ordered items may
be picked at a retailer's fulfillment site in batches, but each order is
handled in a singular
manner. A recipient of a product may place an order to a retailer. The
retailer accepts the
order, packages the ordered item and then ships the package along with other
packages via a
package delivery service. Once the package delivery service picks up the
package from the
retailer, the package is usually taken to an initial distribution center where
it is sorted
according to the destination address of the recipient. It will then be shipped
by air, land or sea
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to one or more distribution centers where it is resorted every time. Once the
package reaches
the distribution center that services the recipient locale, the package will
be transported on a
delivery track, along with other packages to be delivered in that local area,
to the customer-
specified address of each package on the delivery truck, until the delivery
truck reaches the
customer-specified address of the recipient's package for final delivery.
Inherent in these delivery and handling processes are numerous inefficiencies
that in
the end, result in increased cost. Firstly, the packages of ordered items are
packed
ineff ciently for the entire distance that they are transported. This is due
to the nature of
trying to pack items of different shapes and sizes into a box or container
that is large enough
to hold all the items, with added packing materials to prevent the differently
shaped items
from damaging each other during transport. Secondly, packages are moved from
cargo-
carrying vehicles and packages sorting facilities a numerous amount of times
as packages are
distributed. The packages are moved from a delivery vehicle to a facility and
vice-versa. At
each point that a package changes hands when being routed through a package
shipper's
distribution network, it is resorted and grouped with other packages to fit
onto the next cargo-
carrying vehicle. This translates to an increased shipping and handling cost.
Thirdly, each
package delivered to its final distribution center has to be carried on an
individual basis to the
recipient's delivery address. The packages are delivered to recipient
addresses on smaller
cargo-carrying vehicles and can only be delivered during reasonably acceptable
business
hours. If the recipient is not available at the time of the attempted
delivery, a package may
either be left outside of a xecipient's home where it is susceptible to theft,
mischief, or
weather damage, or it may remain undelivered until a further delivery attempt
is made. The
shipping cost is further compounded in instances where several attempts have
to be made to
finalize the delivery.
Analysts have predicted that the buying habits of mainstream consumers will
change,
in the near future, to one that is heavily dependent on the Internet. In
addition to the
inefficiencies described above, if and when this growth occurs, the current
delivery methods
and infrastructure will be vastly inadequate to accommodate this growth.
Given these inefficiencies, there exists a need to achieve more efficient
methods and
systems for delivering packages.
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SUMMARY OF THE INVENTION
One aspect of the invention discloses a method and system fox efficient bulk
package
delivery for recipients. The method for efficient bulk package delivery for
recipients can
include the steps of delivering the packages in bulk for a plurality of
recipients in a single
delivery stop to a destination centralized pickup location and loading the
bulk delivered
packages randomly into an automated system of storage locker bins. The step of
delivering
the packages in bulk for a plurality of recipients can further include,
delivering items destined
for recipients of the packages. The step of delivering the packages in bulk
can include the
step of sorting at an central location, for example an origination regional
distribution center
(RDC), items received from a plurality of retailers delivered to the
origination RDC location,
the items being organized by a common item identifier and destined for a
plurality of
recipients.
The step of sorting the received items at the origination RDC location can be
further
comprised of the steps of identifying the received items based on their
destination centralized
pickup location, or their destination local distribution hub. Additionally,
the received items
can be identified to a destination RDC location. The identified items which
are organized by
a common item identifier can be sorted and grouped based on the identified
destination RDC.
In one aspect of the invention, the step of delivering packages in bulk can
include
transporting the sorted and grouped items to the identified destination RDC,
sorting the
transported items by either the destination centralized pickup location or a
destination local
distribution hub, and creating the bulk delivered package by organizing the
sorted items for a
specific recipient. The sorted items can be sorted by either a destination
centralized pickup
location or a destination local distribution hub. The created bulk delivered
package having
items organized for a specific recipient can then be transported in bulk to
the destination
centralized pickup location selected when the customer placed the order or to
the destination
local distribution hub serving the area in which the customer specified
address is located, if a
customer specified address was entered.
In a further aspect of the invention, the step of creating the bulk delivered
package at
the destination RDC location can further include locating items destined to a
specific
recipient from items organized by the common item identifier. The method can
further
include consolidating items originating from more than one retailer, destined
to the specific
recipient. The method can further include receiving the located items
associated with a single
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order from more than one fulfillment location, the fulfillment location being
at least one of a
retailer, a manufacturer, a merchant and a supplier.
The step of randomly loading the bulk delivered package into an automated
system of
storage locker bins can further include capturing electronically, an identif
er for the bulk
delivered package, and associating the electronically captured identifier of
the bulk delivered
package with an electronically captured identifier of one of the storage
locker bins within the
automated system of storage locker bins. The bulk delivered package created
for a specific
recipient can be retrieved from a storage locker bin. Suitable electronics and
circuitry can be
used to facilitate authenticating an identity of the recipient prior to
revealW g the identity of
' the storage locker bin and/or providing access to that storage locker bin.
In a further aspect of the invention, the method for efficient bulk package
delivery can
further include creating a returns package having one or more items from
either the bulk
delivered package retrieved by a recipient and or packages delivered to a
customer specified
address, wherein the returns package can be destined for a retailer associated
with the items
of the returns package. Sorted and grouped created returns packages can be
delivered in bulk
to returns facility of the associated retailer. The invention can further
include submitting the
returns package for pickup at a destination centralized pickup location.
A further aspect of the invention can include creating a returns package that
can
consist of at least one item from either a bulk delivered package retrieved by
a recipient and a
package delivered to a customer specified address, the returns package
destined for the
retailer associated with the items of the returns package. A returns facility
identifier and a
returns local market identifier can be identified based upon an identifier of
the retailer. An
origination RDC identifier associated with the identified returns local market
identifier can
also be identified. The returns package can be submitted for pickup at a
destination
centralized pickup location. The submitted returns package can be transported
from the
destination centralized pickup location of the returns package submission, to
a destination
RDC associated with the destination centralized pickup location of returns
package
submission. At the associated destination R.DC, the transported returns
package can be sorted
and grouped by the RDC identifier associated with the returns local market
identifier
identified for the returns package for bulk delivery to an origination RDC
associated with the
identified RDC identifier. The sorted and grouped returns package can be
transported from
the associated destination RDC to the associated origination R.DC. At the
associated
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origination RDC, the transported returns package can be sorted by the
identified returns local
market identifier of the returns package. At the associated origination RDC,
the sorted
returns package can be sorted and grouped according to the identified returns
facility
identifier of the sorted returns package for bulk delivery to a returns
facility associated with
the returns facility identifier. The sorted and grouped returns package can be
delivered to the
associated returns facility.
In a further aspect of the invention, the step of randomly loading the bulk
delivered
package into the automated system of storage locker bins can include
automatically triggering
the dispatch of an electronic notification to the recipient of the bulk
delivered package, the
electronic notification having at least an identifier of the destination
centralized pickup
location. Suitable electronic circuitry and software can be used to facilitate
the triggering and
dispatch functions.
The step of automatically triggering the dispatch of the electronic
notification can
further include recording information necessary for billing at least one of
the retailer shipping
the ordered items of the bulk delivered package, a customer who ordered the
item of the bulk
delivered package, and the recipient of the bulk delivered package. The
information can
include at least one of an order identifier, an ordering customer identifier,
a recipient
identifier or a customer identifier, a package identifier, a delivery date; a
delivery time, a
delivery notification date, a delivery notification time, a retrieval date and
a retrieval time, or
any combination thereof. The electronic notification to the recipient can be a
facsimile, an
email, a telephone call, and a page or any combination thereof.
In a further aspect of the invention, the delivery method can further include
retrieving
the bulk delivered package by the recipient through self service. Prior to
retrieval, the
package must be delivered and loaded into the storage bin. The step of loading
the bulk
delivered package randomly into the automated system of configurable storage
locker bins
can include the step of loading the bulk delivered package into any unoccupied
storage locker
bin within the automated system of configurable storage locker bins, having
dimensions that
are large enough to accept the bulk delivered package. The temperature within
the bins of the
automated system of storage locker bins can also be controlled by locating the
bins in a
temperature-controlled environment.
The step of delivering the package in bulk to a destination centralized pickup
location
can further include accommodating the delivery of the package in bulk to the
destination
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centralized pickup location from a plurality of different shippers. The
loading of the bulk
delivered package randomly into the automated system of storage locker bins
can further
include accommodating the loading of the delivered package into the automated
system of
storage locker bins from a plurality of different shippers.
- Alternately, the step of delivering the package in bulk to the destination
centralized
pickup location can further include, creating the bulk delivered package at a
retailer
fulfillment site, the bulk delivered package containing at least one ordered
item organized for
a specific recipient. In a further aspect of the invention, either a specified
destination
centralized pickup location or a destination local distribution hub can be
determined for the
bulk delivery of the package. Similarly, a destination RDC for the bulk
delivered package
can also be determined. The bulk delivered package can then be transported
from the retailer
fulfillment site to an origination RDC, where the transported bulk delivered
package can be
sorted and grouped based on its determined destination RDC. The bulk delivered
package
can be transported from the origination RDC to the determined destination RDC.
At the
destination RDC, the transported bulk delivered package can then be sorted and
grouped for
bulk delivery by its previously determined destination centralized pickup
location or
destination local distribution hub. The bulk delivered package can be
delivered to the
previously determined pickup location and or the local distribution hub in
bulk with the other
bulk delivered packages with which it has been grouped.
In another aspect of the invention, the step of delivering the bulk delivered
package to
the destination centralized pickup location can further include creating the
bulk delivered
package at a retailer fulfillment site, with the bulk delivered package
containing at least one
item organized for a specific recipient. The specified destination centralized
pickup location
or the destination local distribution hub can be determined for the bulk
delivery of the created
bulk delivered package. Based on the determined specified destination, the
bulk delivered
packages can be sorted and grouped at the retailer fulfillment site for bulk
delivery. The
packages can be delivered in bulk from the retailer fulfillment site to the
determined specified
destination.
The method for efficient bulk package delivery can further include creating a
bulk
delivered CDC outbound package consisting of at least one item destined for a
recipient at a
specified destination centralized pickup location or a specified address,
submitting the bulk
delivered CDC outbound package for pickup at a destination centralized pickup
location, and
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delivering the CDC outbound package in bulk to either the specified
destination centralized
pickup location or a destination local distribution hub,
In yet another aspect of the invention, the method for efficient package
delivery can
also include a method for efficient package cxeation. The method for efficient
package
creation can include determining either a specified destination centralized
pickup location or
a destination local distribution hub for delivery of at least one item
destined for a recipient.
Items can be located for a specific recipient and the specified destination
centralized pickup
location or the local distribution hub from said items within a destination
RDC, with the
items being organized by a common item identifier. The located items can be
consolidated
into a package to be delivered to either the destination centralized pickup
location or the
destination local distribution hub for a recipient. The located items can
originate from one or
more retailers.
The method for efficient package creation can further include delivering in
bulk items
that can be organized by a common item identifier from a retailer to an
origination RDC to
fill an order destined for the recipient. A destination RDC can be determined
for the items
based on a predefined relationship between a series of local' markets served
by a destination
RDC and a local market of the determined one of a specified pickup location
and a local
distribution hub. The items can be transported from the origination RDC to the
determined
destination RDC.
In yet another aspect of the invention, a method for efficient package
creation can
include delivering items organized by a common item identifier in bulk from a
retailer to an
origination RDC to fill an order destined for a recipient. A destination RDC
can be
determined for the delivered items based upon the destination delivery
location of the order
destined for the recipient, and the items can be transported from the
origination RDC to the
destination RDC. At the destination RDC, items destined for a specific
recipient can be
located from the items organized by a common item identifier, and the located
items can be
consolidated into a package destined for that recipient. The located items,
which can be
consolidated into a package for a recipient, can originate from more than one
retailer if items
fox more than one order destined fox the recipient have been received into the
destination
RDC.
In a further embodiment of the invention, a system for efficient bulk package
delivery
for recipients is disclosed. The system can include a delivery means for
delivering of the
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packages in bulk for recipients by using a single delivery stop to a
destination that can be a
centralized pickup location and a means for randomly loading bulk delivered
packages into
an automated system of storage locker bins. The delivery means for delivering
of the
packages in bulk can include a means for sorting at a RDC location, items
received from
suppliers, which can include but are not limited to, retailers, manufacturers,
wholesalers, and
distributors, delivered to the origination RDC location. The items can be
destined for
recipients and can be organized by a common item identifier or SITU.
The means for sorting the received items at the origination RDC location can
include
identification means for identifying the received items according to a
destination centralized
pickup location or a destination local distribution hub, and a destination RDC
for the received
items. The means for sorting the received items can also include means for
sorting and
grouping the identified received items by the identified destination RDC, the
grouped items
being organized by a common item identifier.
The means for delivering the packages in bulk can include a transportation
means for
shipping sorted and grouped items to the destination RDC, means for sorting at
the
destination RDC, the received items by either a destination centralized pickup
location or a
destination local distribution hub. The means for delivering the packages in
bulk can also
include means for creating at the destination RDC, the bulk delivered package
by organizing
the items sorted by the destination centralized pickup location or the
destination local
distribution hub for a specific recipient and a transportation means for
shipping the created
bulk delivered package to either the destination centralized pickup location
or the destination
local distribution hub.
In a further aspect of the invention, the means for randomly loading the bulk
delivered package into the automated system of storage locker bins can
comprise means for
capturing electronically, an identifier or SKU for the bulk delivered package
and means for
associating the electronically captured identifier of the bulk delivered
package with an
electronically captured identifier of one of the storage locker bins within
the automated
system of storage locker bins. The means for randomly loading the bulk
delivered package
into the automated system of storage locker bins can also include suitable
electronic circuitry
and software for automatically triggering the dispatch of an electronic
notification to a
recipient of the bulk delivered package. The electronic notification can have
at least an
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identifier of the destination centralized pickup location. The circuitry and
associated software
can record information necessary for billing customers, retailers, suppliers
and or recipients.
Another aspect of the invention discloses a method for efficient delivery of
packages
for recipients. The method for efficient delivery of packages for recipients
can include the
steps of delivering the packages in bulk fox different recipients in a single
delivery stop to a
destination centralized pickup location and loading the bulk delivered
packages randomly
into an automated system of storage locker bins, the automated system of
storage locker bins
enabling self service retrieval of the bulk delivered packages by the
recipients. The delivery
step can further include the step of coordinating workers to travel amongst
the destination
centralized pickup locations to meet delivery of the bulk delivered packages.
The
coordinated workers can unload the bulk delivered packages from a cargo
carrier into the
destination centralized pickup location. Unloading the bulk delivered packages
from a cargo
carrier can include, unloading the bulk delivered packages into a secured area
within the
destination centralized pickup location, the secured area having a first
region accessible by all
shippers and/or a second region restricted to a specific shipper.
The delivery step of the method for efficient delivery of packages for
recipients can
include the steps of delivering an item destined for a recipient. The delivery
step can further
include contracting by a first retailer with one or more parties which can
include a second
retailer, a manufacturer, a supplier, a distributor, a merchant and/or an
order fulfillment
operation to purchase over a predetermined duration of time, a predetermined
quantity of
items and/or a predetermined dollar volume of items. A customer order for an
item destined
for a recipient can be filled by forwarding information of the customer order
to the contracted
party (or parties), with the customer order information including at least a
quantity of an
ordered item. The delivering step can further include a retailer accepting the
customer order
for the item. Information related to the accepted customer order can be
communicated from
the retailer to the contracted party (or parties). The contracted party can
pick items to meet a
demand for items which can be based on the ordered item quantity of the
related information.
The delivering step can further include sorting transported items received at
a
destination RDC according to an identified destination centralized pickup
location or
destination local distribution hub location, with the items being organized by
a common item
identifier. At the destination RDC, the bulk delivered package can be created
by picking
items for a recipient from the sorted transported items, with the sorted items
still being
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organized by a common item identifier (located within a case or container of
like items).
Furthermore, the cases of items could have been sorted according to a selected
location which
can be either a destination centralized pickup location or a destination local
distribution hub
location.
The creating step can further include differentiating between items that are
received
from different retailers when creating the bulk delivered package to prevent
an item ordered
from a particular retailer from being fulfilled by an identical item received
from a different
retailer. Moreover, the creating step can further include printing at least
one packing list for
the bulk delivered package at the destination RDC. Each of the packing lists
can be specific
to a retailer, listing only the items within the bulk delivered package
received from one
retailer of the different retailers from which the items were received. The
packing list can be
formatted according to a retailer specific formatting and/or a general
retailer formatting.
The creating step can further include utilizing a protective container which
has been
pre-sized to fit into a storage locker bin of the automated system of storage
locker bins. The
container can be adjustable in order to minimize an empty space located
therein. For
example, if an adjustable container such as a package bag is only filled half
way with items,
the additional empty space can easily be compressed andlor cut-away to result
in the package
only consuming a volume slightly larger than the items within it. In contrast,
if a non-
adjustable container such as a box is only filled half way with items, it
consumes as much
space as it would if it were completely filled. Because the package bag of
this example only
takes up half of the volume of the box, it can be transported on a cargo
carrier approximately
twice as efficiently as (or for approximately half of the cost of) the
exemplary box containing
the same items. This type of improved package space efficiency can also reduce
the cost
incurred to store the package at a destination centralized pickup location.
The delivering step can further include minimizing labor that is necessary for
organizing bulk delivered packages into groups of bulk delivered packages for
delivery to the
selected location for which the packages are destined. The minimizing step can
include,
organizing within an area of the destination RDC, the created bulk delivered
packages into
the groups of organized packages prior to moving the packages from the area of
the
destination RDC where the packages were created. The packages can be grouped
by the
selected locations for which they are destined with only minimal labor,
because the packages
have been created from items which were previously sorted according to those
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locations. Thus, the packages can be accumulated from a source of packages
having the same
destination rather than being sorted from a source of packages having many
different
destinations.
The sorting step can further include identifying the transported items to a
local market
and sorting the transported items by the identified local market prior to
sorting the transported
items by the identified destination centralized pickup location or destination
local distribution
hub location. A local market being a grouping unit representing a grouping of
destination
centralized pickup locations and/or destination local distribution hub
locations. The
transported items being organized by a common item identifier.
The delivering step can further include the step of minimizing a distance that
the
items are transported as a package by transporting the items within a
container (or item case).
The package contains items organized for a recipient and the container
contains items
organized by a common item identifier. The minimizing step can occur when the
items are
transported from a retailer fulfillment site to an origination RDC location
and/or when the
items are transported between the origination RDC location and a destination
RDC location.
The minimizing step can further include, locating destination RDC locations in
close
proximity to local markets having greatest demand for items. The local market
can be a
designated geographic area containing a plurality of destination centralized
pickup locations.
Fox example, destination RDC locations can be located within approximately 100
miles of
local markets having greatest demand for items. It should be understood by one
skilled in the
art that other factors might dictate where the destination RDC is located.
The delivering step can further include printing labels having an identifier
of the
items. The labels can be organized as a pick list, and a quantity of
containers of a particular
item can be picked to satisfy a number of the printed labels having the item
identifier of the
particular item. The labels can be printed in an amount necessary to satisfy a
group of orders
for the items and the picked quantity of containers can be labeled. The step
of printing the
labels can include printing a pick grouping identifier associated with a group
of the labels for
containers of the items and updating a data record associated with the
containers of the items
whenever the pick grouping identifier associated with the labels of those
containers is
optically read, for example, by a scanner.
The delivering step can further include utilizing a hands-free optical
scanning device
to optically read an identifier and access information associated with the
optically read
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identifier. The optically read identif er can be any of the following
identifiers: an identif er of
a container of items which are organized by an item identifier, an identifier
of a grouping of
the containers, an identifier of a bulk delivered package, an identifier of a
grouping of bulk
delivered packages organized by a destination centralized pickup location
identifier, an
identifier of a cargo carrier, an employee identifier, and an identifier of a
stoxage locker bin of
the automated system of storage locker bins. The delivering step can further
include the step
of distributing the item through at most two distribution facilities between a
retailer
fulfillment site from which the item originates, to delivery of the item
packaged as a bulk
delivered package at the destination centralized pickup location. The
efficiency of
distributing the item through no more than two distribution facilities can be
realized by a
shipper when distributing the item within a single country. In some cases the
efficiency of
distributing the item through no more than two distribution facilities can
also be realized in
distributing an item from one country to another.
The delivering step can further include packing the bulk delivered packages
tightly
into a container wherein the packages are prevented from moving within the
container. The
packed bulk delivered packages can be transported in the container to
facilitate moving a
group of the bulk delivered packages destined for a destination centralized
pickup location.
The container can be constructed to be collapsible and reconstructable. The
collapsible and
reconstructable nature of the container allows the container to be transported
efficiently when
empty by minimizing the space necessary for transporting the empty containers.
The self service retrieval of the bulk delivered packages by the recipients
can include
the step of locating video teleconferencing equipment in the destination
centralized pickup
location. The video teleconferencing equipment can be connected to a remote
customer
service operation center. Assistance can be provided to package recipients via
the video
teleconferencing equipment located in the destination centralized pickup
location without
requiring customer service personnel to be located on-site at each destination
centralized
pickup location. It should be readily appreciated by those skilled in the art
that video
teleconferencing can include, for example, an audio capturing device
(microphone), an audio
playback device (speaker), a video device (camera) or any combination thereof.
Furthermore,
the self service retrieval of the bulk delivered packages by the recipients
can include locating
video monitoring equipment in the destination centralized pickup location. The
video
monitoring equipment can be connected to a remote security monitoring service
operation to
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provide security monitoring services to the destination centralized pickup
location without
requiring security personnel to be located on-site at each destination
centralized pickup
location.
The delivering step can further include reducing labor costs by organizing a
majority
S of labor intensive tasks in RDC locations and a minority of labor intensive
tasks in the
destination centralized pickup locations. The destination centralized pickup
locations being
substantially more numerous than the RDC locations. The organized majority of
labor
intensive tasks can include any work that is necessary for accomplishing such
tasks as sorting
the items, shipping the items between multiple RDC locations, and creating
packages for
recipients from the items. The organized minority of labor intensive tasks can
include any
work that is necessary fox accomplishing such tasks as loading the created
bulk delivered
packages into the automated system of storage locker bins.
The delivering step can include updating a first data record associated with a
container
of the items and/or a second data record associated with a bulk delivered
package, whenever a
third data record containing an identifier of the container and/or an
identifier of the bulk
delivered package gets updated. The third data record can contain one or more
of an
identifier associated with a shipment between one of a retailer fulfillment
site, a RDC, a
destination centralized pickup location, a destination local distribution hub
location, or a
retailer returns facility and one of a retailer fulfillment site, a RDC, a
destination centralized
pickup location, a destination local distribution hub location or a retailer
returns facility.
The method for efficient delivery of packages in bulk can further include
validating an
access card and a first code for the recipient prior to identifying an
identifier of a storage
locker bin unit within the automated system of storage locker bins. The
identified storage
locker bin unit can have a storage locker bin that contains the bulk delivered
package for the
recipient and the access card can contain at least an identifier of the
recipient. The first code
can be a PIN. The step of identifying an identifier of a storage locker bin
unit within the
automated system of storage locker bins can further include, creating a report
listing the
identifiers of the identified storage locker bin units containing a
recipient's bulk delivered
packages.
The validation step can further include communicating a second code which can
be
entered along with the PIN at each of the identified storage locker bin units
to enable self
service retrieval of the bulk delivered packages. The second code can be
assigned to a
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specific recipient for a predetermined length of time. The validating step can
further include
electronically opening an entrance door to the destination centralized pickup
location.
The method for efficient delivery of packages in bulk cari further include,
automatically triggering a dispatch of an electronic notification to the
recipient of the bulk
S delivered package. The triggering of the dispatch can occur when the bulk
delivered package
is loaded into the automated system of storage locker bins. The electronic
notification can
have at least an identifier of the destination centralized pickup location.
The method for
efficient delivery of packages in bulk can also include recording a retrieval
date and a
retrieval time for a bulk delivered package, when one is retrieved from the
automated system
of storage locker bins. The automatic triggering step can further include,
recording
information necessary for billing one or more selected parties which can
include any of a
customer who ordered an item of the bulk delivered package, a recipient and/or
a retailer.
The information can include at least one selected data entity from the group
including an
order identifier, an ordering customer identifier, a recipient identifier, a
customer identifier, a
package identifier, a delivery date, a delivery time, a delivery notification
date and/or a
delivery notification time. The step of recording a retrieval date and a
retrieval time can
further include, assessing the selected party a discount for early retrieval.
The early retrieval
can be based on at least one of the recorded retrieval date, the recorded
retrieval time and/or
the information recorded during the triggering step and a predefined standard
of an acceptable
duration of time from delivery notification to package retrieval.
The step of recording a retrieval date and a retrieval time can further
include assessing
the selected party a predetermined financial penalty for late retrieval. The
late retrieval can
be based on at least one of the recorded retrieval date, the recorded
retrieval time and/or the
information recorded during the triggering step and a predefined standard of
an acceptable
duration of time from delivery notification to package retrieval. The step of
assessing a
financial penalty can be periodic.
The step of delivering the package in bulk to the destination centralized
pickup
location can further include enabling a customer to submit a package at a
destination
centralized pickup location for shipment to a specified destination
centralized pickup location
for a recipient. The customer submitted package can contain an item that is
destined for the
recipient and can be randomly loaded into an automated system of storage
locker bins by a
shipper. The automated system of storage locker bins can enable self service
retrieval of the
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customer submitted package by the recipient. The step of loading the customer
submitted
package can fixrther include triggering automatically, dispatch of an
electronic notification to
the customer. The electronic notification can be a confirmation of delivery
and can have at
least an identifier of the customer submitted package.
The method for efficient delivery of packages can further include determining
bin
configuration adjustments to be made to bins of the automated system of
storage locker bins
to enable more bulk delivered packages to be loaded into the automated system
of storage
locker bins. A report can be created to update data records corresponding to
bins of the
automated system of storage locker bins upon which the determined bin
configuration
adjustments will be physically made. Bin size data corresponding to a bin that
is being
configured can be updated such that the update can be achieved through data
optically read
from the created report.
The method can further include adding temporarily, additional storage locker
bins to
the automated system of storage locker bins by locating additional storage
locker bin units
inside the destination centralized pickup location and/or outside the
destination centralized
pickup location, and connecting the additional storage locker bin units to a
data network of
the automated system of storage locker bins. The data network infrastructure
can either be
wired or wireless. The delivering step can further include enabling shipping
fees to be
tracked by a customer order. The method for efficient delivery of packages can
include
enabling a quantity of storage locker bins to be reserved in aggregate for a
quantity of bulk
delivered packages prior to shipping the bulk delivered packages to the
destination
centralized pickup location and/or receiving the bulk delivered packages at
the destination
centralized pickup location.
In another embodiment of the invention, a method for efficient delivery of
packages
for recipients can include a shipper or a party contracted by the shipper
creating the packages
for recipients. The shipper created packages can be delivered in bulk by the
shipper for
different recipients in a single delivery stop to a destination centralized
pickup location. The
delivery step includes delivering an item destined for a recipient. The
creating step can
further include sorting transported items received at a destination RDC
according to an
identified destination centralized pickup location or destination local
distribution hub
location, with the items being organized by a common item identifier.
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At the destination RDC, the bulk delivered package can be created by picking
items
for a recipient from the items sorted according to either an identified
destination centralized
pickup location or destination local distribution hub location, wherein the
sorted items can
still be organized by a common item identifier. The sorting step can further
include
identifying the transported items to a local market and sorting the
transported items by the
identified local market prior to sorting the transported items by the
identified destination
centralized pickup location or destination local distribution hub location. A
local market
being a grouping unit representing a grouping of a destination centralized
pickup locations
and/or destination local distribution hub locations. The transported items
being organized by
a common item identifier.
The method for efficient delivery of packages can further include, utilizing a
hands-
free optical scanning device to optically read an identifier and access
information associated
with the optically read identifier. The optically read identifier can be any
of the following
identifiers: an identifier of a container of items organized by an item
identifier, an identifier
of a grouping of the containers, an identifier of a bulk delivered package, an
identifier of a
grouping of bulk delivered packages organized by a destination centralized
pickup location
identifier, an identifier of a cargo carrier, an employee identifier and an
identifer of a storage
locker bin of the automated system of storage locker bins.
The delivery step can further include minimizing a distance that the items are
transported as a package by transporting the items within a container;
moreover, the package '
contains items organized for a. recipient and the container contains items
organized by a
common item identifier. The minimizing step can occur when the items are
transported from
a retailer fulfillment site to an origination RDC location and/or when the
items are
transported between the origination RDC location and a destination RDC
location. The
minimizing step can further include, locating destination RDC locations in
close proximity to
local markets having greatest demand for items. The local market can be a
designated
geographic area containing a plurality of destination centralized pickup
locations.
The creating step can further include utilizing a pre-sized protective
container with
the container being adjustable to minimize empty space therein. The delivery
step can further
include minimizing labor required to organize bulk delivered packages into
groups of bulk
delivered packages for delivery to the selected location fox which the
packages are destined.
The minimizing step can include organizing within an area of the destination
RDC, the
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created bulk delivered packages into the groups of organized packages prior to
moving the
packages from the area of the destination RDC where the packages were created.
The
packages can be grouped by the selected locations for which they are destined
with only
minimal labor, because the packages have been created from items which were
previously
sorted according to those selected locations. Thus, the packages can be
accumulated from a
source of packages having the same destination rather than being sorted from a
source of
packages having many different destinations.
The delivering step can further include contracting by a first retailer with a
selected
party which can include a second retailer, a manufacturer, a supplier, a
distributor, a merchant
and an order fulfillment operation to purchase over a predetermined duration
of time one of a
predetermined quantity of items and a predetermined dollar volume of items. A
customer
order can be filled for an item destined for a recipient by forwarding
information of the
customer order to the selected party, the customer order information including
at least a
quantity of an ordered item. The delivery step can further include a retailer
accepting the
. customer order for the item. Information related to the accepted customer
order can be
communicated from the retailer to the selected party (or parties). The
selected party can pick
items to meet a demand for items which can be based on the ordered item
quantity of the
related information.
The delivery step of method for efficient delivery of packages can further
include
distributing the item through at most two distribution facilities between a
retailer fulfillment
site from which the item originates to delivery of the item packaged as a bulk
delivered
package at the destination centralized pickup location. The efficiency of
distributing the item
through no more than two distribution facilities can be realized by a shipper
when distributing
the item within a single country. Labor cost can be reduced by organizing a
majority of labor
intensive tasks in RDC locations and a minority of labor intensive tasks, in
destination
centralized pickup locations. The destination centralized pickup locations
being substantially
more numerous than the RDC locations. The organized majority of labor
intensive tasks can
include the work necessary for sorting the items, shipping the items between
multiple RDC
locations, and creating packages for recipients from the items. The organized
minority of
labor intensive tasks can include the work necessary for distributing the
created bulk
delivered packages to recipients.
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The delivering step can further include coordinating workers to travel amongst
the
destination centralized pickup locations to meet delivery of the bulk
delivered packages. The
coordinated workers can unload the bulk delivered packages from a cargo
carrier into the
destination centralized pickup location. The unloading step can include
unloading the bulk
delivered packages into a secured area within the destination centralized
pickup location,
wherein the secured area has a first region accessible by all shippers and/or
a second region
restricted to a specific shipper.
The delivering step can further include printing a pick grouping identifier
associated
with a group of labels for containers of the items and updating a data record
associated with
' the container of the items when the pick grouping identifier associated with
the Iabel of the
container of the items is optically read. The delivering step can further
include updating a
first data record associated with a container of the items and/or a second
data record
associated with a bulk delivered package, when a third data record containing
an identifier of
the container and/or an identifier of the bulk delivered package gets updated.
The third data
record can contain at least an identifier associated with a shipment between
any one of a
retailer fulfillment site, a RDC, a destination centralized pickup location, a
destination local
distribution hub location, and a retailer returns facility and any one of a
retailer fulfillment
site, a RDC, a destination centralized pickup location, a destination local
distribution hub
location, and a retailer returns facility. The method can also include
enabling shipping fees to
be tracked by a customer order.
In another embodiment of the invention, a method for efficient delivery of
packages
for recipients can include aggregating customer order information to determine
a total ordered
quantity for an item. Items, which can be organized in containers by a common
item
identifier, can be picked in bulk at an order fulfillment site based upon the
aggregated
information. The picked quantities of items can be transported in bulk from
the .order
fulfillment site to a distribution facility. Order quantity information can be
sorted according
to at least one of a distribution facility, a destination centralized pickup
location, a destination
local distribution hub location and/or a local market, with a local market
being a grouping
unit representing a grouping of destination centralized pickup locations
and/or destination
local distribution hub locations. The transported items can be sorted at the
distribution
facility according to the sorted order quantity information.
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BRIEF DESCRIPTION OF THE DRAWINGS
There are presently shown in the drawings embodiments of which are presently
preferred, it being understood, however, that the invention is not so limited
to the precise
arrangements and instrumentalities shown, wherein:
FIG. 1 is an illustrative flow diagram of the processing that occurs at the
various
distribution centers from the moment of capturing a customer order to the
point of a recipient
retrieving a delivered package containing the ordered items from a Customer
Distribution
Center (CDC), wherein the ordered items are distributed through two separate
distribution
facilities before being delivered to the CDC or a local delivery distribution
hub (LDDH) -- an
origination regional distribution center (RDC) and a destination RDC.
FIG. 1A is an alternate illustrative flow of the embodiment of the processing
described in FIG. 1, wherein the ordered items are distributed through only
one distribution
facility before being delivered to the CDC or LDDH - a RDC which serves as
both the
origination RDC and the destination RDC for those ordered items.
FIG. 2 is an illustrative embodiment of the various exemplary entities of the
delivery
process and their relative location to each other.
FIG. 3 is an illustrative embodiment of an exemplary layout of a Regional
Distribution Center (RDC).
FIG. 4 is an illustrative embodiment of an exemplary package creation side of
a
Customer Distribution Center (CDC) Packing Station.
FIG. S is an illustrative embodiment of an exemplary Package Sealing side of a
Customer Distribution Center (CDC) Packing Station.
FIG. 6 is an illustrative embodiment of an exemplary layout of a Customer
Distribution Center (CDC).
FIG. 7 is an illustrative embodiment of an exemplary layout of a Package
Creation
Screen.
FIG. 8 is a view of an exemplary tractor-trailer parked at an exemplary
shipping or
receiving dock area.
FIG. 8A is a detailed layout of an exemplary local market shipping dock area
within a
RDC.
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FIG. 9A shows various illustrative embodiments of exemplary tables and data
views
for the distribution system and method.
FIG. 9B is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 9C is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 9D is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 9E is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 9F is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 9G is a continuation of the exemplary data tables and data views of FIG.
9A.
FIG. 10A is an illustrative embodiment of exemplary data tables and data views
used
in conjunction with the automated system of storage locker bins.
FIG. lOB is a continuation of the exemplary data tables and data views of FIG.
10A.
FIG. l OC is a continuation of the exemplary data tables and data views of
FIG. 10A.
FIG. lOD is a continuation of the exemplary data tables and data views of FIG.
10A.
FIG. 11A is a list of exemplary applications and programs of the distribution
method
and system disclosed in FIG. 1.
FIG. 11B is a continuation of the exemplary list of FIG. 1 1A.
FIG. 12 is an illustrative embodiment of an exemplary SmartBin Unit (SBU)
containing storage locker bins within an automated system of storage locker
bins.
FIG. 13 is an illustrative flow diagram of the processing that occurs at the
various
distribution centers in sending an item return package from a CDC to a
retailer's returns
processing facility and/or in sending a CDC outbound package from one CDC to
another
CDC for a recipient.
DETAILED DESCRIPTION OF THE INVENTION
There is shown in FIG. l,'an embodiment of the instant invention depicting
illustrative steps that can be used to efficiently deliver packages in bulk,
wherein ordered
items of that bulk delivered package are processed in two separate
distribution facilities
before being delivered to a customer distribution center (CDC) or a local
delivery distribution
hub (LDDH) -- an Origination regional distribution center (RDC) and a
Destination RDC. A
LDDH can also be known as a destination local distribution hub location.
Customers can
place orders with retailers or manufactures. In step 1100, these orders can be
captured by the
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retailer. Following capture of the orders, in step 1102, retailers can fill
the orders by picking
cases of the ordered items to meet the total ordered quantity of each item
across all unfilled
orders. As cases of ordered items get picked from the inventory in their
fulfillment
operations, the retailer's workers can label each case with a package label.
The cases of
ordered items can be organized into one or more retailer shipments on shipping
docks of a
retailer's fulfillment site. In step 1106, the shipments of items prepared by
the retailer can be
loaded onto a carrier, such as, a tractor-trailer via a system of dock and
trailer conveyors.
Steps 1100, 1102 and 1106 can be carried out at a retailer fulfillment center
1194. The terms
cargo carrier or carrier as used throughout the specification can include, but
is not limited to,
a mover operating by land - a tractor trailer, a cargo van, truck, train; a
mover operating by
sea - ship; and a mover operating by air - airplane.
In step 1108, the cases of items can then be then shipped to the nearest
regional
distribution center which serves as an origination Regional Distribution
Center (RDC) 1170
for all items received from retailers. In step 1110, the cases of shipped
items can be received
at the origination RDC 1170 and sorted by a RDC identifier (RDC Id) in step
1112. After the
items are sorted, they can be shipped in cases to the destination RDC's
identified on their case
labels, for example RDC 1180-l, as shown in step 1114. The item cases can then
be received
into a destination RDC as shown in step 1116, where a local market sort can be
performed as
shown in step 1118. Following the local market sort 1118, a CDC sort, step
1120, can be
performed at the destination RDC 1180-1. This sorting leads to the creation of
packages, step
1122, consisting of items for a common recipient that are destined to be
delivered to an
identified common customer distribution center (CDC) 1190-1 (FIG. 2) or a
common local
delivery distribution hub (LDDH) 1192-1. The resulting packages, which are
already
organized by a CDC identifier (CDC Id), can then be grouped and loaded into
special crates
in order to create a delivery shipment of packages, step 1124, which can be
shipped from the
destination RDC 1180-1. The delivery shipment of packages can be shipped in
bulk to a
local delivery distribution hub (LDDH) 1192-l, step 1126, or to a CDC 1190-1,
step 1128.
Packages can be shipped to a LDDH 1192-l, whenever the packages are to be
delivered to a
customer-specified location. Packages can be shipped in bulk to a CDC 1190-1
whenever the
recipient can be expected to pickup the package at a destination centralized
pickup location
(or CDC) 1190-1. If the packages are received into the local delivery
distribution hub 1192-1,
step 1130, they can be sorted by, for example, recipient zip code, step 1132.
The sorted
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packages can then be loaded onto delivery trucks, step 1134, where they can be
delivered to
the individual recipient addresses as shown in step 1136. The retailers can
then be billed for
the orders they shipped, step 1138, following the delivery step 1136. Also
shown in FIG. 2,
is a customer distribution center (CDC) 1190-4 and a local delivery
distribution hub (LDDH)
(1192-4).
If the packages are destined to a destination centralized pickup location (or
CDC)
1190-1 being served by the destination RDC 1180-1, then, following the
shipment step 1128,
the packages can be received in bulk at the CDC 1190-1, step 1142. Following
the receipt of
delivery step 1142, the bulk delivered packages can be loaded into an
automated system of
storage lockers such as SmartBin units (SBU's), step 1144. Throughout this
document, the
term SmartBin Unit (SBU) refers to a storage locker bin unit of the automated
system of
storage locker bins. A storage locker bin unit can contain a plurality of
storage locker bins
and an automated system of storage locker bins can contain a plurality of
storage locker bin
units. The loading step 1144 can trigger automatic notifications of the
delivery to the
recipients, step 1148. Following the notification step 1148, the retailers can
then be billed as
shown in step 1138, and the recipients can then retrieve their packages from
the automated
system of storage lockers, step 1150. Returning to the receipt of delivery
shipment step 1142
at the CDC 1190-1, in addition to receiving packages shipped in bulk from the
destination
RDC 1180-1, step 1142, bin configuration adjustments can be performed, step
1140, prior to
step 1142.
There is shown in FIG. 1A, a different illustrative example of the embodiment
depicted in FIG. 1. The illustrative example shown in FIG. 1A depicts the
steps that can be
used to efficiently deliver in bulk packages of items, which,are ordered from
a retailer having
a fulfillment site 1194 in a local market served by one of a shipper's RDC's
1170, for
delivery to a CDC 1190 or customer specified address located in a local market
served by that
same RDC 1170. In this illustrative example, the cases of items can be
received into an
origination RDC 1170 using the same steps as depicted in FIG. 1, steps 1100
through 1110.
Some of those cases of items - the ones containing items to be processed into
one or more
packages to fill orders to be delivered to CDC's 1190 or customer-specified
addresses in a
local market served by the origination RDC 1170 -- can be moved into the local
market sort
step 1118 from the RDC sort step 1112, within the RDC 1170, which serves as
both an
origination RDC and a destination RDC for those cases of items. The local
market sort step
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1118 and all the steps that follow it in this illustrative example of the
process, steps 1120 to
1150, can be performed in the illustrative example of FIG. 1A consistent with
the way they
are performed in the illustrative example of FIG. 1.
Referring now to FIG. 2, and by way of example, an illustrative delivery
process
consistent with the principles of the invention is described. The example
illustrated by FIG.
2, describes the delivery process from the view point of one shipper, as it
depicts the
interaction between the different RDC's of one shipper and the interaction of
those RDC's
with retailer fulfillment sites, CDC's, and LDDH's. Each one of a shipper's
RDC's can serve
as an origination RDC for cases of items received from retailers, and as a
destination RDC for
some of those cases received from retailers (as depicted in FIG. 1A) and for
cases of items
received from other RDC's (as depicted in FIG. 1). For simplicity in referring
to an
origination RDC and a destination RDC within this illustrative example
corresponding to
FIG. 2, an origination RDC will be referred to as RDC 1170 and a destination
RDC will be
referred to as RDC 1180-1. .Consistent with the numbering in FIG. 2, CDC's and
LDDH's
will be referred to as CDC 1190-1 and LDDH 1192-1 respectively when describing
CDC's or
LDDH's related to a destination RDC. Retailer fulfillment sites related to an
origination
RDC will be referred to as retailer fulfillment site 1194 in the illustrative
example description
of FIG. 2. The multiple overlapping shapes behind a retailer fulfillment site
1194-1, CDC
1190-1, and LDDH 1192-1 represent that there can be a plurality of instances
of that type bf
facility related to each RDC facility depicted in FIG. 2. Accordingly, any
reference to an
entity represented by a numbered multiple overlapping shape can be a reference
to any one of
the plurality of instances of that type of entity.
The processing steps of the following illustrative example refer to FIG. 1 in
addition
to FIG. 2 and other figures as stated, except where specifically noted as
referring to FIG. 1A .
The delivery process can begin with customers placing orders with retailers or
manufacturers
that can accept orders via the Internet, television shopping programs, mail-
order catalogs, or
any other means of placing an order for delivery. The term "retailer" will be
used throughout
this disclosure to refer to a retailer, manufacturer or other equivalent
business that accepts
orders for processing. Furthermore, a retailer may operate more than one order
fulfillment
site to process orders. If two or more distinct order fulfillment sites can be
operated by the
same retailer, each one can be identified by a different ePD Retailer Id.
Throughout this
disclosure each entity identified by an ePD Retailer Id will be referred to as
a retailer, even if
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it is only representing one of a retailer's order fulfillment sites. The
customer orders can be
captured by the retailer as shown in step 1100. In most situations, customers
placing the
order can identify themselves as the recipient of that order, but a customer
can also place an
order for a different recipient. Throughout this disclosure, the entity
placing an order will
always be referred to as a customer, and the entity receiving (picking up) an
order will always
be referred to as a recipient, even though the customer and the recipient can
be the same
entity for many orders. In one aspect of the invention, customers can be given
the capability
to choose a delivery option. In addition to the existing delivery options that
can be currently
offered by package shippers (standard delivery and various forms of express
delivery),
I O retailers can also offer the more efficient ePackage Depot (ePD) delivery
option. The ePD
delivery option can typically be priced lower than other delivery options,
since it requires the
recipient to pickup their order from a customer distribution center (CDC) (or
destination
centralized pickup location) 1190-1. ePD delivery service may be provided by
one or more
package shippers or other organizations. A package shipper or other
organization providing
the ePD delivery service will be referred to throughout this disclosure as a
"shipper". A
shipper providing the ePD delivery service can also provide the traditional
package delivery
service of delivering a package to a customer specified address.
Customers who choose the ePD delivery option can enter their ePD customer
identification number (Customer Id) and choose the CDC identifier (CDC Id) of
a CDC
1190-1 where they want to pick-up their order. Customers who have used the ePD
option in
the past can be optionally shown (on a web page or be told over the phone) a
default
destination centralized pickup location (CDC) 1190-1- one that the customer
previously
provided as a preference or the last CDC I 190-I they selected if they have
not provided a
preference. At this point a customer can select the default CDC 1190-l, input
a different
CDC Id or search for a different suitable CDC 1190-1 by providing appropriate
search criteria
including, but not limited to a zip code, a city name or a street name. ' Upon
entering the
appropriate search criteria, a customer can receive a listing of the nearby
CDC locations
1190-1, for example, through a web page or over the phone. As an illustrative
example, the
listing can have the top five closest CDC locations 1190-1 to the search
criteria. CDC's
1190-1 returned from.a search can be listed in order from closest to farthest.
If city is
entered, a complete listing of CDC locations 1190-1 within or near the metro
area of the
entered city can be given including the full address of those CDC locations
1190-1.
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Customers who are new to the ePD Delivery Process can be prompted to provide
information necessary to set themselves up as new customers in the ePD Billing
&
Maintenance application via a linked Internet web page or over the phone by a
person taking
their order who can access the ePD customer setup screen on the Internet web
page. The ePD
Billing & Maintenance application can be a database and a set of programs to
capture and
maintain data related to customers, recipients, retailers, CDC's, RDC's, and
shippers for use in
the shipping operations of all ePD shippers. Exemplary information, which can
be recorded
to set up a customer or a recipient can include, but is not limited to name,
social security
number, zip code, CDC preference, primary contact phone number/e-mail address,
and a
secondary contact phone number/e-mail address. The type of contact can be
recorded for
both primary and secondary contacts. A calling window start time and end time
can also be
recorded for phone number contacts. Credit card or other payment information
does not have
to be captured for the ePD customer set up, but can be maintained or recorded
by the retailer
as part of a customer's order. In one embodiment, shipping costs for ePD
delivery can be
billed by shippers to retailers based on customer orders. Retailers may in-
turn bill their
customers for shipping by payment methods they establish with those customers.
In an alternate embodiment of the invention, shippers can bill retailers for
each
package based on package size instead of a flat shipping fee per order, a fee
based upon the
number of items in an order, a fee based upon the weight of an order, a fee
based upon the
value of an order, or a fee based upon other order-based factors. Alternately,
shippers can bill
the customers placing orders, instead of the retailers accepting those orders.
The amount
billed can be based upon factors including, but not limited to a flat shipping
fee per order, a
fee based upon the number of items in an order, a fee based upon the weight of
an order, a fee
based upon package size, a fee based upon the number of packages in an order,
location-
based storage rates, and seasonal-based storage rates.
In another aspect of the invention, the entity operating a CDC can charge
retailers,
shippers, or customers a storage fee for each package or order delivered based
upon factors
which can include, but are not limited to, the number of SBU bins used to hold
the packages
of an order, the size of each SBU bin used to hold each package, the amount of
time that a
package is in a SBU bin after the package recipient was notified of delivery,
a flat storage
charge per order, a storage charge based upon the value of an order, a flat
storage charge per
package depending upon package size, location-based storage rates, and
seasonal-based
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storage rates.
With reference to FIG. 9E and FIG. l OB, customer, recipient, CDC, shipper,
and
employee information can be maintained centrally on the master copies of a
Customer table
1256, a CDC table 1252, a Zip Code-CDC table 1254, a Shipper table 1260, and
an
Employee table 1308 of the ePD Billing & Maintenance Application. Although a
recipient
can be a different entity than a customer, recipient information can be
maintained on the
Customer table 1256 and can be required by a retailer when an order is placed
for that
recipient. Read-only copies of the Customer table 1256, CDC table 1252 and Zip
Code-CDC
table 1254 can be maintained in the database of each retailer's instance of an
ePD Shipping
Application by replicating data from the ePD Billing & Maintenance
Application's master
tables. A different instance of the ePD Shipping Application can be run by
each retailer and
shipper to facilitate the process of accepting customer orders for both ePD
delivery to a CDC
1190-1 and traditional delivery to a customer-specified address and shipping
ordered items
from retailer fulfillment sites 1194 to shipper origination RDC's 1170. In
referring to an
"instance" of a program or an application throughout this disclosure, each
instance contains
the same basic software program or set of software programs, but the programs
of each
instance can be run against the same database instance or a different database
instance and
can have different pre-defined program values in a referenced file. Different
instances of a
database can have the same table and field structures, but different data
values. In order to
accept and process customer orders, the ePD Shipping Application can be
integrated with the
different order processing systems used by different retailers. The ePD
Shipping Application
can be integrated with each order processing system in such a way as to
minimize the amount
of change to the retailer's system while providing the necessary data and
functionality to,
enable the shipper to use the ePD Shipping Application to support the ePD
Delivery Process.
An instance of the ePD Shipping Application can run on a retailer'workstation
or
server computer. Referring to FIG. 9A, Order information can be recorded in an
Order
Header table 1200 and an Order Detail table 1202 of the ePD Shipping
Application as both
ePD delivery orders and traditional delivery orders are taken by retailers.
Depending upon
how the two systems can be integrated, the ePD Shipping Application can either
receive order
related data directly from customers using a standardized web page front-end
user interface of
the ePD Shipping Application or indirectly through a back-end data interface
from the
retailer's order processing application. Order data elements such as the
following can be
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written to the Order Header table 1200 when a customer order is recorded: an
Order Identifier
(Id), an ePD Retailer Identifier (Id), a Customer Identifier (Id), an Ordering
Customer
Identifier (Id), an ePD Shipper Identifier (Id), a CDC Identifier (Id), an
Order Date/Time, a
Retailer Order Number, a Delivery Type, and a Status. Order data elements such
as the
following, can be written to the Order Detail table 1202 when a customer order
is recorded:
Order Id, a SKU, a SKU Size, a Temperature Code, a Quantity, and Status. The
values
written to the following fields can be provided by the customer: Customer Id,
Ordering
Customer Id, ePD Shipper Id (if the retailer offers a choice of more than one
shipper for ePD
delivery), Delivery Type, CDC Id, SKU, and Quantity. If a customer places an
order with
themselves named as the recipient, Customer Id can be set to the value of the
Customer Id
and Ordering Customer Id can remain empty. If a customer places an order,
having someone
else as a recipient, Customer Id can be set to the recipient's Customer Id
value and Ordering
Customer Id can be set to the value of the customer's Customer Id. Delivery
Type can be a
value that can be selected by the customer to define whether an order is for
ePD delivery or
for traditional delivery to a customer-specified address -- the value of
Delivery Type for an
ePD delivery order can be "ePD" (ePackage Depot), while the value for a
traditional delivery
order can be "LDDH" (local delivery distribution hub). Other values can be
written to the
order tables as follows: a unique Order Id can be generated, for example, by
concatenating
ePD Retailer Id + Customer Id + order date + a 3 digit sequential number (a
"sequential
number" referred to throughout this disclosure can be generated by selecting
the value of the
field on the latest record and increasing it by one); ePD Retailer Id can be
defaulted to the
pre-defined values of that retailer, as configured in the retailer's instance
of the application;
ePD Shipper Id can also be defaulted to a pre-defined value if the retailer
only uses one
shipper (it can also be selected by the customer placing the order); Order.
Date/Time can be
set to the current date/time; Retailer Order Number can be generated by the
retailer's order
processing system; Order Header Status can be set to a value such as "open";
Order Detail
Status can be set to a value such as "new"; SKU Size and Temperature Code can
be set to the
values on the retailer's SKU table 1250 for the SKU selected. Each retailer
can have its own
instance of the SKU table 1250 in its database, containing SKU's and SKU-
related values,
which are specific to that retailer. Fields used to record order-specific or
line item-specific
messages for an order can either be written when an order is taken or when an
order is
fulfilled. Those message fields can include, but are not limited to, Retailer
Message - Order
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Header and Retailer Message - Packing List on the Order Header table 1200, and
Retailer
Message - Order Detail on the Order Detail table 1202. Data for the following
additional
Order Header 1200 fields can also be captured for orders taken by a retailer
for traditional
delivery: Delivery Name, Delivery Address 1, Delivery Address 2, Delivery
City, Delivery
State, Delivery Zip.
Orders taken for express delivery to specific addresses are not usually
written to the
Order Header 1200 and Order Detail 1202 tables of the ePD Shipping
Application, but can be
handled separately by a different order processing application. Express
delivery orders can be
captured differently, because they are normally fulfilled differently. Express
delivery orders
can be usually packed and shipped directly from the retailer's fulfillment
warehouse without
being sent to an origination RDC 1170. If a shipper does create packages for
express delivery
orders in a destination RDC 1180-1, however, those orders can be recorded
using the Order
Header 1200 and Order Detail 1202 tables of the ePD Shipping Application in
the same way
as traditional delivery orders.
Following step 1100, cases of items can be picked, labeled, and prepared for
shipment
to fulfill the orders in step 1102. Prior to the scheduled ePD shipment pick-
up, retailers can
fulfill all of their customer orders that are ready to ship that day,
preparing them for shipment.
A retailer can pick items in batches at different times throughout the day to
prepare the
shipment if the shipment proves to be too large to be prepared at one time.
There can be
several different sorting processes which can be employed in the ePD' Delivery
Process. In
one embodiment of the invention, a case sorting process cari be used. The term
"case" will be
refeiTed to throughout this document to describe a box or other container
filled with a
standard quantity of a particular SKU of a retailer's product. The word
"situation" will be
used to describe different occurrences or situations. Some retailers identify
their products by
SKU (stock keeping unit) numbers, while others may use other item identifiers
to identify
them. The term "SKU" and common item identifier will be used synonymously
throughout
this disclosure to refer to all types of item identifiers, but it should
readily be understood that
the term common item identifier is a more generic term and encompasses SKU.
SKU's are
well known in the art.
In accordance with this embodiment, a retailer can pick (retrieve from
warehouse
. storage locations) items by total SKU quantity rather than order by order.
Unlike the existing
Internet retailer order picking methods, the ePD Delivery Process does not
require a retailer to
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sort items into customer orders or even to break cases to fulfill customer
orders. This is
because items can be shipped out by the caseload to their initial destination,
the shipper's
origination RDC 1170 (the shipper's nearest RDC to the retailer's fulfillment
site 1194).
This efficient shipping process can also reduce the amount of packaging
materials and
available trailer space required for shipment, assuming that same SKU items
can be packed
together into cases more efficiently than different SKU items can be packed
into packages for
each customer. The ePD Delivery Process can save retailers labor costs,
packing material
costs, and can reduce the lead-time needed to prepare shipments.
Retailers can use the ePD Shipping Application to drive the fulfillment sub-
process of
the ePD Delivery Process. Cases of ordered items can be picked and shipped
within the same
sub-process for both ePD delivery orders to CDC's 1190-1 and for traditional
delivery orders
to customer-specified addresses. Orders specified for express delivery to
specific addresses
may be picked and shipped separately from all other orders depending upon how
integrated or
separated a shipper's express shipping process is from its ePD delivery and
traditional non-
express delivery process.
While ePD delivery orders can be delivered to CDC's 1190-1, traditional
delivery
orders can be delivered to local delivery distribution hubs 1192-1. A local
delivery
distribution hub (LDDH) 1192-1 can be a facility within a local market which
can receive
delivery shipments of packages from a destination RDC 11 ~0-1 in much the same
way as a
CDC 1190-1 can receive delivery shipments of bulk delivered packages from a
destination
RDC 110-1. Differences between a LDDH 1192-1 and a CDC 1190-1 can be in the
next
steps of each one's associated delivery process. The process of delivering
individual
packages to individual customer specified addresses can involve sorting those
packages at a
LDDH 1192-1 by zip code-based delivery zones, step 1132, loading those sorted
packages
onto delivery vehicles, step 1134, and routing those vehicles to have drivers
deliver packages
individually to specific addresses, step 1136. The steps in the traditional
delivery process
beyond delivering packages to a LDDH 1192-1 can be consistent with the
traditional delivery
process and are well known in the art. The details of the steps prior to and
including
delivering packages to a LDDH 1192-1 are detailed within this disclosure, as
they can be
similar to and intertwined with the ePD Delivery Process. An LDDH 1192-1 can
be by its
nature very different than a CDC 1190-1, but because the sub-processes
involved in preparing
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and shipping packages to both CDC's 1190-1 and LDDH's 1192-1 can be the same,
both can
be identified by a CDC Id.
Retailers can run the ePD Shipping Application's Pick List Report Program
(310) to
create the report used to guide workers through the fulfillment warehouse to
pick cases for
shipment to the shipper's nearest origination RDC 1170. The following
illustrates an
exemplary embodiment that is not intended to limit the scope of the invention.
The Pick List
Report Program (310) can parse the CDC Id on an Order Header record 1200 to
determine a
Local Market Id embedded within the CDC Id of that CDC 1190-1. It should be
noted that
references to a "record" in this disclosure are references to data records in
a database table or
a data view, unless otherwise noted as data file records or other types of
records. The
program (310) can use that determined Local Market Id and the ePD Shipper Id
on the Order
Header record 1200 to select an RDC Id from a RDC-Local Market table 1264, and
can
update the Order Header record 1200 with the determined Local Market Id and
the selected
RDC Id. This applies to both delivery orders and traditional delivery orders,
as items for both
types of orders can be picked and shipped together. Next, the program (310)
can select Order
Detail records 1202 having Status equal to a value such as "new" or "not in
stock" and the
RDC Id field from the Order Header records 1200 associated with those Order
Detail records
1202. It can then sort and group the order information by SKU and RDC Id to
create a data
view of the information containing the total quantities of each SKU bound for
each
destination RDC (for example 1180-1, 1180-2, 1180-3, 1180-4, and 1170) - a SKU
data view
1204. Data views, as referred to throughout this disclosure, can be similar in
structure and
function to a data table, but the data in the fields of a data view can be
derived by selecting
and manipulating data from fields in one or more data tables. The data in the
records of a
data view can be dynamic, meaning that it can change as data changes on the
tables from
which that data view can be derived. The program (310) can then divide the
total quantities
per SKU-RDC Id combination by the standard case quantity for that SKU, as
listed on the
SKU table 1250, to create another view of the data listing the total number of
cases and items
needed per SKU, per RDC - a Case data view 1206. The remainders of the
division can be
listed as items. For example, if the total quantity of SKU 123456789 bound for
RDC Id
AA001 = 60 and the standard quantity per case for SKU 123456789 is 16, then
the Case data
view would show SKU: 123456789, RDC Id: AA001, Case Quantity: 3, Item
Quantity: 12.
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The program can use the Case data view 1206 and SKU table 1250 of the ePD
Shipping Application and item inventory data from the retailer's inventory
management
system to create new records on a Case table 1208. The value of a Case Id
field on newly
created Case records 1208 can be set to a unique alphanumeric descriptor
generated for each
labeled case, for example, by concatenating ePD Retailer Id + date picked
(current date) + a
sequential 6 digit number. The ePD Retailer Id on each new Case record 1208
can be set to
the value of the current retailer as configured within the retailer's instance
of the ePD
Shipping Application. The term "current" will be used throughout this
disclosure to refer to
the particular instance currently being described for data and objects for
which there can be
multiple instances within the ePD Delivery Process. The program (310) can set
Status to a
value such as "picked" on each new Case record 1208 it creates. As the program
(310)
compares the Case data view 1206 against the item inventory data in the
retailer's inventory
management system the program (310) can create a number of new Case records
1208 equal
to the Case Quantity on the Case data view 1206, with each new record having
the RDC Id
and SKU values on those Case data view records 1206 and a Quantity equal to
the Standard
Case Quantity on the SKU table 1250 for the current SKU. Where the Item
Quantity on a
Case data view record 1206 is greater than zero, the program (310) can also
create one
additional new Case record 1208 having the current RDC Id and SKU of the
current Case
data view record 1206 and a Quantity equal to the Item Quantity on the current
Case data
view record 1206. SKU Size and Temperature Code on the new Case records 1208
can be
set to the values on the SKU record 1250 corresponding to the SKU on the Case
data view
record 1206. Partial/Mixed Flag can be set to a value such as "no" on the new
Case records
1208 created for the Case Quantity value and can be set to a value such as
"yes" for the
records 1208 created for the Item Quantity value. The other Case fields can
have no value
when Case records 1208 are first created.
With reference to FIG. 9D, the program (310) may only create new Case records
1208
to meet the item quantities that can be found in stock in a retailer's
inventory management
system, for example, on the exemplary item inventory table 1248. Different
retailers may use
different inventory management systems, but the minimum data required for the
ePD
Delivery Process can be to have fields such as the following, accessible to
the ePD Shipping
Application: SKU, a Warehouse Location, and Quantity. As the Pick List Report
Program
(310) creates new Case records 1208, it can also update the Status on the
Order Detail records
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1202, which underlie the Case data view records 1206 from which the Case
records 1208 can
be created. A close relationship exists between the Order Detail data and Case
data. Both
sets of data can refer to the same physical items, and throughout the ePD
Delivery Process
both sets of records can be updated as the physical cases of items are moved
through the
different steps of the process. Order Detail Status can be updated to a value
such as "pick list
-new" or "pick list - back order" on all Order Detail records 1202 having the
SKU and RDC
Id corresponding to the Case records 1208 being created, up until the total
quantity of all the
created Case records 1208 for that SKU and RDC Id combination. The value to
which Status
can be updated can depend upon its previous value. Order Detail records 1202
which
previously had a Status value such as "new" can be updated to a value such as
"pick list -
new", while those which previously had a Status value such as "not in stock"
can be updated
to a value such as "pick list - back order". Where quantities of an ordered
SKU are riot
available in the retailer's item inventory, the Status on Order Detail records
1202 matching
the quantity shortfall can be updated to a value such as "not in stock".
Referring to the prior exemplary embodiment, if the retailer had 60 or more of
SKU
123456789 in stock, four records could have been created to hold the data.
Each record
would have had a unique Case Id. All four records would have had the same ePD
Retailer Id,
RDC Id, and SKU. The first three records would have had a quantity of 16. The
fourth
record would have had a quantity of 12. The Status field on all Order Detail
records 1202
having SKU = 123456789, Status = "new" or "not in stock" and a related Order
Header
record 1200 having RDC Id = "AA001" would have been updated to either "pick
list - new"
or "pick list - back order". If the retailer's inventory management system had
showed less
than 60 of SKU =123456789 in stock, then new Case records 1208 would have been
created
up to the total amount in stock and the Status on the underlying Order Detail
records 1202
would have been updated to either "pick list - new" or "pick list - back
order" only up to the
in-stock amount. The program (310) would have attempted to create new Case
records 1208
and update Order Detail records 1202 for all ordered items by the sequence in
which the RDC
Id's are sorted with priority given to the Order Detail records 1202 which
already had a Status
of "not in stock". Selected Order Detail records 1202 which were not updated
to a Status of
either "pick list - new" or "pick list - back order" would have been updated
to a Status of "not
in stock".
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After the Case records 1208 get created, the program (310) can read through
them to
create a Pick List Report for all the new Case records 1208 (new Case records
can be
identified by selecting Status equal to a value such as "picked"). The Pick
List Report can be
printed on special pre-sized, peel-off sticker label stock. The report can
print one label for
each case to be picked, sorted first, for example, by warehouse location, then
by SKU, and
then by RDC Id. Before printing the report, the program (310) can display the
total number
of case labels to be printed and prompt the program user to enter the desired
number of pick
groupings. The user can then enter the number of pick groupings into which the
report will
be divided. Typically, workers will break the report into pick groupings based
upon the
number of workers picking items and a reasonable assessment of the amount of
items to be
picked and tracked together. The program (310) can create a new record on a
Pick Grouping
table 1210 for each pick grouping it creates. Pick Grouping records 1210 can
be created with
a Pick Grouping Id formed, for example, by concatenating ePD Retailer Id +
date picked
(current date) + "PG" + a sequential three digit number. The other fields on
the Pick
Grouping record 1210 can initially be created without values. The program
(310) can then
print out the report, for example, forcing a page break on each new pick
grouping and
printing the Pick Grouping Id in both readable and barcode format at the top
of the first page
of each pick grouping above the first case label of that pick grouping. The
program (310) can
also write the Pick Grouping Id value to the Pick Grouping Id field on the
Case record 1208
corresponding to each case label printed within that pick grouping. As each
Case record 1208
gets updated, the Case Quantity field on the Pick Grouping table can be
incremented. The
RDC Id printed on a case label is that case's destination RDC 1180-1 -- the
RDC from which
that case will be processed into different packages. Initially cases can be
shipped to the
closest RDC, which can be referred to as the origination RDC 1170. In some
situations the
origination RDC 1170 can also be the destination RDC 1170 (as depicted in FIG
1A).
Generally a retailer can have one origination RDC 1170 for a particular
shipper to
which all shipments can be sent. However, if a retailer is located in a
market, which is
approximately half way between two or more RDC's of a particular shipper (1170
and 1180-
2 for example), that retailer can send shipments for that shipper to more than
one origination
30' RDC. This can be done to minimize situations where cases are shipped to an
origination
RDC 1170 in one direction and then transported from that origination RDC 1170
to a
destination RDC 1180-2 in the opposite direction. If a retailer regularly
prepares shipments
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for more than one origination RDC (1170 and 1180-2 continuing with this
example), a
different customized version of the Pick List Report can be run to create the
shipment for
each origination RDC (1170 and 1180-2 continuing with this example). Each
customized
version of the Pick List Report can be configured to select only the order
information
containing specified RDC Ids. Continuing with the current example, the version
of the report
used to build retailer shipments sent to origination RDC 1170 could include
all items ordered
for CDC's or LDDH's associated with origination/destination RDC 1170 and
destination
RDC 1180-4, and the report used to build retailer shipments sent to
origination RDC 1180-2
could include all items ordered for CDC's or LDDH's associated with
originationldestination
RDC 1180-2, destination RDC 1180-l, and destination RDC 1180-3. Although each
Pick
List Report can be used to prepare one shipment to one origination RDC (1170
or 1180-2), a
shipment of cases picked to go to one origination RDC (1170 for example) may
need to be
split into two or more shipments, bound for that origination RDC 1170 at
different times,
depending upon the amount of available trailer space on the tractor-trailers
bound for that
origination RDC 1170. A retailer shipment can be defined as a group of item
cases being
shipped from one retailer, to one origination RDC I 170, on one trailer.
Referring to FIG. 8, the term "trailer" (202) refers to the cargo-carrying
component of
a tractor-trailer, which can be detachable from the tractor (200) having the
engine to move the
tractor-trailer. References in this disclosure to shipments of cases or
packages being
transported from one location to another on a trailer (202) or tractor-trailer
can also include
other non-tractor-trailer vehicles which are suitable to carry cargo, or an
intermodal shipping
combination using two or more of the following: a tractor-trailer or other
suitable cargo
carrying vehicle, a locomotive, a maritime vessel, and an airplane.
A Pick List Report can contain all the cases of items that can be needed to
fill all open
orders at the time it is printed. The Pick List Report can be divided into
sections by pick
groupings and each worker picking cases of items to fill open orders can be
given one or
more sections of the report. The Pick List Report can be made up mostly of
case labels, with
warehouse locations printed to one side of the labels on the report. The
warehouse locations
. of the cases to be picked can guide one or more workers through the
warehouse in warehouse
location sequence. As a worker arrives at the warehouse location listed on the
report, the
worker can pick one case matching the SKU on one of the labels on the report.
The worker
can then peel the label off the report and place it on the side of the picked
case. The worker
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can continue to pick all the cases listed on the report in this manner,
location by location, in
the sequence listed on the report.
Most of the labels on the report can be for full case quantities, but the
report can also
have labels for partial case quantities. Partial case labels can be marked,
for example, with an
asterisk next to the quantity on the label to easily identify a case to which
it is affixed as a
partial case. There may only be up to one partial case label printed per SKU-
RDC Id
combination. Workers can open a full or existing partial case to pick the
exact number of
items listed on a partial case label into an empty picking tote container.
Partial case labels do
not have to be applied to a case at the time the items get picked, since the
case from which the
items can be picked can remain in the warehouse location. Partial case items
can be grouped
together by RDC Id and packed together into boxes or other suitable containers
for shipment
to the destination RDC identified by each RDC Id. As the partial case items
get packed
together into mixed-item case boxes, the partial case labels can be peeled off
of the report and
placed on the boxes in which the picked items corresponding to those partial
case labels are
packed. Boxes containing partial case items of different SKU's packed together
can have
more than one label on them, but each label will have the same RDC Id.
Each case label can have a readable description containing the following
information:
Case Id, RDC Id, SKU, a Product Description, and Quantity. The RDC Id can be
printed on
the label in larger print to allow for easy identification without close
inspection. The Case Id
can be printed on the label, for example, in a barcode format, in addition to
regular text. A
character such as an "S" (for single-item case) can also be printed in large
easily readable
print, in a distinct area on a case label for a case having a Quantity of "1
".
The labeled cases filled with ordered items can be stacked tightly on the
retailer's
shipping dock conveyor in a manner similar to how boxes would be stacked on
pallets. The
stacked cases can be grouped on the dock conveyor by pick grouping with the
front page of
the Pick List Report containing the Pick Grouping Id attached to one of the
cases at the front
of the grouped stack of cases. The cases can be stacked to make use of space
as efficiently as
possible without extending beyond the edges of the dock conveyor: For
partially filled
mixed-item cases, additional packing materials can be used when trying to
consolidate the
different types of partial case items into mixed-item case boxes.
Turning now to step 1106, tractor-trailers can be used to pickup shipments
from
retailers. These can include trailers that are empty after having completed
deliveries to CDC's
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1190or LDDH's 1192 in the local market in which the retailer's fulfillment
site 1194 is
located. The tractor-trailers can pick-up shipments from retailer fulfillment
sites I 194 in that
local market before returning to the origination RDC 1170 where they might be
based.
Outbound delivery shipments from an RDC 1170 (serving as a destination RDC)
and inbound
retailer shipments to that RDC 1170 (the same RDC, serving as an origination
RDC) can be
coordinated to minimize the need to send empty tractor-trailers from an
origination RDC
1170 to retailer fulfillment sites 1 I94 to pick-up shipments. Empty tractor-
trailers can also be
sent from the origination RDC 1170 to retailer fulfillment sites 1 I94, if
needed, to ensure
shipments get transported to the RDC 1170 in a timely manner. If a retailer's
shipment does
not fill the scheduled tractor-trailer's available capacity, the tractor-
trailer driver can contact
the origination RDC 1170 to determine if there are other retailer fulfillment
sites 1 I94 in the
local market from which the driver could pick up retailer shipments before
returning to the
origination RDC 1170.
A tractor-trailer drieer scheduled to pick up a shipment from a retailer can
contact the retailer
prior to arriving in order to determine how much trailer space is needed fox
the retailer's
shipment. In a situation where there is a retailer which ships to more than
one origination
RDC 1170 the driver can let the retailer know which origination RDC (1170 or
1180-2 using
the prior example) the driver is inquiring about. One of the retailer's
workers can look at the
sides of the shipping dock conveyor where the shipment of cases has been
stacked to
determine the approximate load requirement. Dock conveyors can have ruler
markings on
their sides (for example, meters and centimeters on one side, feet and inches
on the other)
running from front to back. The retailer can report a full shipment or the
Iength of the
shipment if the dock conveyor is less than full. A retailer can have multiple
shipments on
multiple dock conveyors and can communicate, to the inquiring driver, the
total number of
full shipments and/or the total length of any partial shipments it has
prepared. Where the
tractor-trailer had already picked up a shipment from another retailer and its
driver knows that
there will not be adequate space to accommodate the full shipment that the
retailer has
prepared, the driver can notify the retailer as to the length of the shipment
that can be
accommodated. A driver can know the remaining capacity of the trailer by
checking the ruler
markings on the sidewalk of the trailer. Upon being notified by the driver
that the tractor-
trailer picking up the retailer shipment only has a certain remaining
capacity, the retailer can
make adjustments to the prepared retailer shipment to split it into two if
necessary, thereby
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creating a gap on the dock conveyor between the two retailer shipments. Where
the driver is
not able to pick up the entire shipment, even when the trailer is empty, but
the retailer has
more than one full shipment prepared, the driver can contact the origination
RDC 1170 to
alert the origination RDC 1170 of the total amount of trailer space needed to
pick up the rest
of the retailer's shipments) considering the portion of the retailer shipment
that the tractor-
trailer can accommodate. The origination RDC 1170 can make any necessary
scheduling
adjustments to send additional tractor-trailers as needed to pick up any
remaining retailer
shipment(s).
In a further aspect of the invention, a shipper's tractor-trailer can arrive
at a retailer's
~ fulfillment site 1194 empty or partially filled with a shipment previously
picked up from
another retailer. Upon arrival, a worker, for example, a retailer worker can
start a Retailer
Shipment Program (312) on a workstation or suitably configured computer or
terminal
running the ePD Shipping Application. The worker can use a hand-held scanner
connected to
that workstation to scan a barcode on their employee identif cation (id) card
and then a
. . barcode on the label on the back of the trailer door. With reference to
FIG. 9B, the Retailer
Shipment Program (312) can create a Retailer Shipment record 1212 which can
have
exemplary values such as: a Retailer Shipment Id created for example, by
concatenating ePD
Retailer Id + current date + a sequential three digit number; a Status which
can be set to a
value such as "in-transit"; an ePD Retailer Id, which can be set to the
standard values
configured for the current retailer; an ePD Shipper Id and an Origination RDC
Id which can
either be set to standard values configured for the current retailer or
selected from lists of
values configured for the current retailer (if the retailer uses more than one
shipper and/or
ships to more than one RDC); a Retailer Employee Id and a Trailer Id that can
be set to the
values scanned in by the worker; a Retailer Shipping Date/Time that can be set
to the current
date/time; and all other fields on the Retailer Shipment Record 1212 can be
created with no
value or a standard initialized value.
There is shown in FIG. 8, a trailer parked at a Shipping/Receiving Dock Area.
FIG..8
shows, tractor 200, trailer 202, trailer conveyor 204, facility exterior wall
231,
shipping/receiving dock (bay) door 233, shipping/receiving dock conveyor
(extension) 235,
and shipping/receiving dock conveyor 236.
Referring to FIG. 8, a tractor-trailer driver can back the tractor-trailer up
to the
shipping dock of the retailer fulfillment site 1194 and open the trailer door.
After opening the
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trailer door, the driver or a retailer worker can reposition a cargo
restraining barrier out of the
way, if one is being used to hold a partial shipment in place. A driver or
retailer worker can
then start a trailer conveyor (204) in the loading direction. Where there is
already a shipment
of cases on the trailer conveyor (204), the cases can remain stationary at the
front end of the
trailer (202) as the trailer conveyor (204) moves in the loading direction and
pushes them up
against the front wall of the trailer. A continuous three-section conveyor
system can be
realized when a conveyor extension (235) at the end of the retailer's dock
conveyor can be
lowered from its upright vertical position to a horizontal position which
extends from the end
of the dock conveyor, through the open loading dock door (233) and trailer
door, to the end of
the trailer conveyor (204) on the floor of the trailer (202). The three
conveyor sections - the
dock conveyor, conveyor extension (235), and trailer conveyor (204) - can be
used to
facilitate the continuous flow of cases from the shipping dock into the
trailer (202). Based
upon the availability of space on the trailer (202), a worker can determine
how many pick
groupings of stacked cases on the dock conveyor can be loaded into the trailer
(202). The
' worker can scan the Pick Grouping Id barcode on the Pick List Report page
attached to each
pick grouping of stacked cases to be loaded onto the trailer (202). As each
Pick Grouping Id
gets scanned, the Retailer Shipment Program (312) can update its Pick Grouping
record 1210
with the Retailer Shipment Id of the current Retailer Shipment record 1212.
The program
(312) can then update Case records 1208 which have that Pick Grouping Id to
set Retailer
Shipment Id to the current Retailer Shipment Id and Status to a value such as
"retailer
shipment". After updating Retailer Shipment Id and Status on the Case records
1208
associated with a pick grouping, the program (312) can update values such as
the Retailer
Shipment Id and Status on a number of Order Detail records 1202 up to the SKU
(or item
identifier) quantity, which was updated on the Case records 120.
. To determine appropriate Order Detail records 1202 to be updated, the
program can
determine the total quantity across all Case records 1208 having a particular
SKU that has
been updated with the current Retailer Shipment Id. The program (312) can
determine that
quantity by selecting all the records from the Case table 1208 having the
current item
identifier (SKU) and Retailer Shipment Id and calculating the total quantity
for the selected
records. It can then select and update Order Detail records 1202, having the
current SKU and
a Status such as "pick list - back order", to set Retailer Shipment Id to the
current Retailer
Shipment Id and Status to a value such as "retailer shipment - back order".
Where enough
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Order Detail records 1202 to equal the SKU quantity total calculated for the
selected Case
records 1208, have not been updated from the selected Order Detail records
1202 having the
current SKU and a Status such as "pick list - back order", the program (312)
can select and
update Order Detail records 1202, having the current SKU and a Status such as
"pick list -
new", to set Retailer Shipment Id to the current Retailer Shipment Id and
Status to a value
such as "retailer shipment - new". Priority can be given to back orders, since
even though the
program (312) is only looking at cases which are in stock and have already
been picked,
depending upon available trailer space, some of the picked cases may be
delayed until a later
retailer shipment.
In updating Order Detail records 1202 with Retailer Shipment Id's, the program
(312)
can make adjustments to an Order Detail record 1202 to partially fill an
order, where a
selected Order Detail record 1202 has a SKU quantity greater than what can be
filled by the
cases, which have been included in the retailer shipment. If for example, out
of the Order
Detail records 1202 having a particular SKU, remaining to be updated with a
Retailer
Shipment Id, the lowest Quantity is two. After assigning Retailer Shipment
Id's to other
Order Detail records 1202 having that SKU, there is a remaining difference of
only one
between the total SKU quantity of Case records 1208 and Order Detail records
1202 with the
current Retailer Shipment Id. Since the program (312) can only update Order
Detail records
1202 for up to a quantity of one, and the lowest remaining Order Detail
Quantity is two, the
program (312) can attempt to partially fill the order by creating a new Order
Detail record
1202 and splitting the Order Detail Quantity across the new record 1202 and
the existing
record 1202. Continuing with the example, the program (312) creates a new
Order Detail
record 1202 by copying all the values of the existing record 1202, except for
Quantity.
Quantity on the new record 1202 can be set to the amount, which can be updated
with the
current Retailer Shipment Id. Status can be updated to either a value such as
"retailer
shipment - new" or "retailer shipment - back order" on the new Order Detail
record 1202,
depending upon the Status of the existing record 1202. Retailer Shipment Id
can be updated
to the current Retailer Shipment Id on the new Order Detail record 1202.
Quantity on the
existing record 1202 can be reduced by the Quantity of the new record 1202.
Status and
Retailer Shipment Id on the existing record 1202 are not changed when the
record 1202 is
split.
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After scanning all of the Pick Grouping Id's intended to be loaded onto the
trailer
(202), the worker can start the dock conveyor in the loading direction. The
stacked cases can
be moved from the dock conveyor, across the conveyor extension (235), and onto
the trailer
conveyor (204). The trailer conveyor (204) can move the cases toward the front
of the trailer
(202), up against the trailer's front wall or the cases of previously loaded
shipments. The
worker can stop the dock conveyor when the trailer is filled or the shipment
is fully loaded
onto the trailer (202). If necessary, the dock conveyor can be switched to the
unloading
direction to move cases back from the conveyor extension (235) to the dock
conveyor. The
driver or the retailer worker can stop the trailer conveyor (204) and if the
trailer (202) is not
completely filled, the driver or retailer worker can reposition a cargo net or
other restrictive
barrier to prevent the cases on the trailer (202) from moving. Whenever the
trailer (202)
cannot accept all the cases of a pick grouping that can be partially loaded
onto a trailer (202)
or if there is still available space to accommodate more cases on the trailer
(202) after the
cases of the scanned pick groupings have been loaded, the worker can initiate
a Retailer
Shipment Adjustments Program (314) to remove or add cases to the retailer
shipment.
The Retailer Shipment Program (312) can have three menu options which end the
program (312). If no adjustments are necessary, the retailer worker can end
the Program
(312) by selecting for example, a menu option such as, "confirm shipment" at
the workstation
running the program (312). If more cases or pick groupings of cases are to be
added to the
retailer shipment, a menu option such as "add cases" can be selected. To
remove cases or
pick groupings of cases from the retailer shipment, a menu option such as
"remove cases" can
be selected. The "confirm shipment" option can simply end the program (312).
By selecting
either the "add cases" or "remove cases" option, the Retailer Shipment Program
(312) can be
terminated and the Retailer Shipment Adjustments Program (314) can be
initiated in either an
"add cases" or a "remove cases" mode. After initiating the Retailer Shipment
Adjustments
Program (314), a worker can for example, use a hand-held scanner to scan the
case labels or
Pick Grouping Id's of any cases the worker is adding to or removing from the
retailer
shipment. If adding or removing a mixed-item case having more than one case
label, all the
case labels need to be scanned to add or remove that mixed-item case.
The Retailer Shipment Adjustments Program (314) can select the Case record
1208 of
each scanned Case Id and can delete the value in its Retailer Shipment Id
field and update its
Status field to a value such as "picked" if removing the case. If adding a
scanned case, the
CA 02441053 2003-09-15
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program (314) can set the value of the Retailer Shipment Id field on the Case
record 1208 of
the scanned case to the value of the current retailer shipment and update its
Status to a value
such as "retailer shipment". Where a Pick Grouping Id is scanned, the program
(314) can
select and update the Pick Grouping record 1210 and the related Case records
1208 having
that Pick Grouping Id to add or remove the cases of that pick grouping to/from
the retailer
shipment by making the Retailer Shipment Id and Status updates as described
for adding or
removing a single scanned case from a retailer shipment. The program (314) can
also update
Order Detail records 1202 to add or remove the current Retailer Shipment Id
and update their
Status appropriately. Updates made to Order Detail records 1202 when adding
cases can be
done in the same way as they are when pick groupings of cases are scanned into
a retailer
shipment by the Retailer Shipment Program (312), although lesser quantities
can be updated
as single cases get scanned. In an example where the possible values of the
Status field on
Order Detail records 1202 corresponding to the cases of a retailer shipment
are "retailer
shipment - new" or "retailer shipment - back order", the Retailer Shipment
Adjustments
Program (314) can update Order Detail records 1202 when removing cases by
first selecting
the ones having a Status of "retailer shipment - new" and the SKU of the
scanned case. The
program (314) can delete the Retailer Shipment Id value of the selected Order
Detail records
1202 and can update their Status to "pick list - new". Continuing with this
example, Order
Detail records 1202 having a Status of "retailer shipment - back order" can be
removed from
the retailer shipment only after all Order Detail records 1202 having a Status
of "retailer
shipment - new" for the scanned SKU have already been removed. The program
(314) can
update the selected Order Detail records 1202 having a Status of "retailer
shipment -
backorder" in the same manner as described for the other record update in this
example,
except that the Status of the selected records 1202 can be set back to "pick
list - back order".
After all the cases and/or pick groupings to be adjusted to or from the
retailer
shipment are scanned, a suitable menu option such as the "confirm shipment"
menu option of
the Retailer Shipment Adjustments Program (314) can be selected to terminate
the program's
(314) operation. When the retailer shipment is confirmed from either the
Retailer Shipment
Program (312) or the Retailer Shipment Adjustments Program (314), a Retailer
Shipment
Report can be created to list, for example, the total number of pick groupings
and the total
number of cases associated with the retailer shipment. The Retailer Shipment
Id can be
printed at the top of the page, for example, in barcode format as well as in
readable format.
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The driver can then obtain that printed report, close the trailer door, and
proceed to an
origination RDC 1170 if the trailer (202) is full or to another retailer
fulfillment site 1194 in
the local market if the driver still has trailer space available.
The Retailer Shipment Program (312) can create an association between specific
cases
and a specific retailer shipment when it writes the Retailer Shipment Id of a
retailer shipment
to Case records 1208. Associating specific cases with a specific retailer
shipment can allow
the shipper and the retailer to track the location of ordered items at the
case level from the
retailer fulfillment site 1194 to a specific tractor-trailer to an origination
RDC 1170. It can
also give the retailer visibility to which cases remain on its shipping dock.
The ePD Shipping
Application can also provide visibility to which lines of an order have been
picked and
remain on the shipping dock, and which ones have been picked and shipped on a
specific
tractor-trailer. Thus, the application can provide visibility to the item
quantities sent within a
particular retailer shipment through both the Case records 1208 and the Order
Detail records
1202 associated with that retailer's shipment. Since each can provide a
different view of the
same shipped items, the total item quantity across all the Case records 1208
for any given
SKU within a retailer shipment is equal to the total item quantity across all
the Order Detail
records 1202 for that same SKU within that same retailer shipment. Although in
total their
item quantities move together, there is no direct link between Case records
1208 and Order
Detail records 1202. There is no direct link, because an Order Detail record
1202 is not tied
to any one specific case. Because Order Detail records 1202 do not have to be
tied to specific
cases (and specific Case records 1208), the RDC sorting process is more
flexible and requires
less effort than it would if it required RDC workers to find specific cases to
fill specific
orders.
There is shown in FIG. 3, an exemplary embodiment of a Regional Distribution
Center (RDC). The regional distribution center can comprise the following
entities: Local
market receiving dock (bay) door 12, Local market receiving dock conveyor 14,
RDC sort
conveyor - inbound section 16, RDC sort conveyor - outbound section 18, RDC
sort conveyor
- overflow section 20, RDC shipping dock conveyor 22, Local market sort
conveyor 24,
Intermodal rail yard 25, Intermodal railcar loading equipment 26, RDC inbound
receiving
dock (bay) door 31, RDC inbound receiving dock conveyor 32, RDC inbound
conveyor -
unloading section 34, RDC inbound conveyor - local market connection 36, RDC
inbound
conveyor - case diverting section 38, RDC inbound conveyor - overflow section
40, CDC sort
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conveyor 42, CDC packing station conveyor 44, CDC packing station 45, Package
conveyor -
left-side feed 46A, Package conveyor - right-side feed 46B, Package conveyor -
merging
section 46C, Package conveyor - outbound section 46D, Package conveyor -
overflow section
46E, CDC Package conveyor - CDC feed 47A, CDC Package conveyor - local market
feed
47B, Local market shipping dock conveyor 48, Local market shipping dock (bay)
door 50,
RDC shipping dock (bay) door 52, Bubble wrap bag production machine 58, RDC
Worker
Entrance door 60.
In a further aspect of the invention, inbound shipments from a plurality of
retailers can
be received for processing at an origination RDC 1170 as shown in step 1110.
Referring to
FIG. 3 in addition to FIG. l, FIG. 2 and FIG. 8, a driver can back the tractor-
trailer up to a
local market receiving dock bay (12) at the origination RDC 1170 and signal to
let RDC
workers know that a shipment has arrived. Upon arrival at the origination RDC
1170, a
worker can open a receiving dock door, scan a barcode on their employee
identification (id)
card, scan the barcode on the trailer label (located on the trailer door of a
trailer (202)), and
then open the trailer door. The worker can use a suitable barcode reading
device such as a
hand-held barcode scanner or a hands-free barcode scanner. A hands-free
barcode scanner, as
referenced throughout this disclosure, can include, but is not limited to
barcode scanning
devices in which the barcode scanning mechanism can be mounted onto a ring,
glove, or
bracelet. The barcode scanner used by the RDC worker can communicate via a
wired and/or
wireless access methodology with a workstation that can be connected to a RDC
server
running an instance of a Receive Retailer Shipment Program (316) of the
current RDC's
instance of the ePD Shipping Application. The programs of the ePD Shipping
Application
and an ePD Delivery Application, as referenced in describing the steps
performed at a RDC
(1110 through 1124) throughout this disclosure, can run on either a
workstation connected to
the RDC server or on the RDC server. After opening the trailer door, the
worker can
reposition a cargo net (or cargo restraining barrier) to, one side of the
trailer (202), if there is
one holding the cases on the trailer (202) in place. The worker can then lower
a conveyor
extension (235) of a local market receiving dock conveyor (14) from its raised
vertical
position to its horizontal loading position to bridge the gap between the
local market
receiving dock conveyor (14) and the trailer conveyor (204). The worker can
start the local
market receiving dock conveyor (14) (including its conveyor extension (235))
in the
unloading direction, and can then start the trailer conveyor (204) in the
unloading direction.
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The retailer shipments of cases can flow from the trailer conveyor (204),
across the conveyor
extension (235), and onto the local market receiving dock conveyor (14).
The RDC worker unloading the current retailer shipments can receive all the
Retailer
Shipment Reports from the tractor-trailer driver, for the retailer shipments
on the trailer (202).
The worker can scan the Retailer Shipment Id barcode at the top of each
report. By scanning
the Retailer Shipment Id's on the Retailer Shipment Reports after scanning
their Employee Id
and the Trailer Id, the worker can accept all the retailer shipments and
associated cases
arriving on that trailer (202) into the current origination RDC 1170, by
initiating the Receive
Retailer Shipment Program (316) to add a new record to a Retailer Shipment
Receiving table
1214 for each Retailer Shipment Id scanned. Each new Retailer Shipment
Receiving record
1214 can have the scanned Retailer Shipment Id, Employee Id, and Trailer Id
values. Each
record 1214 can also be created with a Status field value such as "received"
and an ePD
Shipper Id field that can be set to the value of the shipper operating the
current origination
RDC 1170. After creating each Retailer Shipment Receiving record 1214, the
program (316)
can search a Retailer table 1246 for the record having the ePD Retailer Id
embedded in the
Retailer Shipment Id of the current Retailer Shipment Receiving record 1214.
Data in a
Coimection Script field of that retailer's record 1246 can be read and used to
establish a
remote connection to a server running that retailer's instance of the ePD
Shipping
Application.
The program (316) can select the record, having the current Retailer Shipment
Id on
the Retailer Shipment table 1212 in the database of the retailer's instance of
the ePD Shipping
Application and make the following updates to it: Status can be set to a
suitable value such
as "received"; Retailer Shipment Arrival Date/Time can be set to the current
date/time; and
Receiving Employee Id can be set to the Employee Id on the current Retailer
Shipment
Receiving record 1214. The program (316) can then copy the Retailer Shipment
record 1212
from the database of retailer's instance of the application to the database of
the origination
RDC's 1170 instance of the application. The program (316) can select the Case
records 1208
and Order Detail records 1202 in the retailer's database instance having the
current Retailer
Shipment Id and can update the Status field on both sets of records to a value
such as either
"origination RDC" or "destination RDC". Case record Status can be updated to
"destination
RDC" if the RDC Id on the Case record 1208 is the one for the current
origination RDC
1170. Order Detail record Status can be updated to "destination RDC" if the
related Order
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Header record 1200 has the RDC Id of the current origination RDC 1170. The
Status on all
other Case records 1208 and Order Detail records 1202 can be updated to
"origination RDC".
After making the Status updates, the program (316) can copy the selected Case
records 1208
and Order Detail records 1202 to the RDC's database instance along with the
Order Header
records 1200 associated with the selected Order Detail records 1202.
After all the cases get loaded onto the local market receiving dock conveyor
(14), the
worker can stop the trailer conveyor (204) and can close the trailer door. The
local market
receiving dock conveyor (14) can run along the floor of an origination RDC
1170, from the
edge of local market receiving dock door (12) to the edge of the inbound
section of the RDC
sort conveyor (16). Although certain hardware, software, types of personnel,
and functions
may be described as being in either an origination RDC 1170 or a destination
RDC (1180-1
or others), each RDC can have the same hardware, software, types of personnel,
and
functions as another RDC, as each one can serve as an origination RDC for some
items and a
destination RDC for some items. Hence, such description is not intended to be
a limitation
on the system and method. When the local market receiving dock conveyor (14)
is moving in
the unloading direction, it can carry cases unloaded from a trailer (202) onto
the inbound
section of the RDC sort conveyor (16). The inbound section of the RDC sort
conveyor (16)
can run along the floor of an origination RDC 1170 perpendicular to all the
local market
receiving dock conveyors (14) and the outbound section of the RI7C sort
conveyor (18) can
run perpendicular to all the RDC shipping dock conveyors (22). Each section of
the RDC
sort conveyor (16, 18 ~ 20) can be left continually running as appropriate to
handle the
activity on any of the dock conveyors (14 and 22) adjacent to it. After all
the cases unloaded
from the trailer (202) have been moved from the dock conveyor (14) onto the
inbound section
of the RDC sort conveyor (16), the worker can stop the dock conveyor (14). The
worker may
need to stop and restart the dock conveyor (14) to coordinate the flow of
cases from the dock
conveyor (14) into the flow of cases already on the RDC sort conveyor (16).
In a further aspect of the invention, items received at the origination RDC
1170 can be
sorted by RDC Id in step 1112. Cases arriving at the origination RDC 1170 on a
bulk carrier
such as a tractor-trailer can be moved from the local market receiving dock
conveyor (14)
onto the inbound section of the RDC sort conveyor (16). The RDC sort conveyor
can be
made up of different conveyor belt sections, for example an inbound section
(16), an
outbound section (18), and an overflow section (20). The inbound section of
the conveyor
CA 02441053 2003-09-15
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(16) can run along the floor perpendicular to and at the same height as the
local market
receiving dock conveyors (14). The inbound section of the RDC sort conveyor
(16) can begin
at the first local market receiving dock conveyor (14), continue along the
floor past alI the
local market receiving dock conveyors (14) and end adjacent to the outbound
section of the
RDC sort conveyor (18). The inbomid section of the conveyor (16) can always
move in the
same direction -- toward the outbound section (18). The stacked cases of
retailer shipments
that enter the RDC on tractor-trailers can flow from the inbound section (16)
to the outbound
section of the R.DC sort conveyor (18). There can be several possible
embodiments of how
the stacked cases of a retailer shipment can be broken down during sorting in
an origination
RDC 1170. In one exemplary embodiment, the stacked cases can be broken down
into
unstacked cases on the inbound section of the RDC sort conveyor (16) by one or
more
workers or by case sorting equipment prior to those cases moving to the
outbound section of
the RDC sort conveyor (18). Continuing with this exemplary embodiment, the
outbound
section of the RDC sort conveyor (18) can gradually rise from the floor to
reach
approximately the height of a typical worker's waist. In a different exemplary
embodiment,
the outbound section of the RDC sort conveyor (18) can run along the floor and
the stacked
cases of retailer shipments can be broken down by workers performing the RDC
case sort
1112 on the outbound section of the RDC sort conveyor (18).
Workers performing the RDC case sort step 1112 can look at the RDC Id printed
on
the case label of each case passing by on the outbound section of the RDC sort
conveyor (18).
The workers can be organized into teams by the destination RDC (for example
1180-1, 1180-
2, 1180-3, 1180-4, and/or 1170) for which they can be preparing RDC shipments.
Members
of each team can pick the cases marked for their destination RDC (for example
1180-1) from
the conveyor ,(18) and move them onto the RDC shipping dock conveyor (22) upon
which
they can be preparing their RDC shipment. In the motion to move a case from
the RDC sort
conveyor (18) to the RDC shipping dock conveyor (22), a worker can scan the
label on the
picked case, for example, by moving it across a stationary barcode scanner
associated with
that RDC shipping dock conveyor (22). The stationary scanner can be located
next to the
dock conveyor (22). Scanners are well known in the art. Prior to scanning the
first case of a
new shipment, workers on the team can scan their employee id card to sign on
as an
author/sorter of that RDC shipment. Upon scanning the first case of a new
shipment, a RDC
Shipment Program (318) of the ePD Shipping Application can create a new record
on a RDC
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Shipment table 1216. The program (318) can select the Case record 1208 of the
scanned case
using for example, the scanned Case Id and can update the new RDC Shipment
record 1216
fields such as: a RDC Shipment Id that can be set to a unique value generated
by
concatenating for example, the RDC Id of the current RDC I I70 (the
origination RDC) + the
current date + a sequential 5 digit number; a Status that can be set to a
value such as "new";
an ePD Shipper Id that can be set to the value of the current shipper; an
Origination RDC Id
that can be set to the value of the current RDC 1170; a RDC Shipping Dock Id
that can be set
to the value of a RDC shipping dock (52) (the one at which the current RDC
shipment is
being created; a Destination RDC Id that can be set to the RDC Id value on,the
selected Case
record 1208; a plurality of Employee Id fields that can be set to the values
scanned in from
the employee id cards (for example, Employee Id#1 can be set to the first
employee id card
scanned and Employee Id #2 can be set to the second employee id card scanned,
etc.); and all
other fields can be created with a null value or no value. The program (318)
can also write
the RDC Shipment Id of the newly created RDC Shipment record 1216 to the R.DC
Shipment
Id field on the Case record 1208 of the scanned case.
The teams of RDC workers can continue to pick, scan, and load cases from the
conveyor (18) onto the dock conveyor (22) until a full RDC shipment is
compiled. A full
RDC shipment can be compiled when the cases on the dock conveyor (22) are
stacked up as
high as the shipment height Limit, which can be marked on both sides of the
shipping dock
door opening (52), as wide as can fit between the side edges of the dock
conveyor (22), and
as long as can fit between the dock conveyor extension against which the cases
can be
pressed up at the dock conveyor's (22) front edge and the shipment limit
marking toward the
back end of the dock conveyor (22). While workers are building the RDC
shipment,
scanning each case picked from the outbound section of the RDC sort conveyor
(18), the
RDC Shipment Program (318) can be validating that the RDC Id associated with
each
scanned case matches the RDC Id of the current RDC Shipment record 1216 and
the first case
scanned. If the scanned case is valid, the program (318) can update the Case
record 1208
setting Status to a value such as "RDC shipment" and RDC Shipment Id to the
value of the
current RDC shipment. If the scanned case does not pass the validation, the
program (318)
can signal an error, for example, by sounding an error tone and lighting up a
warning
light/LED on the scanner to alert the worker that the Case record 1208 of the
scanned case
has not been updated and that the scanned case should not be loaded onto the
dock conveyor
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(22) as part of the current RDC shipment. If an error was signaled, the worker
can react to it
by returning the case causing the error back to the outbound section of the
RDC sort conveyor
(18). .
When the team has finished building the shipment, a worker can scan a command
barcode such as "complete shipment" on, for example, his/her action command
card by
running it across the stationary barcode scanner. The "complete shipment"
command can
trigger the RDC Shipment Program (318) to take certain actions. These can
include, but are
not limited to, the following. First, it can update the RDC Shipment record
1216 by setting
Status to a value such as "ready to ship" and RDC Shipment Prep Date/Time to
the current
date/time. Second, it can associate selected Order Detail records 1202 to the
current RDC
shipment by updating their Status to a value such as "RDC shipment" and
updating their
RDC Shipment Id to the value of the current RDC shipment. The program (318)
can select
the Order Detail records 1202 in a manner that can be similar to the way as
the Retailer
Shipment Program (312) did when it selected Order Detail records 1202 to
associate them
with a retailer shipment. The team of workers can then proceed to another RDC
shipping
dock conveyor (22) to start a new RDC shipment for the same destination RDC
(for example
1180-I). Alternately, separate teams could be working in parallel to create
separate RDC
shipments for one destination RDC (for example 1180-1) at the same time,
instead of only
having one team per destination RDC (for example 1180-1).
Referring now to FIG. 1A in addition to FIG. 2 and FIG. 3 as another
illustrative
example of the embodiment, one of the RDC sorting teams can be responsible for
moving
cases bound for the current RDC 1170, serving as both an origination RDC and a
destination
RDC for those cases of items from the RDC sort conveyor (18) to a local market
sort
conveyor (24). The team members of the current origination/destination RDC
1170 can be
stationed between the RDC sort conveyor (18) and the local market sort
conveyor (24), past
the last RDC shipping dock conveyor (22), where the end of the outbound
section of the RDC
sort conveyor (18) ends and the overflow section of the RDC sort conveyor (20)
begins. The
RDC workers on this team can pick cases marked for.the current
origination/destination R.DC
1170 and place them onto the local market sort conveyor (24).
If any cases were picked and placed onto the local market sort conveyor (24)
by
mistake (such as a case bound for a different destination RDC 1180-4 for
example), the team
of workers picking cases for the current RDC can notice those cases moving by
them on the
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local market sort conveyor (24) with an indicator, such as a RDC sort return
marker for
example, placed on top of them. Upon seeing a case on the local market sort
conveyor (24)
having a RDC sort return marker, a worker picking cases for the current
origination/destination RDC 1170 can pick the case, remove its R.DC sort
return marker, and
place the case on the overflow section of the RDC sort conveyor (20). The
worker can also
flip the RDC sort return marker over and place it back on the local market
sort conveyor (24).
RDC sort return markers can have a descriptor such as "RDC sort" printed on
one side and a
Local Market Id printed on the other. The Local Market Id printed on each
marker can
correspond to the local market for which the worker who identified the case
picking error is
working within the local market sort 1118. The circumstances of catching this
type of error
are discussed later in this description when the local market sort step 1118
is described.
The overflow section of the RDC conveyor (20) can be used to allow cases that
are
not picked by any of the teams to circle back around to the outbound section
of the RDC sort
conveyor (18) and pass by those teams again until they can be picked.
Now referring back to FIG. 1 along with FIG. 2, and FIG. 3, in a further
aspect of the
invention, cases of items resulting from the RDC sorting step 1112 can then be
shipped to
other destination R.DC's (such as RDC 1180-1, RDC 1180-2, RDC 1180-3 or RDC
1180-4)
as shown in step 1114. The RDC shipments which have been created by the RDC
sort teams
can sit on the RDC shipping dock conveyors (22) awaiting the arrival of empty
drayage
. tractor-trailers from an intermodal rail yard (25) used by the current
origination RDC 1170.
Drayage tractor-trailers can normally arrive from the intermodal rail yard
(25) with trailers
full of cases of inbound RDC shipments sent via locomotive freight from other
origination
RDC's (for example 1180-1, 1180-2, 1180-3, and/or 1180-4) to the current
destination RDC
1170. Although FIG. I shows the current RDC I 170 as being the origination
R.DC and
another RDC 1180-1 as being a destination RDC, it should readily be understood
that for
purposes of receiving a RDC shipment from other RDC's, the current RDC 1170
cari be
considered a destination RDC and each RDC sending a RDC shipment can be
considered the
origination RDC for that shipment. Alternatively, these tractor-trailers can
be long-haul
tractor-trailers or other suitable cargo carrying vehicles and can arrive at
the current RDC
30' 1170, with or without cargo, directly from other RDC's (for example 1180-
1, 1180-2, 11803,
and/or 1180-4), from a local market, from an airport, or from a seaport. After
inbound RDC
shipments on these tractor-trailers are unloaded into the current RDC 1170,
the drayage
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tractor-trailers can be moved from a RDC inbound receiving dock (31) to one of
the RDC
shipping docks (52). Each RDC shipping dock (52) can be designated to ship to
a particular
destination RDC (for example 1180-1). An empty drayage tractor-trailer can
arrive at a
particular RDC shipping dock (22) based upon factors for example, when cargo
trains are
scheduled to Ieave for particular destination RDC's. Referring now to FIG. 8
in addition to
FIG. 3, when an empty tractor-trailer does back into one of the RDC shipping
docks (52), a
worker such as one of the RDC sort team workers can load the prepared RDC
shipment onto
the empty trailer (202) by lowering the RDC shipping dock conveyor extension
(235) into the
loading position (horizontal), initiating the trailer conveyor (204) in the
loading direction, and
' then initiating the RDC shipping dock conveyor (22) in the loading
direction. The cases
stacked on the RDC shipping dock conveyor (22) can move across the dock
conveyor (22)
and its conveyor extension (235) and onto the trailer conveyor (204).
After the shipment has been moved onto the trailer (202), the RDC worker can
stop
the conveyors, reposition the conveyor extension (235) to the shipment
preparation position
(vertical), and close the trailer door. The worker can initiate a RDC Shipment
Loading
Program (320) of the ePD Shipping Application, for example by, using a hand-
held or hands-
free barcode scanner to scan the barcode on their employee id card, scan a RDC
Shipping
Dock Id barcode, located on a label on the side of the RDC shipping dock door
(52), and scan
the Trailer Id barcode, located on a label on the back of the trailer door.
The RDC Shipment
. Loading Program (320) can select the RDC Shipment. record 1216 by searching
for a record
having the scanned RDC Shipping Dock Id and a Status such as "ready to ship".
It can then
update the selected RDC Shipment record 1216, setting its Status field to a
value such as "on
trailer" and writing the scanned Employee Id to a Trailer Loading Employee Id
field, the
scanned Trailer Id to a Trailer Id field, and the current date/time to the RDC
Shipment Trailer
. . Date/Time field. By updating the RDC Shipment record 1216 with a different
Status and
associating it with a specific trailer, the RDC Shipment Loading Program (320)
can associate
the Case records 1208 and Order Detail records 1202 which make up that RDC
shipment
with that trailer (202). The Case records 1208 and Order Detail records 1202
are not actually
updated by the program (320), but for the time that they have a Status such as
"RDC
shipment" and the RDC Shipment Id associated with that RDC shipment, they are
associated
with and thus can be affected by updates to the Status of that RDC Shipment
record 1216.
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The RDC Shipment Loading Program (320) can also access the server of the RDC
shipment's destination RDC 1180-1 through a dial-up connection or a dedicated
wide area
network (WAN) and can create a new record on the RDC Shipment Receiving table
1218
from the current RDC Shipment record 1216, by copying fields such as the
following: RDC
S ~ Shipment Id, ePD Shipper Id, Origination RDC Id, Destination RDC Id, and
Trailer Id. It can
set the Status on the newly created RDC Shipment Receiving record 1218 to a
value such as
"new".
In an illustrative embodiment, a driver of a drayage tractor-trailers can
transport a
RDC shipment to the current RDC's intermodal rail yard (2S). The intermodal
rail yard (2S)
may not be as close to the RDC as shown in FIG. 3. The driver can position
their tractor-
trailer near intermodal railcar loading equipment (26) and can detach the
trailer (202) of the
tractor-trailer from its tractor (200). A worker at the current RDC's
intermodal rail yard (2S)
can use the intermodal railcar loading equipment (26) to lift the trailer up
and onto an empty
flatbed rail car of a cargo train. Once the trailer containing the RDC
shipment is loaded onto
1 S the train, a worker at the intermodal rail yard can initiate a Train
Loading Program (322) of
the ePD Shipping Application at a workstation or terminal, which can be
located in an office
at the rail yard (2S). The worker can enter the Carrier Id of the current
train on the
workstation's keyboard and can use a wireless hand-held or hands-free scanner
to scan their
employee id card. The worker can then take the wireless scanner out to the
train and scan the
trailer label of each trailer loaded onto the train. The Train Loading Program
(322) can select
the RDC Shipment record 1216 of each RDC shipment loaded on the train by
searching for
the record with the scanned Trailer Id value and a Status such as "on
trailer". The program
(322) can update the selected record, setting its fields to values such as
setting Status to, for
example, "on train", Carrier Td to the entered value for the current train,
Train Loading
2S ~ Employee Id to the scanned Employee Id, and RDC Shipment Train Date/Time
to the current
date/time.
A cargo train arriving at a RDC's intermodal rail yard (2S) may be one that is
scheduled to,pick-up outbound shipments going to another RDC 1180-1 (which can
serve as
a destination RDC in the rail yard (2S) of RDC 1170, continuing with the
illustrative example
. . depicted in FIG. 1), one that is scheduled to deliver inbound shipments
from another RDC
1170 (which can serve as an origination RDC in the rail yard (2S) of RDC 1180-
1, continuing
with the illustrative example depicted in FIG. 1), or one that is scheduled to
do both (for
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example, the cargo train bringing an inbound RDC shipment to the rail yard
(25) of RDC
1180-1 can then pick up one or more RDC shipments bound for another RDC, for
example
RDC 1180-3). In one embodiment, cargo trains can unload trailers, containing
RDC
shipments coming from other origination RDC's (for example 1180-2), off of
rail cars and
then load trailers, containing RDC shipments bound for other destination RDC's
(for example
1180-4), onto the rail cars which have just been emptied. In other
embodiments, tractor-
trailers or other suitable cargo carrying vehicles can transport RDC shipments
from an
origination RDC 1170 directly to another RDC 1180-1, or can transfer a trailer
or the contents
of a trailer to a cargo airplane at an airport, or a cargo vessel at a
seaport.
In step 1116, items in cases can be received from other origination RDC's 1170
(continuing with the illustrative example depicted in FIG. 1) at a destination
RDC 1180-1. In
an illustrative embodiment, a carrier, such as a cargo train, can arrive at a
RDC's intermodal
rail yard (25) making a scheduled stop to deliver inbound shipments coming
from another
RDC 1170 (which can serve as an origination RDC for that RDC shipment).
Workers can
use intermodal railcar loading equipment (26) to lift trailers off of flatbed
rail cars and onto
the ground in an unloading area. Drivers of drayage tractor-trailers or
workers at the rail yard
(25), which may have previously detached their trailers to be loaded onto the
current cargo
train or another cargo train, can attach their tractors to one of the trailers
unloaded from the
current train. The drivers can then transport trailers to the destination RDC
1180-1, backing
them into a RDC inbound receiving dock bay (31).
Inbound RDC shipments can be physically unloaded from trailers into the
destination
RDC 1180-1 in the same manner as inbound Retailer shipments, except that cases
can be
moved from a RDC inbound receiving dock conveyor (32) to the unloading section
of a RDC
inbound conveyor (34), instead of being moved from a local market receiving
dock conveyor
(14) to the inbound section of the RDC sort conveyor (16). The end result of
unloading RDC
shipments into the destination RDC 1180-1 can be that cases from one or more
other RDC's
(1170 continuing with the illustrative example depicted in FIG. 1) are on the
unloading
section of the RDC inbound conveyor (34) and the tractor-trailers which
carried those cases
sit empty at RDC inbound receiving dock bays (31).
. To receive a RDC shipment, a worker at the destination RDC 1180-1 can scan,
for
example, his/her employee id card, the trailer label of the trailer in which
the RDC shipment
arrived, and a case label on any one of the cases unloaded from the trailer.
These actions can
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initiate a Receive RDC Shipment Program (324) of an instance of the ePD
Shipping
Application of the current RDC 1180-1. The Receive RDC Shipment Program (324)
can
search a database table, such as the RDC Shipment Receiving table 1218, for a
record having
the scanned Trailer Id and a Status such as "new". An Origination RDC Id value
can be read
S from the selected record 1218 and can be used to search a RDC table 12S8for
a record having
that value in its RDC Id field. The Receive RDC Shipment Program (324) can
then read a
RDC Server Connection Script value from the selected RDC record 1258 arid can
use that
information to establish a remote connection to the RDC server of the RDC
shipment's
origination RDC (1170 continuing with the illustrative example depicted in
FIG. 1).
Alternatively, the RDC Server Connection Script can be used to point to one of
several RDC
servers where a dedicated WAN can be used to link the servers of a shipper's
RDC's. After
establishing the remote connection, the Receive RDC Shipment Program (324) can
validate
that the Case record 1208 of the scanned Case Id on the origination RDC's 1170
server has
the same RDC Shipment Id as the RDC Shipment Receiving record 1218 selected
from the
1 S database on the current destination RDC's 1180-1 server using the scanned
Trailer Id. This
optional step can be done to validate that the case and the trailer on which
it was carried are
both associated with the same RDC Shipment Id. After such optional validation
step is
successfully completed, the Receive RDC Shipment Program (324) can use the RDC
Shipment Id from the selected RDC Shipment Receiving record 1218 to select the
RDC
Shipment record 1216, in the database on the origination RDC's 1170 server,
corresponding
to the current RDC shipment. The program (324) can update the Status field to
a value such
as "received" and can write the scanned Employee Id to a Receiving Employee Id
field on
both the RDC Shipment record 1216 selected on the origination RDC's 1170
server and on
the RDC Shipment Receiving record 1218 selected on the current destination
RDC's 1180-1
2S server. The program (324) can also write the current date/time to the RDC
Shipment Arrival
Date/Time on the RDC Shipment record 1216 selected on the origination RDC's
1170 server.
The Receive RDC Shipment Program (324) can also select all the Case records
1208 and
Order Detail records 1202 on the origination R.DC's 1170 server having the
current RDC
Shipment Id, update their Status to a value such as "destination RDC", and
move the records
(1208 and 1202) from the origination RDC's 1170 server to the current
destination RDC
1180-1 server. When moving the Order Detail records 1202, the program (324)
can also
select .and copy their related Order Header records 1200. Order Header records
1200 can be
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copied instead of moved, because there can be situations when some Order
Detail records
1202 of an order are moved while others for that order remain on the
origination RDC's 1170
database. By copying Order Header records 1200 instead of moving them, Order
Detail
records 1202 which remain on an origination RDC's 1170 database, and have
related Order
Header records 1200 which were copied to a destination RDC 1180-1 database,
will still have
a copy of their related Order Header record 1200 on the origination RDC's 1170
database.
After the program (324) copies the Order Header records 1200, it can search
the origination
RDC's 1170 database for Order Header records 1200 which no longer have related
Order
Detail records 1202 and delete them.
After the cases of the inbound RDC shipment have been moved from the trailer
conveyor to' the RDC inbound receiving dock conveyor (32) and onto the
unloading section
of the RDC inbound conveyor (34), they may continue to travel around the RDC
inbound
conveyor, for example in a clockwise direction from the unloading section
(34), onto an
overflow section of the RDC inbound conveyor (40) and back onto the unloading
section
IS (34). The cases can move in this circular holding pattern, until a RDC
inbound conveyor case
diverting section (38) can be moved into a diverting position. In the
exemplary conveyor
system illustrated, the case diverting conveyor section (38) can normally be
at rest, locked
into an overflow position on the outside edge of the unloading conveyor
section (34). To
redirect the flow of cases from circling around the RDC inbound conveyor (34,
40), a worker
at the destination RDC 1180-1 can release a locking pin on the case diverting
conveyor
section (38) to release it from an overflow position. The worker can then
pivot the case
diverting conveyor section (38) to slide it across and over top of the
unloading conveyor
section (34) and lock it into the diverting position by sliding its locking
pin into place in a
locking slot on the inside edge of the unloading conveyor section (34). When
locked into the
diverting position, the curved-shaped case diverting conveyor section (38) can
intercept the
flow of cases from the unloading section (34) and redirect them to a local
market connection
section (36). The local market connection section (36) of the RDC inbound
conveyor can
move cases onto the local market sort conveyor (24). Alternately, in another
embodiment,
automated sorting equipment can be used to direct the flow of cases from the
unloading
section of the RDC inbound conveyor (34) to the local market sort conveyor
(24).
The local market connection section of the conveyor (36) can be located on an
incline
to facilitate the movement of cases from the case diverting conveyor section
(38), starting at
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the same height as the floor level unloading conveyor section (34) up to a
raised level of the
local market sort conveyor (24). Workers at the destination RDC 1180-1 can
break down the
stacked cases of a RDC shipment to a level that is one case high before using
the diverting
conveyor section (38) to move cases from the RDC inbound conveyor (34) up onto
the local
market sort conveyor (24). Generally, a worker at the destination R.DC 1180-1
can use the
diverting conveyor section (38) to move cases from the RDC inbound conveyor up
onto the
local market sort conveyor (24) as soon as possible after the cases have been
broken down. If
space is unavailable on the local market sort conveyor (24), however, the flow
of cases can be
left so that it is directed to the overflow section of the RDC inbound
conveyor (40).
In a further aspect of the invention, the following steps, consistent with
step 1118, can
be used to achieve a local market sort at a destination RDC processing center
1180-1. An
ePD Delivery Application can run on a destination RDC's 1180-1 server to
facilitate the RDC
sub-processes involved in creating packages to fill customer orders for either
ePD delivery to
CDC's 1190-1 or traditional delivery to customer specified addresses. The
steps of the ePD
Delivery Process previously described in this illustrative embodiment involved
moving cases
of ordered items and the Case 1208, Order Header 1200, and Order Detail 1202
data records
related to those cases to the destination RDC 1180-1 in which customer orders
will be filled
from those cases. At this point in this illustrative embodiment of the ePD
Delivery Process,
cases of ordered items, which have been designated for the current destination
RDC 1180-1,
have been received by and can be on the local market sort conveyor (24) of the
current
destination RDC 1180-1. The Case 1208, Order Detail 1202, and Order Header
1200 records
related to those cases can be in the database on the current destination RDC's
1180-1 server
and the Status of those Case 1208 and Order Detail records 1202 can be a value
such as
"destination RDC". The database on the destination RDC's 1180-1 server can be
shared by
the ePD Shipping Application, which can be used to drive the RDC-related steps
prior to the
local market sort step 1118, and the ePD Delivery Application, which can be
used to drive the
local market sort step 1118 and the remaining RDC-related steps of the ePD
Delivery
Process.
A Local Market Order List data view 1220 can be created from underlying Order
Header 1200 and Order Detail 1202 tables, for example, by selecting, grouping
and
subtotaling the Quantity of each SITU from a particular ePD Retailer Id having
a Status such
as "destination RDC", to be delivered to CDC's 1190-1 or LDDH's 1192-1
associated with a
CA 02441053 2003-09-15
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particular Local Market Id. The Local Market Order List data view 1220 can be
dynamic,
meaning the Quantity subtotal of each ePD Retailer Id-SKU combination for a
Local Market
Id can increase as new Order Header 1200 and Order Detail 1202 records are
added or can
decrease as the Status of Order Detail records 1202 changes from a value such
as "destination
RDC" to a value such as "package". New Order Header 1200 and Order Detail 1202
records
with a Status such as "destination RDC" can be added as RDC Shipments and
Retailer
Shipments are received into the current destination RDC 1180-1. The Status on
Order Detail
records 1202 can be changed from a value such as "destination RDC" to a value
such as
"package" as packages are created to X11 orders.
A Local Market Case Inventory data view 1222 can be created from the
underlying
Case table 1208, for example, by selecting, grouping and subtotaling the
Quantity of each
SKU (or item identifier) and ePD Retailer Id combination for each Local Market
Id on Case
records 1208 having a Status such as "CDC sort" or "package sort". Case
records 1208 can
be assigned a Local Market Id when their related cases are scanned and picked
from the local
~ market sort conveyor (24) onto a CDC sort conveyor (42). In one embodiment,
Case records
1208 of cases on the local market sort conveyor (24) do not have Local Market
Id's and can
be therefore not selected as part of the Local Market Case Inventory data view
1222.
Workers at the destination RDC 1 I80-1 who can be stationed between the local
market sort conveyor (24) and the CDC sort conveyors (42) can for example, use
hands-free
barcode scanners to scan case label barcodes on cases moving by them on the
local market
sort conveyor (24). The barcode scanners can communicate with a workstation
running an
instance of a Local Market Sort Program (326) of the ePD Delivery Application
via a wired
or wireless data architecture. The Local Market Sort Program (326) can read
the Case table
1208 to determine field values such as, the RDC Id, Local Market Id, SKU (item
identifier)
and ePD Retailer Id of the record having the Case Id of the scamled case
label. The Local
Market Sort Program (326) can evaluate the RDC Id value and if it is found
that the RDC Id
value on the Case record 1208 of the scanned case differs from the RDC Id of
the current
destination RDC 1180-1, an alert, such as a double invalid pick warning tone
and/or an error
warning light, can alert the RDC worker that the scanned case should not be on
the local
market sort conveyor (24). This situation can occur when an error has been
made in the RDC
sort step 1112, and a case bound for a different destination RDC (for example,
RDC 1180-2)
is mistakenly placed on the local market sort conveyor (24) of the current
destination RDC
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1180-1. Upon hearing the double invalid pick tone alert and/or seeing an error
warning light,
the worker at the destination RDC 1180-1 can place, for example, a RDC sort
return marker
on the case, and can let the case pass by on the local market sort conveyor
(24). The RDC
sort return marker can signal other workers performing the local market sort
1118 for other
local markets not to scan that case. A worker performing the RDC, sort 1112
for the current
destination RDC 1180-1 can see the case with the RDC sort return marker on it,
return the
case to the overflow section of the RDC sort conveyor (20), flip the RDC sort
return marker
over, and place it on the local market sort conveyor (24). The worker who
placed the RDC
sort return marker on the case can later see the RDC sort return marker with
the Local Market
Id on it, as it moves around the local market sort conveyor (24), and can
retrieve it from the
conveyor (24).
In the situation where the RDC Id matches the value of the current destination
RDC
1180-1, the Local Market Sort Program (326) can evaluate the Local Market Id
value. If the
Case record 1208 of the scanned case has no Local Market Id, the scanned case
can be
processed as a local market sort pick -- picking a case from the local market
sort conveyor
(24) to a CDC sort conveyor (42). If the Case record 1208 has the Local Market
Id of the
current CDC sort conveyor (42), the case can be processed as a reverse local
market soot pick
-- picking a case to remove it from the current CDC sort conveyor (42) and
returning it to the
local market sort conveyor (24). If the Case record 1208 has a Local Market Id
of a different
CDC sort conveyor (42), the case can be processed as a corrective local market
sort pick --
picking a case to remove it from its previous CDC sort conveyor (42) to the
current CDC sort
conveyor (42).
In processing a local market sort pick, the Local Market Sort Program (326)
can
search for the record on the Local Market Order List data view 1220 having the
SKU (item
identifier) and ePD Retailer Id of the scanned case, and the Local Market Id
associated with
the current CDC sort conveyor (42) (the one to which the worker's scanner is
communicating). If there is a record 1220 for that SKU (item identifier), ePD
Retailer Id, and
Local Market Id combination, the Local Market Sort Program (326) can compare
the Quantity
of that record 1220 against the Quantity of its related record on the Local
Market Case
Inventory data view 1222, if there is one (a related record has the same SKU,
ePD Retailer Id,
and Local Market Id). The Local Market Sort Program (326) can subtract the
Local Market
Case Inventory Quantity (representing the total quantity of an ePD Retailer Id-
SKU
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combination which has already been picked for that local market) from the
Local Market
Order List Quantity (representing the total quantity of an ePD Retailer Id-SKU
combination
needed to fill the open orders for that local market) to determine the net
quantity of that ePD
Retailer Id-SKU combination still needed for that local market. If the Local
Market Order
List record 1220 does not have a related Local Market Case Inventory record
1222, the full
quantity of the Local Market Order List record 1220 can be considered the net
quantity
needed. If the net quantity needed of that ePD Retailer Id-SKU combination for
that local
market is greater than zero, the Local Market Sort Program (326) can signal
the worker to
pick the case, for example, by producing a pick confirmation tone and can
assign the scanned
case to the local market by writing the Local Market Id of the current CDC
sort conveyor (42)
into the Local Market Id field of its Case record 1208 and updating the Status
of its Case
record 1208 to a value such as "CDC sort". Upon hearing the pick confirmation
tone (or
recognizing another signal indicating to pick a scanned case), the worker at
the destination
RDC 1180-1 who scanned the case can pick it from the local market sort
conveyor (24) and
place it on the CDC sort conveyor (42) of the local market for which the
worker is working.
Where there is not a Local Market Order List record 1220 for the current local
market with
the ePD Retailer Id-SKU combination of the scanned case, or where there is
one, but the
Local Market Sort Program (326) determines that the net quantity needed for it
is less than
one, the Local Market Sort Program (326) can signal the worker not to pick the
case, for
example, by sounding an invalid pick warning tone. Upon hearing the invalid
pick warning
tone (or recognizing another signal indicating not to pick a scanned case),
the worker can let
the scanned case pass by on the local market sort conveyor (24).
Many cases picked from the local market sort conveyor (24) onto the CDC sort
conveyor (42) for a local market can be used completely to satisfy orders for
that local
market. In that situation, the quantity of the picked case can be less than
the net quantity
needed for that local market. As the net quantity of an ePD Retailer Id-SKU
combination
needed for a local market decreases toward zero, a picked case can have a
quantity greater
than the net quantity needed. In that situation, the case can be picked and
the net quantity
needed can become negative. After all the item quantities of that ePD Retailer
Id-SKU
combination needed to fill orders for the current local market are picked from
that case to
create packages (as described in the create packages step 1122), a local
market sort return
marker, for example, can be placed on top of the case and the case can be
returned to the
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CDC sort conveyor (42). As a worker picking cases from the local market sort
conveyor (24)
sees a case traveling around the CDC sort conveyor (42) with a local market
sort return
marker on it, the case can be picked from the conveyor (42), its label can be
scanned, and it
can be placed on the local market sort conveyor (24). The local market sort
return marker can
be removed from the case, flipped up-side-down, and placed back on the CDC
sort conveyor
(42). The Local Market Sort Program (326) determining that the Case record
1208 of the
scanned case already has the Local Market Id of the current CDC sort conveyor
(42), can
process the scanned case as a reverse local market sort pick. In processing
the scanned case
as a reverse local market sort pick, the program (326) can verify that the
needed quantity of
the ePD Retailer Id-SKU combination of the scanned case for the current local
market is less
than one. If the needed quantity is one or greater, the program (326) can
sound, for example,
an invalid pick tone and can refrain from updating the Case record 1208. Upon
hearing the
invalid pick tone (or recognizing another indication not to pick a case), the
worker can
remove the local market sort return marker from the scanned case, place the
marker up-side-
down on tile CDC sort conveyor (42), and let the case remain on the CDC sort
conveyor (42).
If the Local Market Sort Program (326) finds that the needed quantity is less
than one, it can
delete the Local Market Id value from the Case record 1208 of the scanned
case, update the
Status of that Case record 1208 to a value such as "destination RDC", and
sound, for
example, a pick confirmation tone. Upon hearing the pick confirmation tone (or
recognizing
another indication that a case should be picked) the worker can pick the case
from the CDC
sort conveyor (42) and place it on the local market sort conveyor (24).
Changing the Status
and removing the Local Market Id value from the Case record can automatically
reduce the
Quantity of the ePD Retailer Id-SKU combination of the scanned case on the
Local Market
Case Inventory data view record 1222, since the Case record 1208 of the
scanned case will no
longer be selected by the Local Market Case Inventory data view 1222. By
reducing the
Quantity on the Local Market Case Inventory data view record 1222, the net
quantity needed
for the current local market can increase, since the value that the Local
Market Sort Program
(326) subtracts from the Local Market Order List data view record 1220 has
been reduced. If
the full needed amount of items is picked from the case before the reverse
local market sort
pick is processed, the end result of the reverse pick action can be that a
negative needed
quantity is increased to zero.
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Two situations which can result in a case being physically located on the
local market
sort conveyor (24), but logically associated with a CDC sort conveyor (42)
will be discussed
here as an illustrative example. One situation in which this can occur is when
a case is
picked from a CDC sort conveyor (42) and placed back on to the local market
sort conveyor
(24) without being scamled to initiate a reverse local market sort pick.
Another situation in
which it can occur is when a case is scanned on the local market sort conveyor
(24), but is not
physically picked from that conveyor (24) to a CDC sort conveyor (42). Where a
case having
a Local Market Id because of either situation is traveling around on the local
market sort
conveyor'(24) and is scanned, the Local Market Sort Program (326) can process
that case as a
corrective local market sort pick. The Local Market Sort Program (326) can
update the Local
Market Id value on the Case record 1208 of the scanned case to the value
associated with the
current CDC sort conveyor (42) and can sound, for example, a pick confirmation
tone. Upon
hearing the pick confirmation tone (or recognizing another indication that a
case should be
picked), the worker can pick the case from the local market sort conveyor (24)
and place it on
the CDC sort conveyor (42). In updating the Local Market Id on the Case record
1208 of the
scanned case, the Local Market Sort program (326) can correct the error that
existed in the
Local Market Case Inventory data view 1222 by reducing the Quantity of that
ePD Retailer
Id-ST~U combination fox the local market to which it was being credited
incorrectly. At the
same time the Local Market Sort program (326) can correctly update the Local
Market Case
Inventory data view 1222 for the local market of the current CDC sort conveyor
(42) as the
case is picked and placed on that conveyor (42).
There can, however, be one exception to the normal result of a corrective
local market
sort pick. If a case on the local market sort conveyor (24) already has a
Status such as "CDC
sort" and a Local Market Id, and the worker scanning the case happens to be
working at the
CDC sort conveyor (42) identified by the same Local Market Id as the one on
the Case record
1208 of the scanned case, then the program (326) can process the scanned case
as a reverse
local market sort pick instead of a corrective local market sort pick. The
Local Market Sort
program (326) can remove the Local Market Id from the Case record 1208 and
sound, for
example, a pick confirmation as the worker picks the case from the local
market sort
conveyor (24) to the CDC sort conveyor (42). The result of this action can
actually switch the
database from being in error in one direction to being in error in the
opposite direction.
Before the case was scanned and picked, the database could have incorrectly
included the
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quantity of the case in the Local Market Case Inventory data view 1222, when
the case was
not physically on the CDC sort conveyor (42) of that local market. After the
case is scanned
and picked, the case can physically be on the CDC sort conveyor (42), but the
database can
no longer be including the quantity of that case in the Local Market Case
Inventory data view
1222. This error can be corrected the first time the case is scanned during a
CDC sort
processing step 1120.
Most of the cases on the local market sort conveyor (24) can be full cases
containing
the standard case quantity for one ePD Retailer Id-SKU combination or
partially picked cases
containing less than the standard case quantity for one ePD Retailer Id-SKU
combination.
There can be situations where a mixed-item case can be found on the local
market sort
conveyor (24). Mixed-item cases can contain multiple SKU's from one retailer.
There
should be no instance when the SKU's of different retailers can be found mixed
together in
the same case within a destination RDC 1180-1. Workers at the destination RDC
1180-1
performing the local market sort 1118 can break apart mixed-item cases into
separate cases or
other suitable containers containing a quantity of a single SKU (or item
identifier) as they
find them on the local market sort conveyor (24). Mixed-item cases can be
easily identified
because they can have multiple case labels on them. Workers can pick the mixed-
item cases
off of the local market sort conveyor (24) and read the information on each of
the case labels
to determine the quantity of each SKU (item identifier). They can remove the
different item
quantities from the mixed-item case, separating the items of different SKU's
into different
totes (or other suitable containers). The item quantity of one of the SKU's
can be left in the ,
case. The labels of each different SKU can be removed from the mixed-item case
and placed
face-up on top of the items inside each tote. The label corresponding to the
SKU (item
identifier) remaining in the case can be left on the case. Workers can place
the totes and the
case back onto the local market sort conveyor (24) where they can be processed
in the same
manner as other cases.
After the local market sort 1118 is performed at the destination RDC 1180-1,
the
CDC sort step 1120 can then be performed at the destination RDC 1180-1. The
CDC sort
step 1120 can be achieved in a manner similar to the local market sort step
1118. Both
include methods for directing cases of items toward a CDC packing station (45)
at which
packages can be created from those cases. The local market sort 1118 can be a
higher level
sort used to direct cases which have been designated for the current
destination RDC 1180-1
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to the CDC sort conveyor (42) of a particular local market to meet the ePD
Retailer Id-SKU
quantity levels needed to fill the orders bound for that local market. The CDC
sort 1120 can
be a lower level sort used to direct cases which have been designated for the
current local
market to a CDC packing station conveyor (44) of a particular CDC 1190-1 or
LDDH 1192-1
(within the destination RDC 1180-1) to meet the ePD Retailer Id-SKU quantity
levels needed
to fill the orders bound for that CDC 1190-1 or LDDH 1192-1. A CDC packing
station
conveyor (44) can be dedicated to creating packages for either a LDDH 1192-1
or a CDC
1190-1.
In accordance with the invention, a CDC Order List data view 1224 can be
created
from the underlying Order Header 1200 and Order Detail 1202 tables by for
example,
selecting, grouping, and subtotaling the Quantity of each SKU (item
identifier), from a
particular ePD Retailer Id, having, a Status such as "destination RDC", to be
delivered to a
particular CDC 1190-1 or LDDH 1192-1. The CDC Order List data view 1224 can be
dynamic, meaning that the Quantity subtotal of each ePD Retailer Id-SKU
combination for a
CDC Id can be increased as new Order Header records 1200 having that CDC Id
and their
related Order Detail records 1202 can be added, or it can be decreased, as the
Status of Order
Detail records 1202 related to Order Header records 1200 having that CDC Id
changes from a
value such as "destination RDC" to a value such as "package". New Order Header
1200 and
Order Detail 1202 records with a Status such as "destination RDC" can be added
as RDC
Shipments and Retailer Shipments are received into the current destination RDC
1180-1. The
Status on Order Detail records 1202 can be changed from a value such as
"destination RDC"
to a value such as "package" as packages can be created to fill orders.
With reference to FIG. 9C, the CDC Case Inventory data view 1226 can be
created
from the underlying Case table 1208 by, for example, selecting, grouping and
subtotaling the
Quantity of each SKU and ePD Retailer combination for each CDC Id on Case
records 1208
having a Status such as "package sort". Case records can be assigned a CDC Id
when they
get scanned and picked from a CDC sort conveyor (42) onto one of the CDC
packing station
conveyors (44).
Workers stationed between a CDC sort conveyor (42) and a CDC packing station
~ conveyor (44) at the destination RDC 1180-1 can, for example, use hands-free
barcode
scanners to scan case label barcodes on cases moving by them on the CDC sort
conveyor
(42). A CDC Sort Program (328) of the ePD Delivery Application can read the
Case table
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1208 to find, for example, a RDC Id, a Local Market Id, a CDC Id, a SKU, and
an ePD
Retailer Id of the scanned Case Id. The CDC Sort Program (328) can validate
the RDC Id
value in a similar manner as the Local Market Sort Program (326). Although it
is highly
unlikely to find a case for a different RDC on the CDC sort conveyor (42), if
such a condition
is detected by the CDC Sort Program (328), the worker performing the CDC sort
can react
with the same actions as described for the worker that performed the local
market sort 1118
when a similar error was detected.
After validating the RDC Id, the CDC Sort Program (328) can validate that the
Local
Market Id on the Case record 1208 of the scanned case matches the Local Market
Id of the
current CDC sort conveyor (42). The Local Market Id is normally correct for
all cases on the
CDC sort conveyor (42), but if a picking error was made and the Case record
1208 did not
have a Local Market Id or had a Local Market Id different than the one of the
current CDC
sort conveyor (42), the CDC Sort Program (328) can correct the situation by
updating the
Local Market Id to the value of the current CDC sort conveyor (42). If the CDC
Sort
Program (328) does make ari update to the Local Market Id on a Case record
1208, the Local
Market Case Inventory 1222 data view can be automatically updated in the same
manner as it
would if the Local Market Sort Program (326) was making the update. This
corrective
function of the CDC Sort Program (328) can correct the previously described
local market
sort picking error in which the Local Market Sort Program (326) processes a
scanned case as
a reverse local market sort pick instead of a corrective local market sort
pick.
Consistent with the invention, after checking that the Local Market Id matches
the one
for the current CDC sort conveyor (42), the CDC Sort Program (328) can check
the CDC Id
value. If the program (328) finds that the Case record 1208 of the scanned
case has no CDC
Id, it can process the scanned case as a CDC sort pick -- picking a case from
the current CDC
sort conveyor (42) to the current CDC packing station conveyor (44). If it
finds that the Case
record 1208 has the CDC Id of the current CDC packing station conveyor (44),
it can process
the case as a reverse CDC sort pick -- removing a case from the current CDC
packing station
conveyor (44) to the current CDC sort conveyor (42). If the program (328)
finds a CDC Id of
a different CDC packing station conveyor (44), it can process the case as a
corrective CDC
sort pick -- removing a case from its previous CDC packing station conveyor
(44) and
picking it for the current CDC packing station conveyor (44).
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In processing a CDC sort pick, the program (328) can search for the record on
the
CDC Order List data view 1224 with, for example, the SKU and ePD Retailer Id
of the
scanned case, and the CDC Id associated with the current CDC packing station
conveyor
(44). If a record 1224 corresponding to that SKU, ePD Retailer Id, and CDC Id
combination
is located, the CDC Sort Program (328) can compare the Quantity of that record
1224 against
the Quantity of its related record on the CDC Case Inventory data view 1226,
if there is one.
(A related record can have the same SKU, ePD Retailer Id, and CDC Id). The CDC
Sort
Program (328) can subtract the CDC Case Inventory Quantity (representing the
total quantity
of an ePD Retailer Id-SKU combination which has already been picked for that
CDC 1190-1
or LDDH 1192-1) from the CDC Order List Quantity (representing the total
quantity of an
ePD Retailer Id-SKU combination needed to fill the open orders for that CDC
1190-1 or
LDDH 1192-1) to determine the net quantity of that ePD Retailer Id-SKU
combination still
needed for that CDC 1190-1 or LDDH 1192-1. If the CDC Order List record 1224
does not
have a related CDC Case Inventory record 1226, the full quantity of the CDC
Order List
record 1224 can be considered the net quantity needed. If the net quantity
needed of that ePD
Retailer Id-SKU combination for that CDC 1190-1 or LDDH 1192-1 is greater than
zero, the
CDC Sort Program (328) can indicate that the case should be picked by, for
example,
producing a pick confirmation tone and can assign the case to the CDC 1190-1
or LDDH
1192-1 by writing the CDC Id of the current CDC packing station conveyor (44)
into the
CDC Id field of the Case record 1208 and updating the Status of the Case
record to a value
such as "package sort". Upon hearing the pick confirmation tone (or
recognizing another
indicator to pick a case), the worker who scanned the case can pick it
from'the CDC sort ,
conveyor (42) and place it on the CDC packing station conveyor (44) of the CDC
1190-1 or
LDDH 1192-1 for which the worker is working. If there is not a CDC Order List
record 1224 ,
for the current CDC 1190-1 or LDDH 1192-1 with the ePD Retailer Id-SKU
combination of
the scanned case, or if there is one, but the CDC Sort Program (328)
determines that the net
quantity needed for it is less than one, the program (328) can indicate that
the case should not
be picked by, for example, sounding an invalid pick warning tone. Upon hearing
the invalid
pick warning tone (or recognizing another indicator not to pick,a case), the
worker can let the
case pass by on the CDC sort conveyor (42).
Some cases picked from the CDC sort conveyor (42) onto the CDC packing station
conveyor (44) for a CDC 1190-1 or LDDH 1192-1 can be used completely to
satisfy orders
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fox that local market. If that is the situation, the quantity of the picked
case will be less than
the net quantity needed for that CDC 1190-1 or LDDH 1192-1. As the net
quantity of an ePD
Retailer Id-SKU combination needed for a CDC 1190-1 or LDDH 1192-1 decreases
close to
zero, a picked case can have a quantity greater than the net quantity needed.
In that situation,
the case can be picked and the net quantity needed can become negative. After
all the item
quantities of that ePD Retailer Id-SKU combination needed to fill orders for
the current CDC
1190-1 or LDDH 1 I92-1 are picked from that case to create packages, a CDC
sort return
marker can be placed on top of the case and the case can be returned to the
CDC packing
station conveyor (44). As the worker picking cases from the CDC sort conveyor
(42) sees a
case traveling around the CDC packing station conveyor (44) with a CDC sort
return marker
on it, the worker can, for example, pick the case from the conveyor (44), scan
the case's label,
place the case on the CDC sort conveyor (42), flip the CDC sort return marker
up-side-down,
and place the marker back on the CDC packing station conveyor (44). Because
the CDC Sort
Program (328) can determine that the Case record 1208 of the scanned case
already has the
CDC Id of the current CDC packing station conveyor (44), it can perform
reverse CDC sort
pick processing. The program (328) can first check to make sure that the
needed quantity of
the ePD Retailer Id-SKU combination of the scanned case for the current CDC I
190-1 or
LDDH 1192-1 is less than one. If the needed quantity is one or greater, the
program (328)
can sound, for example, an invalid pick tone and can refrain from updating the
Case record
1208. The worker can, for example, remove the CDC sort return marker, place it
up-side-
down on the CDC packing station conveyor (44), and let the case remain on the
CDC packing
station conveyor (44). If the CDC Sort Program (328) determines that the
needed quantity is
less than one, it can, for example, delete the CDC Id value on the Case record
1208 of the
scanned case, update the Status of that Case record 1208 to a value such as
"CDC sort", and
indicate to pick the case by sounding a pick confirmation tone. Upon hearing
the pick
confirmation tone (or recognizing another indicator to pick a case) the worker
can, for
example, pick the case from the CDC packing station conveyor (44) and place it
on the CDC
sort conveyor (42). Changing the Status and removing the CDC Id value from the
Case
record 1208 can automatically reduce the Quantity of the ePD Retailer Id-SKU
combination
of the scanned case on the CDC Case Inventory data view record 1226, since
that Case record
1208 will no longer be selected by the CDC Case Inventory data view 1226. By
reducing the
Quantity on the CDC Case Inventory data view record 1226, the net quantity
needed for the
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current CDC 1190-1 or LDDH 1192-1 can be increased, since the value that the
CDC Sort
Program (328) subtracts from the CDC Order List data view record 1224 has been
reduced.
If the full needed amount of items was picked from the case before the reverse
CDC sort pick
was done, the reverse pick action can result in a negative needed quantity
being increased to
zero.
Situations can occur in which a case is physically on a CDC sort conveyor
(42), but
logically associated with a CDC packing station conveyor (44). In one
situation, a case can
be picked from a CDC packing station conveyor (44) and placed back on to a CDC
sort
conveyor (42) without being scanned to initiate a reverse CDC sort pick. In
another, a case
can be scanned on the CDC sort conveyor (42), but not physically picked from
that conveyor
(42) to a CDC packing station conveyor (44). If a case having a CDC Id because
of either
situation is traveling around on the CDC sort conveyor (42) and gets scanned,
the CDC Sort
Program (328) can process that case as a corrective CDC sort pick. The CDC
Sort Program
(328) can update the CDC Id value on the Case record 1208 of the scanned case
to the value
of the current CDC packing station conveyor (44) and can indicate that the
scanned case
should be picked, for example, by sounding a pick confirmation tone. The
worker can pick
the case from the CDC sort conveyor (42) and place it on the CDC packing
station conveyor
(44). In updating the CDC Id on the Case record 1208 of the scanned case as
part of the
corrective CDC sort pick, the CDC Sort Program (328) can correct the error
that existed in
the CDC Case Inventory data view 1226 by reducing the Quantity of that ePD
Retailer Id-
SKU combination for the CDC 1190-1 or LDDH 1192-1 that it was being credited
to
incorrectly. The corrective CDC sort pick action can also correctly update the
CDC Case
Inventory data view 1226 for the CDC 1190-1 or LDDH 1192-1 of the current CDC
packing
station conveyor (44) as the scanned case gets picked and placed on that
conveyor (44).
An exception to the normal result of a corrective CDC sort pick can occur when
the
Case record 1208 of a case on the CDC sort conveyor (42) already has a Status
such as
"package sort" and a CDC Id, and the worker scanning the case happens to be
working at the
CDC packing station conveyor (44) identified by the CDC Id of that Case record
1208. In this
situation, the CDC Sort Program (328) can process the scanned case, for
example, as a
reverse CDC sort pick instead of a corrective CDC sort pick. The program (328)
can remove
the CDC Id from the Case record 1208 and make an indication to pick the case,
such as
sounding a pick confirmation tone as the worker picks the case from the CDC
sort conveyor
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(42) to the CDC packing station conveyor (44). The result of this action
actually switches the
database from being in error in one direction to being in error in the
opposite direction.
Before the case was scanned and picked, the database incorrectly included the
quantity of the
case in the CDC Case Inventory data view 1226, when the case was not
physically on the
CDC packing station conveyor (44) of that CDC 1190-1 or LDDH 1192-1. After the
case
gets scanned and picked, the case can be physically on the CDC packing station
conveyor
(44), but the database no longer includes the quantity of that case in the CDC
Case Inventory
data view 1226. This error can be corrected when the case is scanned in the
process utilized
for creating packages. The CDC sort step 1120 can result in cases containing
the item
quantities needed to fill a CDC's 1190-1 or a LDDH's 1192-1 orders being on
the CDC
packing station conveyor (44) of that CDC 1190-1 or LDDH 1192-1.
Once the CDC sort step 1120 is completed, packages can be created from the
sorted
items as illustrated in step 1122. One of the main purposes that each
shipper's RDC can serve
within the ePD Delivery Process can be as an origination RDC -- acting as an
initial receiving
point for all cases of product from nearby retailers and sorting and
forwarding those cases
onto their destination RDC's. Another main purpose a shipper's RDC can serve
can be as a
destination RDC -- creating bulk delivered packages for recipients from the
cases of ordered
items received from other RDC's or directly from retailers and shipping those
packages in
bulk to the CDC's and LDDH's in the local markets served by that RDC.
In accordance with a further aspect of the invention, refrigerated items,
frozen items,
and standard temperature items are not packaged together, because each type of
item requires
a different storage temperature. In the one embodiment, refrigerated and/or
frozen
temperature items can be packed into packages by retailers at their
fulfillment sites and
delivered directly into CDC's 1190-1 by a shipper or the retailer. Because
many retailers will
either ship only items requiring cold temperature storage or items which can
be stored at
standard temperatures, many retailers can employ one order fulfillment method
and can either
ship item cases to the nearest origination RDC 1170 or ship customer packages
directly to
their destination CDC 1190-1. If a retailer ships both types of items, it can
employ separate
order fulfillment methods to ship each type of item. Although in this
exemplary embodiment
packages are described as being created in a destination RDC 1180-1 for
standard
temperature items only, the database and programs of the ePD Delivery
Application~can be
designed to provide the capability to create separate packages for items
requiring different
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storage temperatures. Retailers that ship bulk delivered packages directly to
CDC's 1190-1
can utilize a Retailer Package Creation Program (315) of the ePD Shipping
Application or a
modified version of their own order fulfillment software to create Package
records 1234 and
print packing lists and package labels as they create packages to ship
directly to CDC's 1190-
1.
The workers at the destination RDC 1180-1 that create packages can be
stationed at a
CDC packing station (45) at which they can be working. CDC packing stations
(45)
designated to a particular CDC 1190-1 or LDDH 1192-1 can be located adjacent
to the CDC
packing station conveyor (44) designated to that CDC 1190-1 or LDDH 1192-1.
One RDC
worker can be assigned to one CDC packing station (45) at one time, and that
worker can be
dedicated to the task of creating packages for only the one CDC 1190-1 or LDDH
1192-1 to
which that CDC packing station (45) is dedicated. A Package Creation Program
(330) of the
ePD Delivery Application can drive the package creation process. CDC packing
stations (45)
can be grouped together by the CDC 1190-1 or LDDH 1192-1 to which they can be
dedicated. Each CDC packing station (45) within the group can be connected to
and can be
powered by its own workstation, located, for example, within its back console.
Each packing
station workstation (not shown separate from a CDC packing station (45)) can
run a different
instance of the Package Creation Program (330), but each instance running
within the group
(of CDC packing stations (45) organized for a specific CDC 1190-1 or LDDH 1192-
1) can
have the same pre-defined program value for CDC Id. All program instances
running within
the current destination RDC 1180-1 can have the same pre-defined program value
for RDC Id
and ePD Shipper Id.
There is shown in FIG. 4, an illustrative embodiment of an exemplary package
creation side of a Customer Distribution Center (CDC) Packing Station. The
Customer
Distribution Center (CDC) Packing Station of FIG. 4, can have the following
entities: rack
frame (70), large package bag holder (71), small package bag holder (72),
fixed location bar
code label plate (74), packing material storage bin (76), packing document
printer (77), back
console (78), program display monitor (79), keypad (80), label printer (81),
package bag
storage dispenser (82), and package bag storage dispenser opening (83).
30. Referring to FIG. 4, in one embodiment of the invention, the package
creating side of
a CDC packing station (45) can consist of a rack frame (70) made of metal or a
suitable
composite which can contain, for example, multiple wire mesh package bag
holders arranged
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in rows. For illustrative purposes, there can be 11 package bag holders
arranged into two
rows. Likewise, there can be two different sizes of package bag holders. A CDC
packing
station (45) can have, for example, large package bag holders (71) in three of
its corners. For
example, five of its eight small package bag holders (72) can be spaced a few
inches apart
between the two large package bag holders (71) in the second row of the
packing station. The
other three small package bag holders (72) can be in the front row of the
packing station --
one can be directly in front of the middle small package bag holder (72) of
the second row
and two can be spaced a few inches apart, directly in front of one of the
large package bag
holders (71) in the second row of the packing station. There can be sufficient
space inside the
front row of the packing station to allow free access to the surrounding
package bag holders
or any of the components on the back console of the packing station (78). The
package bag
holders can be spaced a few inches apart from each other on each side and
there can be a few
inches of space between the front and second rows. The tops of the package bag
holders in
the second row can be raised a few inches above the tops of the package bag
holders in the
first row. The wire mesh package bag holders can be open at the top, having
four sides and a
bottom. Each package bag holder can have a fixed location barcode label plate
(74) mounted
just above its top edge either a few inches in front of the center of its top
front edge (for the
package bag holders in the front row) or a few inches behind the center of its
top back edge
(for the package bag holders in the second row). A fixed location barcode
label plate (74) can
be a thin metal or plastic plate with a barcode label affixed to it, and can
be attached to the
bottom of a package bag holder (71 or 72), for example, by two thin metal
beams which can
extend out one or more inches from the front or back side of the package bag
holder and can
run parallel to the front or back side of the package bag holder. A fixed
location barcode
label plate (74) can be designed to allow for a barcode label to be physically
associated with a
package bag holder, without being covered and/or blocked by a package bag,
which can be
placed in and around that package bag holder. A packing station (45) can also
have, for
example, two packing material storage bins (76) on either side of the back
console (78)
extending from and attached to the back of the rack frame of the packing
station (70). These
two bins (76) can be made of material, such as, wire mesh or comparable
material similar to
the package bag holders. The packing material storage bins (76) can be used to
store bubble
wrap packing sheets which can be packed between items within a package bag to
protect
those items from damage. The back console (78) of the CDC packing station (45)
can be
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situated behind the rack frame (70) of the CDC packing station (45) in between
the two
storage bins (76). The back console (78) can have, for example, a program
display monitor
(79), a keypad (80), a packing document printer (77), and a label printer
(81). There can be
two package bag storage dispensers (82) located on either side of the back
console (78) at
approximately the same height as the program display monitor (79). Each of the
package bag
storage dispensers (82) can have an open back to facilitate loading and an
opening (83) in the
center of its front side, through which a worker can take package bags as they
can be needed.
One of the package bag storage dispensers (82) can be used to dispense small
package bags
while the other can be used to dispense large package bags.
In a further embodiment, specially designed ePD package bags can be used in
creating
packages. ePD package bags can be made of material, for example, plastic
bubble wrap,
which can be approximately one inch in thickness. Pre-sized plastic bubble
wrap bags can
advantageously cushion and protect items from damage while in transit or in a
Smart Bin
Unit (SBU) at a CDC 1190-1. Furthermore, pre-sized bags can ensure a proper
fit for the
SBU bins at a CDC 1190-1 when delivered. For illustration, the outer
dimensions of the
small package bags can measure 12 inches by 17 inches by 40 inches, with an
inner capacity
of 10 inches by 1 S inches by 24 inches. The opening of the small package bag
can be
approximately 10 inches by 15 inches with the thickness of the sides of the
bubble wrap bag
accounting for the other approximate two inches of each outer dimension. The
small package
bag can have a pre-marked capacity fill line on it located at approximately 25
inches from~the
bottom of the bag. As an illustration, the height of the bag can consist of
approximately 24
inches of inner capacity on top of one inch of the bottom of the bag's
thickness, with
approximately 15 inches of height allowing for the bag to be cinched closed at
the top -- 8 '/Z
inches (one-half of 17 inches, the larger of the bag opening's dimensions) to
bring the widest
sides of the bag together, plus another 6 %a inches (approximately a handful)
of extra material
above the point where the bag is cinched. The outer dimensions of the large
bags can
measure 28 inches by 17 inches by 63 inches, with an inner capacity of 26
inches by 15
inches by 44 inches. The inner capacity dimensions can be calculated in the
same manner as
for the small bag, but the large bag can have three pre-marked capacity fill
lines on it -- at 21,
33, and 45 inches. In an alternate embodiment of the invention, other material
suitable for
packing can be utilized. This can include cardboard boxes, packaging paper, or
other
material known in the art.
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The package bag holders can be sized to fit the package bags inside them
allowing for
the outer sides of the package bag to fit easily but snugly within its mesh
wire sides -- for
illustration, small package bag holders (72) can be approximately 12 inches
left to right, by
17 inches front to back, by 25 inches top to bottom; the large package bag
holders (71 ) can be
approximately 28 inches left to right, by 17 inches front to back, by 45
inches top to bottom.
The extra material of the bubble wrap package bags extending above the package
bag holders
(71 & 72) can be folded back over the top edges and down the sides of the
package bag
holders.
In one embodiment, each item SKU shippable by the ePD Delivery Process can be
categorized into one of five different sizes. A small-sized SKU can be one
that is small
enough to fit into a small package bag. A medium-sized SKU can be one that is
too large to
fit into a small package bag, but is small enough to fit into a large package
bag. A large-sized
SKU can be one that is too large to fit into a large package bag, but is small
enough to fit into
one of the divided sections within a configured stationary bin of a Smart Bin
Unit (SBU) at a
CDC 1190-1. An extra-large-sized SKU can be one that is too large to fit into
a divided
section of a SBU stationary bin, but is small enough to fit into the largest,
undivided,
configured stationary bin of a SBU. A LDDH-sized item SKU can be too large to
fit into the
largest, undivided, configured stationary bin of a SBU and can be considered
unshippable to a
CDC 1190-1, but it can be delivered to a customer-specified address after
being distributed to
a local delivery distribution hub (LDDH) 1192-1. In addition to being too
large to fit into
SBU bins at a CDC 1190-1, LDDH-sized items can be generally too bulky and
heavy for a
person to carry without moving equipment and can therefore be delivered more
efficiently via
a LDDH to a customer-specified address. Some SKU's which can be small enough
to fit into
the largest configured stationary bin of a SBU can still be classified as LDDH-
sized if their
weight and dimensions make it dangerous or impractical for a recipient to
carry them away
from a CDC 1190-1 without moving equipment. Large-sized, extra-large-sized,
and LDDH-
sized SKU's will be referred to collectively as over-sized items throughout
the remainder of
this disclosure. SKU size can be tracked on the Case 1208 and Order Detail
1202 tables and
some of the data views created from those tables.
With reference to FIG. 9C, there can be three data views created and used by
the
Package Creation Program (330) of the ePD Delivery Application. One can be a
Customer
By SKU Order List data view 1228, which can subtotal the Quantity needed for
each recipient
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of each ePD Retailer Id-SKU combination. It can be created from the underlying
Order
Header 1200 and Order Detail 1202 tables by selecting, grouping, and
subtotaling, for
example, Customer Id's (representing the recipient of each order) and their
Quantities for
each CDC Id-ePD Retailer Id-SKU combination. A temperature Code and SKU Size
associated with each SKU can also be selected as part of the data view 1228.
The following
illustrative Structured Query Language (SQL) can be used in creating the
Customer By SKU
Order List data view 1225:
select CDC Id, ePD Retailer Id, SKU, Customer Id,
Temperature Code, SKU Size, Quantity from Order Header and
Order Detail where Order Detail.Status = "destination RDC"
group by CDC Id, ePD Retailer Id, SKU, Customer Id,
Temperature Code, SKU Size order by CDC Id, ePD Retailer
Id, SKU, Customer Id
A SKU By Customer Order List 1230 can be another data view, which can be
created from
the underlying Order Header 1200 and Order Detail 1202 tables. Instead of
selecting
Customer Id's and theirf Quantities for CDC Id-ePD Retailer Id-SKU
combinations, the SKU
By Customer Order List data view 1230 can be created by selecting and
grouping, for
example, ePD Retailer Td-SKU combinations and their Quantities for each CDC Id-
Customer
Td-Temperature Code combination. The SKU Size associated with each SKU can
also be
selected as part of the data view 1230. The purpose of this data view 1230 can
be to subtotal
the Quantity of each ePD Retailer Id-SKU combination needed for each CDC Id-
Customer
Id-Temperature Code combination. The following illustrative Structured Query
Language
(SQL) can used in creating the SKU By Customer Order List data view 1230:
select CDC Id, Customer Id, Temperature Code, ePD Retailer
Id, SKU, SKU Size, Quantity from Order Header and Order
Detail where Order Detail.Status = "destination RDC" group by
CDC Id, Customer Id, Temperature Code, ePD Retailer Id,
SKU, SKU Size order by CDC Id, Customer Id, Temperature
Code, ePD Retailer Id, SKU
The other data view used by the Package Creation Program (330) can be an Open
Package
List data view 1232. It can be created by selecting, for example, the CDC Id,
Customer Id,
Temperature Code, Package Id, Package Bag Holder Id, and Package Size for each
Packing
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Employee Id from the underlying Package table 1234. The purpose of this data
view 1232
can be to organize selected package information for the open packages of each
worker
creating packages. The following illustrative Structured Query Language (SQL)
can be used
in creating the Open Package List data view 1232:
S select CDC Id, Packing Employee Id, Customer Id,
Temperature Code, Package Id, Package Bag Holder Id,
Package Size from Package where Status = "open" order by
CDC Id, Packing Employee Id, Customer Id, Temperature Code
All three data views can be dynamically updated as data changes on their
underlying tables.
The ePD Retailer Id's and SKU's can be selected together in combination for
the data views
to ensure that a customer who orders a particular SKU from one retailer does
not receive the
same SKU from a different retailer who may sell the same item. Customer Id's
and
Temperature Codes can be selected together in combinations to separate items,
requiring
different shipping and storage due to their temperature, into different
packages, even if those
1S packages are for the same recipient and CDC 1190-1 or LDDH 1192-1.
The Package Creation Program (330) can use the three data views in combination
with its
program rules to coordinate the creation of packages by multiple workers
destined for
recipients at one CDC 1190-1 or LDDH 1192-I. The Package Creation Program
(330) can
allow one open package at a time for a given combination of recipient,
temperature code, and
CDC 1190-1 or LDDH 1192-1. It is possible for a recipient to have more than
one open
package if the packages are for different CDC's 1190-1 or LDDH's 1192-1 or if
the packages
have different temperature codes. As one worker closes or completes a package
for a given
Customer Id-Temperature Code-CDC Id combination, a new package can be opened
for that
same combination by that same worker or by another worker. The Package
Creation Program
2S (330) can attempt to pick a SKU to finish an open package, before it picks
a SKU to create a
new package. Each worker can have a limited number of small-sized and medium-
sized
packages open at one time, which can be configured based upon the number of
package bag
holders of each size contained within their packing station (4S). In one
embodiment a worker
may have up to three medium-sized and eight small-sized packages open at the
same time.
When creating a new package for a recipient, the Package Creation Program
(330) can
determine the size of the package by the size of the SKU's needed for that
recipient
(Customer Id). If the SKU Size on any of the SKU by Customer Order List
records 1230 for
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the open orders of a Customer Id-Temperature Code combination for the current
CDC Id is a
value such as "medium", the Package Creation Program (330) can direct the
worker to use
one of the large package bag holders on the packing station (45). If all of
the SKU Sizes
needed for the open orders of a Customer Id-Temperature Code combination for
the current
CDC Id are either small-sized or over-sized, the Package Creation Program
(330) can direct
the worker to use one of the small package bag holders when the case of one of
those small-
sized SKU's is scanned. Over-sized items are not packed into package bags with
other items.
The Package Creation Program (330) can treat them as separate single-item
packages and can
direct workers to apply package labels directly to them: In one aspect of the
invention, when
a case label is scanned by a worker at a packing station (45), the Package
Creation Program
(330) can result in one of several actions, which can include but are not
limited to: a prompt
to pick a specified quantity from the scanned case to pack into one of the
worker's existing
packages; a prompt to create a new package with a specified quantity from the
scanned case;
a prompt to label the case as a large single-item package; or an indication to
let the scanned
case pass by on the CDC packing station conveyor (44).
Each packing station (45) can be divided into several parts. For example,
there can be
two main parts, namely, a package creation side as illustrated in FIG. 4 and a
package sealing
side (FIG. 5). There is shown in FIG. 5, an illustrative embodiment of an
exemplary Package
Sealing side of a Customer Distribution Center (CDC) Packing Station. The
Package Sealing
side of a Customer Distribution Center (CDC) Packing Station can have the
following
entities: pick confirmation light (84), scanner port (86), trimming slot (88),
package tie holder
(90), tie holder lock button (92), package sealer compartment (94), package
guide ring (96),
package holding ring (98), tie holder release button (100), package holder
lock button (101),
package holder release button (102), package holder support base (103),
package sealing
station top (104), packing list pouch storage bin (105), and package tie
storage bin (106).
Referring to FIG. 5, the package sealing side can be built onto the edge of a
CDC
packing station conveyor (44). The package creation side (FIG. 4) can be an
independently
standing structure, which can be located opposite to the package sealing side,
with working
space in between the two sides in which a worker is able to move. A RDC worker
can log
into an instance of the Package Creation Program (330) by using, for example,
a hands-free
barcode scanner attached to a CDC packing station (45) to scan their employee
identification
(id) card. The hands-free scanner can be plugged into a scanner port (86) on
the package
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sealing side of the CDC packing station (4S) at which the worker is stationed.
Upon logging
into the program (330), the scanned employee id value can be written to the
Packing
Employee Id field of all the records on a Package Bag Holder table 1236
associated with that
worker's packing station (4S).
S . As a case moves by on the current CDC packing station conveyor (44) the
worker can
scan the barcode on the case label. The Package Creation Program (330) can
read the Case Id
from the scanned barcode and use it to retrieve information such as, the ePD
Retailer Id and
SKU of that case from the Case table 1208. The Package Creation Program (330)
can use the
ePD Retailer Id, SKU, and the CDC Id associated with the current CDC packing
station (4S)
to retrieve data records from the Customer By SKU Order List data view 1228.
The retrieved
records can be a listing of all the recipients for whom an ordered item of the
scanned case is
to be delivered to the current CDC 1190-1 or LDDH 1192-1. Each of the
retrieved data
records 1228 can include information such as the Customer Id, Temperature
Code, SKU Size,
and Quantity of the item ordered by the customer. The program can check the
SKU Size of
1 S the first Customer By SKU Order List record 1228 retrieved to determine if
single-item
package or mufti-item package processing should be followed. If the selected
record's 1228
SKU Size is a value such as "large", "extra-large", or "LDDH", single-item
package
processing can be performed. If the selected record's 1228 SKU Size is a value
such as
"small" or "medium", mufti-item package processing can be performed.
There is shown in FIG. 7, an illustrative embodiment of an exemplary layout of
a
Package Creation Screen. The Package Creation Screen can have the following:
Package bag
indicator 108, Single item package indicator 109, Pick quantity indicator
field 112, Message
field 114, Current case information display section 116, Current package
information display
section 118, Close out list information display section 120, Information
display section title
2S 122, Information display section column header 124, Information display
section line detail
126, Current package information display -. package indicator 128, and Package
list scroll bar
130. One of the package bag indicators 108 can be displayed as a highlighted
package bag
indicator 110, when the Package Creation Program (330) is trying to identify a
package bag
as part of a program action.
. As part of a mufti-item package processing, the Package Creation Program
(330) can
use the current CDC Id (the CDC Id associated with the current CDC packing
station (4S))
and the worker's Employee Id to select records from the Open Package List data
view 1232,
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having the current CDC Id in the CDC Id field and the worker's Employee Id in
the Packing
Employee Id field. The Package Creation Program (330) can read the list of
Customer Id-
Temperature Code combinations from the selected Open Package List records 1232
sequentially, searching for eac~i Customer Id-Temperature Code combination in
the data that
was retrieved from the Customer By SKU Order List data view 1228 when the case
was
scanned. Whenever a match is found, the worker can already have an open
package, having
the same temperature code as the scanned case, for a recipient for whom the
item of the
scanned ease was ordered. The Package Creation Program (330) can make an
indication to
pick one or more items from the case, for example, by sounding a pick
confirmation tone,
lighting up the pick confirmation light (84), highlighting the package bag
indicator (108)
containing that recipient's open package, displaying the quantity to pick in
the pick quantity
indicator field (112), and displaying a message in the message field (114) of
a Package
Creation Screen, illustrated in FIG. 7, on the program display monitor (79).
The displayed
message can direct the worker to pack the indicated quantity of the item in
the scanned case
into the package bag represented by the highlighted package bag indicator
(110) and scan the
fixed location barcode label plate (74) of the highlighted package bag.
The Package Creation Program (330) can determine which package bag indicator
(108) to highlight from a Package Bag Holder Id on the selected Open Package
List record
1232. A Package Bag Holder Id can be a fixed value that represents a
particular package bag
holder (71 or 72) on a packing station (45) and the package currently in that
package bag
holder (71 or 72). The Package Creation Program (330) can determine the value
to display in
the pick quantity indicator field (112) by selecting the Quantity on the
underlying Order
Detail record 1202 of the transaction. To select the transaction's underlying
Order Detail
record 1202, the Package Creation Program (330) can search for a record 1202
containing the
Customer Id, for which it was able to find a match between the Open Package
List record
1232 and the Customer By SKU Order List record 1228, the current CDC Id, and
the ePD
Retailer Id and SKU of the scanned case. If the recipient (represented by
Customer Id) has
more than one open order (Order Detail record 1202 having a Status such as
"destination
RDC") for the current CDC 1190-1 or LDDH 1192-1 containing the item of the
scanned case,
. . the Order Detail record 1202 associated with the Order Header record 1200
having the
earliest Order Date/Time can be selected.
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Upon hearing the pick confirmation tone or seeing the pick confirmation light
(84)
flash (or recognizing another indicator to pick an item from the scanned
case), the worker can
pick the case from the CDC packing station conveyor (44) and for example,
place it on top of
the packing station -- on either the package sealing side (FIG. 5) or the
package creation side
I (FIG. 4). The worker can look at the case label to determine if the case is
a single-item case
or a mufti-item case. If the case label does not have an indicator, such as a
large "S" printed
on it, to indicate a single-item case, the worker can, for example, open the
case (if it has not
already been opened), pick the indicated quantity of items from the case, pack
the indicated
quantity of items into the highlighted package bag, enter the picked quantity
using for
example, the packing station keypad (80), and scan the fixed location barcode
label plate (74)
associated with the highlighted package. When packing the items into the
package bag, the
worker can use packing materials such as bubble wrap packing sheets, which can
be stored in
the packing material storage bin (76), as needed to protect the items from
damage.
The Package Creation Program (330) can determine the Package Id associated
with
the scanned fixed location barcode label plate (74) by searching the Package
table 1234 for
the record having the Package Bag Holder Id that is printed in barcode format
on that label
plate (74) and a Status such as "open". The program (330) can validate the
scanned Package
Bag Holder Id against the Package Bag Holder Id selected from the Open Package
List data
view 1232. If it does not match, the worker scanned a different label plate
(74) by mistake
and the program (330) can signal that an error has occurred, for example, by
sounding an
error tone and displaying a message indicating that the wrong package was
scanned. The
program (330) can also validate the quantity entered on the keypad (80)
against the value in
the Quantity field of the selected Order Detail record 1202 underlying the
transaction. If the
entered quantity does not match, the worker entered a different value and the
program (330)
can signal that an error has occurred, for example, by sounding an error tone
and displaying a
message indicating that the wrong quantity was entered. If the worker did not
enter a quantity
before scanning the barcode on the label plate (74), the program (330) can
signal that an error
has occurred, for example, by sounding an error tone and displaying the same
error message
as it does when the wrong quantity is entered.
Upon successful validation, the Package Creation Program (330) can update the
selected Order Detail record 1202 by setting its Status to a value such as
"package", writing
the Package Id from the selected Open Package List record 1232 to the Package
Id field, and
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writing the Case Id of the scanned case to the Case Id field. The Package
Creation Program
(330) can also update the Case record 1208 of the scanned case by decrementing
its Quantity
by the quantity the worker entered on the keypad (80). After the worker enters
the indicated
pick quantity and scans the correct label plate (74), the program (330) can
indicate that the
picked quantity of items was successfully associated with the package of the
scanned label
plate (74), for example, by sounding another confirmation tone and displaying
a confirmation
message confirming that the picked items were added to the package
successfully.
If a match was not found when the worker scanned the case label and the
program
(330) searched for the Customer Id-Temperature Code combinations of the
worker's open
packages on the Customer By SKU Order List records 1228 having the current CDC
Id and
the ePD Retailer Id-SKU combination of the scanned case, then none of the
recipients of the
worker's open packages require an item from the scanned case. The program
(330) can then
check to see if a new package should be created for a recipient using the
items of the scanned
case. The Package Creation Program (330) can determine whether a new package
should be
created by sequentially reading the records selected from Customer By SKU
Order List 1228
for the current CDC Id and the ePD Retailer Id-SKU combination of the scanned
case,
checking for the Customer Id-Temperature Code combination of each record 1228
on the
Open Package List records 1232 having the current CDC Id. If all the Customer
Id-
Temperature Code combinations on the Customer By SKU Order List 1228 are also
on the
Open Package List 1232, then all the recipients for whom that item has been
ordered for
delivery to the current CDC 1190-1 or from the current LDDH 1192-1 can already
have open
packages with other workers. In this situation, a new package should not be
created. The
Package Creation Program (330) can indicate not to pick items from the case,
for example, by
sounding an invalid pick tone, turning off the highlight of whichever package
bag indicator
(108) was previously highlighted, setting the pick quantity indicator field
(112) to zero, and
displaying a message in the message field (114) of the Package Creation
Screen. The
message can direct the worker not to pick items from the scanned case, because
its items are
intended for packages at other packing stations (45).
If the Package Creation Program (330) was able to find a Customer Id-
Temperature
Code combination on the Customer By SKU Order List data view 1228, for which
there was
not a matching record on the Open Package List data view 1232, when trying to
determine
whether a new package should be opened for a recipient, then that recipient
does not have an
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open package at any packing station (45) for the current CDC 1190-1 or LDDH
1192-1 and a
new package should be created. To create a new package, the program (330) can
check to
determine if the worker has availability at the packing station (45) to start
the new package.
Determining packing station availability can include determining the package
size. The
Package Creation Program (330) can determine the package size needed for the
recipient by
searching the SKU By Customer Order List data view 1230 for all of the records
with the
current CDC Id and Customer Id-Temperature Code combination. If any of the
selected
records 1230 has a SKU Size value such as "medium", the Package Creation
Program (330)
can search the Package Bag Holder table 1236 for records containing the
worker's id in the
Packing Employee Id field, a Status such as "available", and a Package Bag
Holder Size such
as "large". If none of the selected records has a SKU Size value such as
"medium", the
Package Creation Program (330) can search the Package Bag Holder table 1236
for records
containing the worker's id in the Packing Employee Id field, a Status value
such as
"available", and Package Bag Holder Size value such as "small". If the Package
Creation
Program (330) doesn't find an available package bag holder (71 or 72) of the
right size, it can
indicate that a new package cannot be created with items from the scanned
case, for example,
by sounding an invalid pick tone, turning off the highlight of whichever
package bag
indicator (108) was highlighted, setting the pick quantity indicator field
(112) to zero, and
displaying a message in the message field (114) of the Package Creation
Screen. The
message can direct the worker not to pick items from the case, because the
worker's packing
station (45) doesn't have a package bag holder of the correct size (71 or 72)
available. It can
be possible for a worker to override the Package Creation Program (330) and
start a new
package for the recipient, using for example, a package creation override key
sequence on the
packing station keypad (80), if the Package Creation Program (330) was looking
for a small
package bag holder (72) and only a large one (71) was available.
On finding an available package bag holder (71 or 72) of the appropriate size,
the
Package Creation Program (330) can create a new record on the Package table
1234 having,
for example, the Customer Id and Temperature Code from the Customer by SKU
Order List
1228, the value of the current CDC Id of the packing station (45), the ePD
Shipper Id and
RDC Id values of the current destination RDC 1180-1, the Packing Employee Id
of the
worker logged into the current instance of the program (330), the Package Bag
Holder Id
from the selected Package Bag Holder record 1236, and a Status set to a value
such as
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"open". The Package Id value on the new record can be generated, for example,
by
concatenating Customer Id + RDC Id + current date + a sequential 3 digit
number. All other
fields can be initially created without values. The program can update the
selected Package
Bag Holder record 1236, setting Status to a value such as "package" and
Package Id to the
value of the newly created Package record 1234. In addition to creating the
new Package
record 1234 and updating the selected Package Bag Holder record 1236, the
program (330)
can indicate to pick items from the scanned case for a new package, for
example, by sounding
a confirmation tone, lighting up the pick confirmation light (84),
highlighting the package bag
indicator (108) of the selected package bag holder where the new package can
be created,
displaying the quantity to pick in the pick quantity indicator field (112),
and printing a
package label. Package labels can contain the Package Id in both a barcode and
a readable
format and the destination CDC Id in a readable format. The Package Creation
Program
(330) can also display a message in the message field (114) directing the
worker to create a
new package.
The worker can pick the case from the CDC packing station conveyor (44) and
place
it on top of the packing station (45). The worker can take a new package bag
of the
appropriate size from one of the package bag storage dispensers (82)
(depending upon
whether the program (330) highlighted a large or small bag holder). After
peeling the
package label from the label stock printout, which can be hanging out of the
packing station's
label printer (81), the package label can be affixed to the outer surface of
the package bag.
Package labels can be placed on the side of package bags near the bottom. The
worker can
scan the barcode on the package label and position the package bag in the
package bag holder
(71 or 72) indicated by the highlighted package bag indicator (110), pushing
the bottom of the
bag down into the center of the package bag holder (71 or 72), and folding the
sides of the
package bag, which can extend above the top of the package bag holder (71 or
72), down
around the outside edges of the package bag holder (71 or 72). The package bag
can be
pushed down into the package bag holder (71 or 72) so that the top fill line
marked on the
package bag is aligned with the top of the package bag holder (71 or 72).
After labeling and
positioning the new package bag in a package bag holder (71 or 72), the
remaining actions of
' creating a new package -- picking the indicated quantity of items from the
scanned case into
the new package -- can be the same as picking items into an existing package
(as previously
described).
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The step of scanning the barcode label on the package bag, in creating a new
package
(between the normal packing steps of scanning a case label and then scanning a
fixed location
barcode label (73)), can associate the package bag label with a specific
package bag holder
location on the packing station (45). For the time while a package is open and
in the process
of being packed, the Package Creation Program (330) can consider the value of
the fixed
location barcode label (73) to be synonymous with the value of the barcode on
the package
label. This can enable the Package Creation Program (330) to validate that a
package has
been initially set up in the correct package bag holder (71 or 72), and to
validate on each
packing action that the worker has packed the items into the correct package.
. After a worker picks a quantity of an item from a case and packs it into
either a new
or an existing package, the picked case can be sitting on top of the worker's
packing station
(45). Before returning the case to the CDC packing station conveyor (44), the
worker can
scan the barcode label on the case again to see if additional items should be
picked from it.
The Package Creation Program (330) can perform the processing that it performs
when a case
is scanned, which can result in the worker packing another quantity from that
case into an
existing package, creating a new package, or placing the case back onto the
conveyor (44).
The worker can continue to scan the case until the case is empty or the
program (330) directs
the worker to return the case to the conveyor (44). When the program (330)
determines that a
case is empty -- for example, when the Quantity on the Case record 1208 has
been
decremented to zero -- it can display a message indicating that the case is
empty. Empty
cases can be placed back onto the conveyor (44) and can be moved through the
destination
RDC 1180-1 to one of the local market shipping dock conveyors (48) to be sent
into a
recycling process.
If a case only has part of the quantity needed for a customer order, the
Package
Creation Program (330) can indicate a need to pick only the remaining quantity
in the case.
After the worker scans the barcode on the fixed location barcode label plate
(74) of the
package, the Package Creation Program (330) can update the existing Order
Detail record
1202 as it normally would when performing a pack action, including writing the
Package Id
and Case Id to the record 1202 and changing the Status to a value such as
"package". In
addition to its normal updates, the Package Creation Program (330) can reduce
the Quantity
on the Order Detail record 1202 to equal the picked quantity and can create a
new Order
Detail record 1202 with the same information as the existing record except for
a few
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differences. The differences can be that the Package Id and Case Id can be
empty, Status can
be set to a value such as "destination RDC", and Quantity can be set to the
difference
between the Quantity value that was on the existing record before it was
updated, and the
Quantity value to which it was updated. If the Package Creation Program (330)
directs the
worker to pick a higher quantity than what is physically in the case, the
worker has uncovered
a previously made packing error -- an over-packing error. In this situation,
the worker can
leave the items in the case, cancel the current pick action, run a RDC Package
Inspection
Report, and place the case to the side of the packing station (45).
After the program (330) makes the previously described update to the Status on
Order Detail
records 1202 as items are packed into packages (updating Status from a value
such as
"destination RDC" to a value such as "package"), it can check the CDC Order
List 1224 and
Local Market Order List 1220 data views to determine if there is still a
demand for the
scanned case's items in both the current CDC 1190-1 and the current local
market. If the
(needed) Quantity of the ePD Retailer-SKU combination for the current CDC Id
on the CDC
Order List 1224 reaches zero, as the Quantity on the underlying Order Detail
record 1202 is
decremented, the Package Creation Program (330) can, for example, sound a
message alert
tone and display a message on the Paekage Creation Screen, indicating that the
scanned case
should be redirected back to the CDC sort conveyor (42) of the local market.
The worker can
place, for example, a CDC sort return marker on top of the case after placing
the case back
onto the CDC packing station conveyor (44). Upon seeing a case with a CDC sort
return
marker, a worker performing the CDC sort function 1120 for the current CDC
1190-1 or
LDDH 1192-1 can.scan the case to initiate a reverse CDC sort pick and can move
the case
back to the CDC sort conveyor (42) of the current local market. When moving
the case, the
CDC sort worker can, for example, remove the CDC sort return marker, flip it
up-side-down,
and place it back on the CDC packing station conveyor (44). The CDC sort
return marker
can have for example, a packing station id written on one side and text such
as "CDC sort" on
the other. When the packing worker who originally placed the CDC sort return
marker on the
case sees the marker on the CDC packing station conveyor (44) with their
packing station id
on it, the worker can retrieve it for later use.
. When the (needed) Quantity of the ePD Retailer-SKU combination for the
current
Local Market Id on the Local Market Order List data view 1220 reaches zero,
the Package
Creation Program (330) can, for example, sound a message alert tone and
displays a message
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on the Package Creation Screen, indicating that the scanned case should be
redirected back to
the local market sort conveyor (24). The worker can place, for example, a
local market sort
return marker on top of the case after placing the case back onto the CDC
packing station
conveyor (44). Upon seeing a case with a local market sort return marker, a
worker
performing the CDC sort function 1120 for the current CDC 1190-1 or LDDH 1192-
1 can
scan the case to initiate a reverse CDC sort pick and can move the case, with
the local market
sort return marker still on top of it, back to the CDC sort conveyor (42) of
the current local
market. Upon seeing a case on the CDC sort conveyor (42), with a Local market
sort return
marker, a worker performing the local market sort function 1118 for the
current local market
can scan the case to initiate a reverse local market sort pick and can move
the case back to the
local market sort conveyor (24). When moving the case, the local market sort
worker can
remove the local market sort return marker, flip it up-side-down, and place it
back on the
CDC sort conveyor (42). The local market sort return marker can have, for
example, a CDC
Id and a packing station id written on one side and text such as "local market
sort" on the
other. When a CDC sort worker sees the marker with the CDC Id on it, the
worker can pick
it from the CDC sort conveyor (42) and place it on the CDC packing station
conveyor (44) at
which the worker is working. When the packing worker who originally placed the
local
market sort return marker on the case sees the local market sort return marker
on the CDC
packing station conveyor (44), with their packing station id on it, the worker
can retrieve it
for later use.
The Package Creation Program (330) can also check the SKU By Customer Order
List
data view 1230, after the Order Detail Status update is made during the
packing action, to
determine if there are any remaining Order Detail records 1202 for that
recipient (represented
by Customer Id) with a Status value such as "destination RDC" and a SKU Size
such as
"small" or "medium". If it finds at least one record on the SKU by Customer
Order List data
view 1230 having the Customer Id of the Order Header record 1200 underlying
the SKU by
Customer Order List data view record 1230, a SKU Size such as "small" or
"medium" and a
Status such as "destination RI7C", then there are still some items currently
in the destination
RDC 1180-1 to be packed for that recipient and the Package Creation Program
(330) can
refrain from initiating an action to close that recipient's package. If the
program (330) is
unable to find any SKU by Customer data view records 1230 for that recipient
having a SKU
Size such as "small" or "medium" and a Status such as "destination RDC", then
there are no
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items remaining in the destination RI7C 1180-1 for that recipient which are
small enough to
be packed into a package for the recipient and the Package Creation Program
(330) can, for
example, sound a message alert tone and display a message in the message field
(114) of the
Package Creation Screen, indicating that the package should be closed.
The worker can also initiate the action to close a package by, for example,
pressing a
close package key on the packing station keypad (80), and then confirming the
action by
pressing a confirmation key, when the Package Creation Program (330) prompts
for a
confirmation. The confirmation prompts of the ePD Delivery Application's
programs can
consist of displaying a message which shows the worker what action is being
confirmed and
asks the worker to press a confirmation key. There can be several
circumstances in which a
worker realizes the need to close a package. One circumstance can occur when
the worker
has finished packing the full quantity of a picked SKU into the package bag
and sees that
although the SKU quantity fit in the package bag completely, there is very
little remaining
available space below the package's top fill line for other items. Another
circumstance can
occur when the worker scans a case and the Package Creation Program (330) can
direct the
worker to pick one or more items into a package bag in which there is not
enough space
available to accept the full quantity of items. In the latter situation, the
worker can pack as
many of the items into the package, as can be accommodated and can key in the
quantity that
was packed. If the items are too large to pack even one of them into the
package, the worker
can enter a zero for the quantity. When the worker enters a quantity less than
what the
Package Creation Program (330) directed the worker to pick, the Package
Creation Program
(330) can indicate that the correct quantity was not picked by, for example,
sounding an error
tone and displaying a message indicating that the correct quantity was not
entered and the
picked quantity should either be re-entered or confirmed. If there was truly
either a picking
error or a data entry error, the worker can count the quantity in the package,
compare it to the
quantity directed by the Package Creation Program (330), and re-pick and/or re-
enter the
quantity so that the quantity picked matches both the quantity entered and the
quantity
directed by the Package Creation Program (330). If the situation was not
really an error, but
one in which the worker needs to open a new package for the picked items,
instead of re-
entering the amount picked, the worker can close the package by, for example,
pressing a
close package key or other suitable key. The Package Creation Program (330)
can prompt the
worker to confirm the action, and when the worker presses the confirmation
key, the Package
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Creation Program (330) can update the Order Detail 1202 and Case 1208 records
to reflect
the actual amount picked. The update to the Order Detail record can be made in
the same
way as the one described earlier, in which the picked quantity is less than
the amount directed
by the Package Creation Program (330) because only part of the ordered amount
is available
in the case -- a new Order Detail record 1202 can be created having the
unpicked quantity. If
the quantity picked and entered was zero, the program (330) can end the
pick/pack action and
begin the close package action Without making any updates to the Order Detail
1202 or Case
1208 records.
Regardless of whether the Package Creation Program (330) or the worker
initiates a
close package action, the Package Creation Program (330) and worker can follow
the same
set of package closing procedures. If the package is in one of the large
package bag holders
(71), the program (330) can display a message on the program display monitor
(79) to prompt
the worker to enter the package size. The worker can look into the package bag
to count the
number of visible fill lines on the inside of the package. The worker can
enter the number of
visible fill lines completely above all the items in the package as the
package size ("3", "2",
or "1"). The Package Creation Program (330) can update Status on the Package
table 1234 to
a value such as "closed" and can set the Package Size to a value such as "2",
"3", or "4"
depending upon the value entered by the worker -- for example, an entered
value such as "3"
can be set to a Package Size such as "2", an entered value such as "2" can be
set to a Package
Size such as "3", and an entered value such as "1" can be set to a Package
Size such as "4".
If the package is in one of the small bag holders, the program (330) can
update Status on the
Package table to a value such as "closed" and can set the Package Size to a
value such as "1 ",
without prompting the worker to enter a package size.
The Package Creation Program (330) can call or initiate or cause to be
initiated, a
Packing List Report Program (332) to print packing lists for the items in the
package. A
separate packing list can be created for each distinct retailer having items
in the package.
Each packing list can contain the same basic information -- the quantity of
each SITU
included in the package -- as well as retailer specific information - retailer
order number(s), a
' customizable packing list header message, a customizable order header
message, and
customizable line item detail messages. The retailer order number can be a
different number
than the Order Id. A packing list can also contain an Order Id for each order
listed on it and
an item return barcode for each line item listed on it. An item return barcode
can contain, but
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is not limited to the following information associated with a line item
printed in barcode
format: Package Id, Order Id, and SKU. Each retailer can provide
specifications and/or
document templates to shippers to enable a packing list to be printed to look
exactly the way
it would if the retailer had printed it itself. To create the packing Lists,
the Package Creation
Program (330) can select a list of Order Detail records 1202 with the Package
Id of the
current package, sorted by, for example, Order Id. The Package Creation
Program (330) can
use the Order Id to select the corresponding Order Header records 1200 and can
then pass
certain data fields to the Packing List Report Program (332). These fields can
include, but are
not limited to, the ePD Retailer Id, Order Id, Customer Id, ePD Shipper Id,
Order Date/Time,
Retailer Order Number, Retailer Message-Order Header, Retailer Message-Packing
List,
SITU, Quantity, Package Id, and Retailer Message-Order Detail. The Package
Creation
Program (330) can pass the Order Header 1200 and Order Detail 1202 data
selected for the
current package to the Packing List Report Program (332) one retailer at a
time, for example,
by sub-selecting data from the selected data using each ePD Retailer Id
contained in the
selected data. If one retailer has more than one order in the same package,
the report
information can be grouped by Order Id, with common header information printed
at the top
of the report and order-specific header information printed at the top of each
order grouping.
The Package Creation Program (330) can then sub-select the data corresponding
to the next
retailer, from the data selected for the current package, and can call or
cause to be called the
Packing List Report Program (332) again to print the next packing list for the
current
package. This sub-process can be repeated until all packing lists are printed
for the current
package. The worker can take the packing list reports from the packing
document printer
(77) and place them inside the package bag.
After putting packing lists in the package, the worker can seal the package,
for
example, by pulling up the sides of the package bag from around the outside of
the package
bag holder (71 or 72) and cinching them closed above the packed items. The
package bag can
then be lifted out of the package bag holder (71 or 72) and brought to the
package sealing side
of the packing station (FIG. 5). The following description of sealing a
package bag using the
exemplary package sealing side of a CDC packing station depicted in FIG. 5 is
an illustrative
example of how a package can be sealed after it is created at a destination
RDC 110-1, other
suitable means and methods can alternately be used to close a package bag in
the create
'packages step 1122 of the ePD Delivery Process. The package can be placed in
the package
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sealer compartment (94) by sliding the cinched part of the package bag through
the trimming
slot (88), while placing the bulk of the package containing the items below
the package
sealing station top (104). When placing the package bag into the package
sealing side of the
packing station (FIG. 5), the worker can hold the cinched part of the package
bag with two
hands, one tightly holding the bag closed just above the items, and the other
several inches
above the lower hand. In the motion to slide the cinched part of the package
bag through the
trimming slot (88), the worker can push the bottom portion of the cinched part
of the package
bag, below their lower hand, into the package guide ring (96), and the top
portion of the
cinched part of the package bag, between their upper and lower hands, into the
package
holding ring (98). In entering the package guide ring (96), the package bag
can push the
spring-hinged collapsible side of the package guide ring (96) to force entry
inside the ring,
and the spring-hinged collapsible side of the package guide ring (96) can
spring back into its
normal position, reforming a solid ring around the cinched part of the package
bag. The
package holding ring (98) can have a gap in its outer edge, which can allow
the worker to
pass the cinched part of the package bag through its outer edge to its inner
circumference. At
this point, the package bag can be suspended above the bottom of the package
sealer
compartment (94) by the worker's hands, although the package guide ring can
now be
holding the top of the bag cinched together. The worker can release one of
their hands from
holding the package bag and use it to press the package holder lock
button~(101). When the
package holder lock button (101) is pressed, the inside of the package holder
ring (98) can
constrict around the top portion of the cinched part of the package bag, until
it is tight enough
to hold the weight of the package. The worker no longer needs to hold the
package as it can
be suspended within the package sealer compartment (94) by the package holder
ring (98).
The package holder ring (98) can be attached to and supported by a package
holder support
base (103). The package holder support base (103) can be attached to and
supported by the
entire structure of package sealing side of the packing station (FIG. 5),
which can be attached
to and supported by the CDC packing station conveyor (44) and the floor of the
destination
RDC facility 1180-1.
For illustration, the package ties used to seal packages can be a strand of
tubular
rubber approximately 30 inches long and 3/16t'' of an inch in diameter. Once
the package is
held in place by the package sealing side of the packing station (FIG. 5), the
worker can grab
a package tie from the package tie storage bin (106) and pull the two ends of
the package tie
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together. The worker can place the two ends in the package tie holder (90) and
press the tie
holder lock button (92) to secure the package tie in place. The package tie
holder (90) can
clamp down on the two ends of the package tie to hold them in place securely.
The worker
can grab the package tie and stretch it to end its mid-point. Holding it at
its mid-point, the
worker can loop the double-strands of the package tie around the bottom of the
cinched part
of the package bag, just above the package guide ring (96), and pull it
through the loop to
form a knot. The worker can continue to pull the mid-point of the package tie
toward them,
tightening the knot around the cinched part of the package bag. A package
handle can be
formed by the loop of excess package tie on one side of the knot, which can
now be sealing
the package closed. The worker can press the package holder release button
(102) initiating
movements by the components that make up the package.holder ring (98). Cutting
blades
which can be located on the underside of the package holder ring (98), can
move toward the
center of the ring to cut through the cinched package bag material in one
movement. In
another movement the package holder cutting blades can move back to their
original state
within the protective cutting blade covers on the underside of the package
holder ring (98). In
another movement the inside edges of the package holder ring (98), which are
constricting the
package bag material that has now been separated from the package, can move
back to their
original non-constricted position. Package labels that were applied near the
bottom of
package bags can remain on the package undamaged, when the excess material at
the top of
the package is trimmed away. After the excess material at the top of the
package has been
severed, the package is no longer suspended by the package holder ring (98),
but the weight
of the package can now be supported by the package tie knot and the two ends
of the package
tie, which can be clamped to the package sealing station top (104) by the
package tie holder
(90).
The worker can grab the scraps of package bag material that have been cut away
from
the top of the package and place them in a scrap container. The worker can
slip one of their
hands through the package tie handle and can press the tie holder release
button (100) with
their other hand. The package tie holder (90) can be lifted off of the two
ends of the package
tie and the worker can now be holding the package up by its package tie
handle. The worker
can grab the bottom of the package with their other hand and lower it to the
bottom of the
package sealer compartment (94), removing their hand from the package tie
handle and
letting the cinched part of the package and the package tie handle to slip
down through the
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package guide ring (96) and the trimming slot (88). The package tie handle can
then be used
to lift the package out of the package sealer compartment (94), and it can be
placed on the
CDC packing station conveyor (44). After sealing the package and placing it on
the conveyor
(44), the worker can return to the case at their packing station (the case
from which the
worker had last picked the items for the package that the worker has just
finished sealing).
The worker can scan the case to have the program (330) direct their next
action.
In another aspect of the invention, single-item package processing can be
performed
when cases containing one over-sized item (large-sized, extra-large-sized or
LDDH-sized) are
scanned by a worker creating packages at a CDC packing station (45). Although
all items
received into a destination RDC 1180-1 have been referred to as being in
cases, it should be
readily understood by one skilled in the art that an over-sized item case may
actually just be a
single over-sized item with a case label attached to it rather than an over-
sized item physically
inside a box or other suitable container. Some over-sized items may be too
large or odd
shaped to fit into a box or other suitable container. When a worker scans the
case label of an
over-sized item case, the Package Creation Program (330) can read the Case Id
and perform
the same initial actions as it does when processing a case containing a small-
sized or
medium-sized SKU. It can retrieve a listing of records from the Customer By
SKU Order
List data view 1228 and can check the SKU Size of the first record 1228 to
determine
whether single-item package processing or multi-item package processing should
be
performed. The retrieved record can represent a list of all the recipients for
which the item of
the scanned case has been ordered for delivery to/from the current CDC 1190-1
or LDDH
1192-1. Because an over-sized item has been scanned, the program (330) can
find ari over-
sized SKU Size on the selected Customer by SKU Order List data view 1228 and
can perform
single-item package processing. Instead of selecting a list of records from
the Open Package
List data view 1232 to try to determine if the current packing employee has
any open
packages, for any of the recipients on the selected Customer by SKU Order List
records 1228,
in single-item package processing, the program (330) can simply create a
single-item package
to meet the demand of the first selected Customer by SKU Order List record
1228. To ensure
that two workers picking the same item SKU at approximately the same time do
not fill the
same order, the program (330) can, for example, select and invoke a table-lock
on the
underlying Order Detail record 1202 before updating it. If another instance of
the program
(330) has already table-locked or updated the Order Detail record 1202
underlying the first
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record selected from the Customer by SKU Order List data view 1228, before the
current
instance is able to invoke a table-lock on it, the current instance of the
program (330) can
attempt to select and invoke a table-lock on the Order Detail record 1202
underlying the next
record selected from the Customer by SKU Order List data view 1228. Other
methods of
preventing multiple simultaneous modifications to records of a database are
well known in
the art.
The Package Creation Program (330) can update the Order Detail record 1202 in
single-item package processing in the same manner as it does in mufti-item
package
processing, including creating a new Order Detail record 1202 for any quantity
of an item
which remains unfilled by the current transaction. The Package Creation
Program (330) can
also select and update the Case record 1208 of the scanned case in a manner
consistent with
mufti-item package processing, including updating its Status to a value such
as "empty" when
its Quantity is decreased to zero. In many situations over-sized items can be
single-item
cases, which can be updated to a Quantity of zero and a Status such as "empty"
when
scanned. However, there can be situations in which an over-sized item case
contains multiple
quantities of an over-sized item SKU. In these situations the Package Creation
Program
(330) can perform single-item package processing to create a new Package
record 1234 for
each over-sized item picked. Package Id, Customer Id, Temperature Code, CDC
Id, ePD
Shipper Id, RDC Id, and Packing Employee Id, for example, can be written to
the new
Package record 1234 in the same manner as they can be in mufti-item package
processing.
The following field updates can be made differently as a Package record 1234
gets created by
single-item package processing: Status can be set to a value such as "closed";
Package Bag
Holder Id can be set to a value such as "none"; and Package Size can be set to
a value based
upon the SKU Size value of the selected Customer by SKU Order List data view
record 1228
Package Size can be set to a value such as "5" for a SKU Size value such as
"large", Package
Size can be set to a value such as "6" for a SKU Size value such as "extra-
large", or Package
Size can be set to a value such as "7" for a SKU Size value such as "LDDH".
' In addition to updating the records involved in a single-item package
processing
transaction, the Package Creation Program (330) can, for example, sound a pick
confirmation
tone, illuminate the pick confirmation light (84), highlight the single item
package indicator
(109), print a package label and a packing list, and display a message in the
message field
(114) directing the worker to attach the packing list and package label to the
picked item.
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Upon hearing a pick confirmation tone and/or seeing the pick confirmation
light after
scanning a case label, the worker can pick the case from the CDC packing
station conveyor
(44), place it on top of the package sealing station top (104), and look at
the program display
monitor (79) of their packing station (4S). Following the direction of the
program, the worker
S can take the package label from the label printer (81) and the packing list
from the packing
document printer (77), and can look at the label on the picked case to
determine if it is a
single-item case or a mufti-item case. If the case label indicates that the
case is a single-item
case,~for example if there is a large "S" printed on it, the worker can take a
packing list pouch
from the packing list pouch storage bin (lOS), peel the back off of its
adhesive back side, and
attach it to the single-item case, fox example, over top of the case label.
The packing list can
be placed inside the packing list pouch by sliding it through its pouch
opening, and the
package label that was printed for the single-item package can be affixed on
the outside of the
packing list pouch. The single-item case, with its attached packing list and
package label, can
now be considered a single-item package and can be placed back onto the CDC
packing
1 S station conveyor (44). If the case label does not have, for example, a
large "S," or other
suitable marking on it to indicate a single-item case, the picked case can be
a mufti-item case
containing multiple over-sized SKU items. The worker can scan the case label
of the multi-
item case of over-sized SKU. items, pick one of the items from the case, and
attach a packing
list pouch, packing list, and package label to it in manner that can be
similar to that of a
single-item case, except that there is no case label on the over-sized SKU
item to cover with
the packing list pouch. The single-item package can be placed on the conveyor
(44) and the
case label of the mufti-item case of over-sized SKU items can be scanned
again. The worker
can continue to pick items from the mufti-item case of over-sized SKU items,
creating single-
item packages, until the case is empty or the Package Creation Program (330)
displays a
2S message telling the worker to redirect the case to a different CDC 1190-
1/LDDH 1192-1 or
local market.
Errors can occur at the destination RDC 1180-1 during the process of creating
packages 1122. When picking items from cases to create packages, if a worker
sees, for
example, a message on their program display monitor (79) that the case the
worker just
scanned is empty, while there are still items in the case, then the worker can
have uncovered a
previously made packing error (an under-packing error). The worker can, for
example, key in
the sequence on their packing station keypad (80) to run the RDC Package
Inspection Report,
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scan the case label of the case in error, key in the quantity difference, and
place the case off to
the side of their packing station (45). A RDC Package Inspection Report
Program (334) can
be initiated. It can use, for example, the scanned Case Id to select all the
Package Id's and
Quantities from the Order Detail records 1202 having that Case Id in the Case
Id field. The
RDC Package Inspection Report Program (334) can use the selected Package Id's
to select the
Status, Delivery Shipment Id, and CDC Id of each package from the Package
table 1234. The
detail of the report, as shown on the RDC Package Inspection Report Detail
table 1242, can
list, for example, the Quantity, Package Id, Package Status, Delivery Shipment
Id, and CDC
Id for each package. The report header, as shown on the RDC/CDC Package
Inspection
. Report Header table 1240, can list, for example, the ePD Retailer Id and SKU
of the case and
the Quantity Difference. The RDC Package Inspection Report can be printed on
the packing
document printer (77) of the packing station (45), upon which it is run, or
other suitably
configured printer, and it can be used to track down the location of each
package regardless of
whether the package is still in the destination RDC 1180-1 or has left on its
way to a CDC
1190-1 or LDDH 1192-1. If the report contains packages that have already left
the
destination RDC 1180-1 on delivery shipments, the RDC Package Inspection
Report Program
(334) can send data to the processing servers, whether remote or local, of the
appropriate
CDC's 1190-1 or LDDH's 1192-1 and can trigger a CDC Package Inspection Report
Program
(336) to run at those CDC's 1190-1 or LDDH's 1192-1.
The CDC Package Inspection Report Program (336) can print a paper report on a
CDC or LDDH printer, to be used by CDC or LDDH workers to find and unload
packages
from SmartBin Units (SBU's) at a CDC 1190-1 or recall packages from the
delivery vehicles
of a LDDH 1192-1 for inspection. The printed CDC Package Inspection Report can
contain,
for example, readable SBU Id's or LDDH Delivery Vehicle Id's to assist in
finding each
package listed, and Inspection Authorization Codes, Over Quantity Adjustment
Codes, and
Short Quantity Adjustment Codes to unload and enter over/short adjustments for
each
package listed in a barcode format. A SBU Id/LDDH Delivery Vehicle Id can be
listed on the
report for a package if it has already been loaded into a SBU/delivery
vehicle. Packages
listed on the report that have not been loaded into a SBU or onto a delivery
vehicle can have a
blank SBU Id/LDDH Delivery Vehicle Id. An Inspection Authorization Code can
consist of
concatenated data, which can include, but is not limited to the following: a
Package Id, a SBU
Id, and a LDDH Delivery Vehicle Id. In FIG. 9D, an exemplary table containing
the detailed
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report is shown on the CDC package inspection report detail table (1244). In
addition to
printing a physical report, once the CDC Package Inspection Report Program
(336) is
initiated on a CDC's 1190-1 or LDDH's 1192-1 processing server, it can
continue to run as a
service until all the packages listed on the report, having the CDC Id of the
processing server
on which it can be rmming, are scanned or until the program is aborted. The
CDC Package
Inspection Report Program (336) can validate each Package Id scanned, during
package
loading at a CDC 1190-1 or package sorting at a LDDH 1192-1, against the
Package Id's
listed on the report having the current CDC Id. The CDC Package Inspection
Report
Program (336) can alert the CDC 1 I90-I or LDDH 1192-1 workers, if they scan a
package
that is listed on the report, to first inspect the package and confirm that it
contains the correct
quantity of the SITU listed on the report, before continuing to load it into a
SBU at a CDC
1190-1 or sort it for delivery at a LDDH 1192-1. The alert can consist, for
example, of an
invalid warning tone and a text message displayed on a scanning device display
screen or on a
SBU display screen in a CDC 1190-1 or a workstation monitor in a LDDH 1192-1.
The CDC
~ Package Inspection Report Program (336), running as a service on the
CDC/LDDH server can
be aborted by a worker at the CDC 1190-1/LDDH 1192-1, or it can be aborted by
a worker
connecting to the CDC/LDDH server remotely from a destination RDC 1180-1.
Program
security permissions can be used to control which workers at CDC's 1190-1,
LDDH's 1192-
1, and destination RDC's 1180-1 have the ability to abort the CDC Package
Inspection
Report Program (336).
The Package Status and Delivery Shipment Id of each line on the RDC Package
Inspection Report can be used to locate packages in the destination RDC 1180-
1. As a
package is located and inspected in the destination RDC 1180-1, the worker
performing the
inspection can open the package and count the number of items, of the SKU
listed on the
RDC Inspection Report, to determine if the package contains the Quantity
listed on the report.
If the physical count in the package matches the Quantity on the report, the
package can be
repacked and the Package Id can be checked-off on the report. If the physical
count doesn't
match the Quantity on the report, the package can be brought back to the CDC
packing
station (45), where the case in error can be located, to be repacked. If the
physical count in
the package varies from the report Quantity by exactly the amount of the
Quantity Difference
on the report, then the workers tracking down the packages on the report can
be notified to
stop their inspections. If not, the package inspections can continue until the
full amount of
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the Quantity Difference is found. To remove the SKU in error from the package,
the worker
at the packing station (45) can, for example, enter a key sequence to initiate
a Packing
Adjustment Program (338), and can then scan the label on the case in error and
the label on
the package in error. The Packing Adjustment Program (338) can reset the
values on the
Order Detail 1202, Package 1234, and Case 1208 records that were updated when
the items
from the case were originally packed into the package. The Packing Adjustment
Program
(338) can use the scanned Case Id to select the Case record 1208 and the
scanned Package Id
to select the Package record 1234. The appropriate Order Detail record 1202
can be selected
by the program (338) using the scamled Package Id and the SKU and ePD Retailer
Id from
the selected Case record 1208. Status can be set to a value such as
"destination RDC" and the
Package Id can be deleted on the Order Detail record 1202. Status can be set
to a value such
as "open" and Delivery Shipment Id can be deleted if it had a value on the
Package record
1234. The amount that was decremented from the Quantity on the Case record
1208, when
the item was originally picked from the case, can be added back to the
Quantity value on that
Case record 1208. The Status on the Case record 1208 can be reset to a value
such as
"package sort" if it had been set to a value such as "empty".
The worker can physically remove all the items of the SKU of the case in error
from
the package, and place them back in the case. After the Packing Adjustment
Program (338)
completes the packing adjustment, the worker can scan the case label of the
case in error to
begin repacking its items. The Package Creation Program (330) can direct the
worker to pack
the identifted quantity from the case into the package as if there had never
been a problem.
After the packing adjustment transaction and the subsequent packing
transaction, the quantity
remaining in the case should be in synch with the data on the Case table 1208.
The Packing
Adjustment Program (338) can also be run against a package that is still open
to remove a
specific SKU from that package.
If a package is not located and inspected until it is already in a CDC 1190-1
or LDDH
1192-1, the CDC Package Inspection Report Program (336) can print a hard copy
report on
the CDC/LDDH printer as previously described. In most situations, a packing
error should be
discovered early on in the process, before the package leaves the destination
RDC 1180-1 or
when it is scanned during processing at a CDC 1190-1 or LDDH 1192-1, but it is
possible
that a package may be loaded into a SBU or onto a LDDH delivery vehicle before
the error is
realized. If there are packages listed on the CDC Package Inspection Report
that have already
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been loaded onto a LDDH delivery vehicle, the LDDH worker reading the report
can attempt
to contact the driver of the delivery vehicle to ask them to look out for the
package in
question. If there are packages listed on the report that have already been
loaded into SBU's
at a CDC 1190-1, a CDC worker arriving at the CDC 1190-1 can use the report to
search for
S the packages listed using the SBU Id listed with each package. The worker
can go to the
SBU listed on the report, connect the hands-free barcode scanner that the
worker can be using
to the SBU, for example, by plugging it into a scanner port of the SBU, scan
their employee
id card, and then scan the Inspection Authorization Code barcode on the report
to initiate a
CDC Package Adjustment Program (3S0) of an ePD SBU Application running on a
server for
the current CDC 1190-1. The CDC Package Adjustment Program (3S0) can use the
Package
Id and SBU Id embedded in the scanned Inspection Authorization Code to
retrieve the
package listed on the report from the SBU.
Once the package requiring inspection is retrieved, the CDC worker can perform
the
inspection in the same manner as a package inspection performed in the
destination RDC
1S 1180-l, but if a difference is found the package is not returned to the
packing station (4S) in
the destination RDC 1180-1 to be repacked. If the package was over-packed
(meaning a
greater quantity was physically placed in the package) the worker can remove
the extra items
to make the physical quantity match the quantity listed on the CDC Package
Inspection
Report and the package's packing list. The worker can send the extra quantity
of the item
back to the destination RDC 1180-1 with the report on a CDC reverse shipment
originating
from the CDC 1190-1 to its destination RDC 1180-1. When the item is received
at the
destination RDC 1180-1 it can be physically added back into the ease that was
set aside
because of the error. Adjustments to the related data records are not required
to correct an
over-pack error because the physical situation has been corrected to match the
data. If the
2S package was under-packed (meaning a lesser quantity was physically placed
in the package),
the package does not need to be changed physically except that the packing
list containing the
under-packed item can be adjusted by hand to show the correct quantity. The
CDC worker
can update the quantities on the related Order Detail 1202 and Case 1208
records to account
for the difference by scanning the short adjustment barcode corresponding to
the package on
the report and entering the quantity adjustment that was made, for example, on
the SBU
keypad. The CDC Package Adjustment Program (3S0) can send the data from the
CDC's
1190-1 processing server to update the Order Detail 1202 and Case 1208 tables
in the
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database on the destination RDC's 1180-1 processing server. The Quantity on
the Case
record 1208 can be increased by the short adjustment quantity and the adjusted
quantity
should match the physical quantity remaining in the case that was set-aside at
the packing
station (45) in the destination RDC 1180-1. A new Order Detail record 1202 can
be created
to split the quantity on the existing record 1202, resulting in the existing
record 1202
retaining its Package Id and Status and having an adjusted Quantity to match
the actual
physical quantity that was in the package and the new record 1202 having the
same Order Id,
a Quantity equal to the short adjustment quantity, a Status value such as
"destination RDC",
and no Package Id value. The under-packed item quantity can be picked from a
case and
packed into a package at the destination RDC 1180-1 as the Package Creation
Program (330)
attempts to satisfy the demand of the new Order Detail record 1202 created by
the transaction
used to correct the under-pack error.
Following the creation of packages step 1122, delivery shipments of packages
to be
delivered to a CDC 1190-1 or LDDH 1192-lcan be created at the destination RDC
1180-1 as
illustrated in step 1124. To create ePD delivery shipments, one or more
workers at a
destination RDC 1180-1 can be stationed between a CDC packing station conveyor
(44) and a
CDC feed of the CDC package conveyor (47A) to organize packages bound for a
particular
CDC 1190-1 or LDDH 1192-1 into an ePD delivery shipment. An ePD delivery
shipment
can consist of a group of packages bound for one CDC 1190-1 or LDDH 1192-1 on
one
trailer or other suitable cargo carrying transport. A worker creating an ePD
delivery shipment
can use, for example, a hands-free barcode scanning device communicating with
the
workstation running their instance of a Delivery Shipment Creation Program
(340) to scan
package label barcodes as the worker picks packages from the CDC packing
station conveyor
(44) and places them into cargo cages sitting on the CDC feed conveyor (47A)
at which the
25, worker is working. In one aspect of the invention, boxes, bins, crates or
other containers
lmown in the art can be employed instead of cargo cages.
Cargo cages can be used to organize packages bound for the same CDC 1190-1 or
LDDH 1192-1 into an ePD delivery shipment. A cargo cage can be a container
designed to
hold many small and medium sized packages. For illustration, each side of a
cargo cage can
be constructed of, for example, 1/l6th inch thick plastic coated metal wires,
which cross each
other perpendicularly every few inches. The metal wires can be bound into the
four
perpendicularly intersecting side edge beams that form each rectangular side
of the cargo
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cage. The sides of the cargo cage can be attached to each other by metal
linking clasps sized
to fit around the width of two edge beams. Linking clasps can be attached near
each corner of
a cargo cage side panel to bind the side panels to each other and to the cargo
cage bottom
panel to form a cargo cage. The bottom panel of the cargo cage can consist of
two panels,
S constructed in a manner that can be similar to the way the side panels are
constructed, with
shock absorbers between the two panels at each corner and at the midpoint of
each side. Each
shock absorber can consist of, for example, a spring made of metal or other
suitable
composite, a few inches high, and a few inches in diameter. Linking clasps can
also be used
to bind different cargo cages together to form a grouping of cargo cages for a
delivery
shipment. A cargo cage label plate holder can be built into the upper corner
of at least one of
the sides of each cargo cage. A cargo cage label plate holder can be a frame
with a hollow
slot in which a label plate can be inserted (and subsequently removed) to
label one or more
grouped cargo cages as a delivery shipment.
A worker can create a new ePD. delivery shipment for a CDC 1 I90-I or LDDH
1192-
1 S 1 by first selecting an option on the program menu of the Delivery
Shipment Creation
Program (340) such as the "create new delivery shipment" menu option. The
Delivery
Shipment Creation Program (340) can create and print a new delivery shipment
label for the
delivery shipment. The delivery shipment label can contain the Delivery
Shipment Id in both
a barcode and a readable format and the CDC Td of the delivery shipment in
readable format.
The worker can, for example, take the delivery shipment label from the label
printer, affix it
to a delivery shipment label plate, and place the label plate in the label
plate holder of an
empty cargo cage. The label plate can be a non-descript rectangular card, made
of plastic,
metal or another firm and durable material, upon which a label can be affixed.
The unique
delivery shipment label on the label plate can make it useful in identifying a
delivery
2S shipment and all its associated packages. The worker can continue creating
the delivery
shipment, by scanning, for example, their employee id card, scanning the label
on the delivery
shipment label plate, picking a sealed package from the CDC packing station
conveyor (44),
and scanning the barcode label on the package, as the worker places it into
the cargo cage.
The worker can continue to pick sealed packages from the CDC packing station
conveyor
(44), scan the package labels, and place the packages into the cargo cage,
until the cargo cage
is filled. Additional cargo cages can be built from cargo cage bottom panels,
side panels, and
linking clasps which can be stored near the CDC feed.conveyor (47A). The cargo
cages can
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be attached next to or on top of cargo cages already filled for the current
CDC (1190-1) or
LDDH (1192-1), as more mufti-item packages get added to the delivery shipment.
The
worker can identify single-item packages to be picked from the CDC packing
station
conveyor (44) by their packing list pouches. The worker can pick single-item
packages, scan
their package labels, and place them on the CDC feed conveyor (47A) next to or
on top of the
cargo cages bound for the same CDC 1 I90-I or LDDH I 192-1. The worker can
continue to
load mufti-item packages into cargo cages and place single-item packages next
to or on top of
the cargo cages on the CDC feed conveyor (47A) until there are enough to fill
an entire
trailer-load. The amount of cargo cages and single-item packages needed to
fill a trailer-load
can be measured in length by ruler markings on the sides of the CDC feed
conveyor (47A),
similar to the ones used on the sides of retailer dock conveyors. In one
embodiment, cargo
cages can be stacked, for example, up to three units high to fit into
trailers. The Delivery
Shipment Creation Program (340) can associate the scanned mufti-item and
single-item
package with the current delivery shipment until the worker selects a menu
option to end the
current delivery shipment.
The Delivery Shipment Creation Program (340) can create a new record on the
Delivery Shipment table 1238 as a worker physically creates each new delivery
shipment.
The Delivery Shipment Creation Program (340) can create the new Delivery
Shipment
records 1238 having the following exemplary field values: a unique Delivery
Shipment Id can
be created by concatenating, for example, the R.DC Id + CDC Id + current date
+ a sequential
three digit number; Status can be set to a value such as "in RDC"; ePD Shipper
Id and RDC
Id can be set to the values for the current destination RDC 1180-1; CDC Id and
Temperature
Code can be set to the value from the Package record 1234 of the first scanned
package; RDC
Employee Id can be set to the value from the scamied employee id card; and the
other fields
can be created without values. The Package record of each package scanned into
a delivery
shipment can be updated to set Status to a value such as "delivery shipment"
and Delivery
Shipment Id can be set to the value on the newly created delivery shipment
record to which
the package was added. As packages are scanned to be added to a delivery
shipment, the
Delivery Shipment Creation Program (340) can validate the CDC Id value of the
scanned
package to verify that it matches the value on the current Delivery Shipment
record 1238. If a
package having a different CDC Id is scanned by mistake the Delivery Shipment
Creation
Program (340) can signal an error, for example, by sounding an invalid warning
tone and
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displaying a message, on the workstation running the Delivery Shipment
Creation Program
(340), indicating that the scanned package is for a different CDC 1190-1 or
LDDH 1192-1.
In a further aspect of the invention, full-trailer-load delivery shipments can
be created
to meet the frequency of tractor-trailers leaving for the local market of
those delivery
shipments' CDC's 1190-1 or LDDH's 1192-1. However, if necessary, delivery
shipments
bound for different CDC's 1190-1 or LDDH's 1192-1 within the same local market
can be
combined together into a full-trailer-load. To combine different delivery
shipments together
into one full-trailer-load, the workers creating the delivery shipments on
nearby CDC feed
conveyors (47A) can collaborate with each other to move their delivery
shipments in close
proximity of each other. A local market feed of a CDC package conveyor (47B)
can be made
up of different independent conveyor sections which can be moved in either
direction or
remain motionless, independently of each other. There can be local market feed
conveyor
sections (47B) in between each of the different CDC feed conveyors (47A), and
between the
CDC feed conveyors (47A) and either a left side feed of a package conveyor
(46A) or a right
side feed of a package conveyor (46B). Multiple delivery shipments can be
organized into a
full-trailer-load by moving the CDC feed conveyors of different CDC's and
LDDH's (47A)
and the different sections of the local market feed conveyor (47B) in between
those CDC feed
conveyors (47A) forward and/or backward in a coordinated effort to align the
different
delivery shipments in close proximity of each other, in a desired sequence.
One delivery
shipment label plate can be located on the back of the last cargo cage, at the
trailing end of
each delivery shipment. A small amount of space can be left between the
different delivery
shipments of a full-trailer-load, to ensure that they can be visibly seen as
separate delivery
shipments within the same full-trailer-load, and to allow access to the label
on each delivery
shipment label plate.
When a full-trailer-load of delivery shipments has been assembled on either
the CDC
feed (47A) or the local market feed (47B) of a CDC package conveyor, one of
the workers
involved in organizing the full-trailer-load, can use the motion controls of
the local market
feed package conveyor (47B) to coordinate all of the conveyor sections of the
local market
feed package conveyor (47B) in between the full-trailer-load and a side
package conveyor
(either left-side 46A or right-side 46B) to move the full-trailer-load onto
the side package
conveyor (46A or 46B). The delivery shipments of a full-trailer-load can
travel together, in
close proximity to each other, from the side package conveyor (46A or 46B)
onto the merging
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section of the package conveyor (46C), and then onto the outbound section of
the package
conveyor (46D).
There is shown in FIG. 8A, a detailed layout of an exemplary local market
shipping
dock area within a RDC. The exemplary local market shipping dock area of FIG.
8A can
contain: a package conveyor - outbound-section 46D, a local market shipping
dock conveyor
4$, a local market shipping dock conveyor extension 48A, a local market
shipping dock (bay)
door 50, a package diverting conveyor unit (inactive position) 208, a package
diverting
conveyor unit (loading position) 208A, a locking pin (in locking slot) 210, a
pivot pin 212, a
pivot support base 214, an inactive locking slot 216, a loading locking slot
218, and a local
market shipping dock workstation (& printer) 220. There is also shown in FIG.
8A, a tractor
I 200 having a trailer 202, the trailer 202 being parked with its rear toward
a RDC exterior wall
206. Within the trailer 202 is a trailer conveyor 204, which can facilitate
loading and
unloading of cargo.
The curved-shaped package diverting conveyor unit (208) can be similar to the
case
, diverting section of the RDC inbound conveyor (38) in its composition and
function.
Referring to FIG. 8A, there can be a package diverting conveyor unit (208) for
each local
market shipping dock conveyor (48). Package diverting conveyor units (208) can
be attached
to the outside edge of the outbound section of the package conveyor (46D) and
can be locked
into one of two positions by a locking pin (210). The conveyor units (208) can
be locked into
the loading position to intercept and divert packages from the package
conveyor (46D) to a
local market shipping dock conveyor (48) or into the inactive position to
remain out of the
way as full-trailer-loads pass by on the outbound section of the package
conveyor (46D).
When it is in the loading position, the leading end of the package diverting
conveyor unit
(208) can sit over top of the package conveyor (46D) and its trailing end can
sit over top of
the local market shipping dock conveyor (48). When it is in the inactive
position, the unit
(208) can sit completely over top of its pivot support base (214), with only
its leading edge
resting on the outer side edge of the package conveyor (46D). When a package
diverting
conveyor unit's locking pin (210) is unlocked, the unit (208) can be shifted
between the
inactive position and the loading position by pushing or pulling it in the
desired direction
until its locking pin (210) lines up with the inactive locking slot (216) or
the loading locking
slot (218). Locking slots can be built into the side edges of the package
conveyor (46D). The
conveyor unit (208) can pivot between the two positions on support roller
wheels attached to
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its bottom. The support roller wheels can allow the bulky conveyor unit (208)
to glide easily,
back and forth, on top of its pivot support base (214) and the package
conveyor (46D). The
unit's pivot pin (212) can anchor the unit (208) on a fixed pivot axis as it
moves between its
two positions. When the unit's leading end is locked into the loading
position, its trailing end
can be aligned over top of the local market shipping dock conveyor (48).
As a full-trailer-load of delivery shipments moves along on the outbound
section of
the package conveyor (46D) and passes by a worker responsible for loading
delivery
shipments onto outbound tractor-trailers, the worker can inspect the delivery
shipment label
plate on the back of the trailing-end of the full-trailer-load's last delivery
shipment. Workers
responsible for loading delivery shipments onto outbound tractor-trailers can
be organized,
for example, so that each one covers a few adjacent local market shipping dock
conveyors
(48) from which tractor-trailers bound for one specific local market can be
loaded. When one
of these workers sees a full-trailer-load containing a delivery shipment bound
for one of the
CDC's 1190-1 or LDDH's 1192-1 of their local market (one worker may also cover
one or
. more local markets), the worker can use a package diverting conveyor unit
(208) to move the
full-trailer-load of delivery shipments onto one of their empty local market
shipping dock
conveyors (48).
To move a full-trailer-load of delivery shipments from the outbound section of
the
package conveyor (46D) onto a local market shipping dock conveyor (48), the
worker can lift
the package diverting conveyor unit's locking pin (210) out of the inactive
locking slot (216),
push the conveyor unit (208) from the inactive position to the loading
position, slide the
locking pin (210) into the loading locking slot (218), and switch on the power
of the conveyor
unit (208) to start its conveyor motion. The worker can start the local market
shipping dock
conveyor (48) upon which the worker positioned the conveyor unit (208) in the
loading
direction. The full-trailer-load can move from the package conveyor (46D) up
onto the
conveyor unit (208). The full-trailer-load can follow the conveyor unit's
(208) curved path,
moving down onto the local market shipping dock conveyor (48), and can be
moved on the
local market shipping dock conveyor (48) from its back end toward the local
market shipping
dock conveyor extension (48A) at its front end. After the full-trailer-load
has been moved
onto the dock conveyor (48) completely, the worker can stop the motion of the
dock conveyor
(48) and the conveyor unit (208) and can reposition the conveyor unit (208)
back to the
inactive position. After repositioning the package diverting conveyor unit
(208), the worker
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can return to the outbound section of the package conveyor (46D) to search for
another full-
trailer-load of delivery shipments bound for their local market. The worker
can continue this
sub-process until a tractor-trailer driver signals that a tractor-trailer is
ready to accept delivery
shipments.
Following the creation of the delivery shipments of packages, step 1124, the
packages
can be ready to be shipped to one or more CDC's 1190-1 or to one or more
LDDH's (1192-
1), as illustrated in step 1128 and step 1126 respectively. After the trailer
door closes at the
end of unloading retailer shipments onto a local market receiving dock
conveyor (14), the
process of receiving retailer shipments into an origination RDC 1180-1 (in the
current
illustrative example RDC 1180-1 can serve as an origination RDC for cases of
items received
into that RDC from retailer fulfillment sites 1194-1 in a local market served
by RDC 1180-l,
in a step similar to step 1110) can be complete. Referring to FIG. 3, the
tractor-trailer driver
can drive a tractor-trailer (200 & 202) from the local market receiving dock
bay (12) to a
local market shipping dock bay (50) corresponding to the local market to which
the driver
, travels. The tractor-trailer (200 & 202) can be backed up to the local
market shipping dock
door (50) and the driver can signal the loading workers at the destination RDC
1180-1 (in the
current illustrative example RDC 1180-1, can now serve as a destination RDC
for delivery
shipments of packages to be delivered to one or more CDC's 1190-1 or LDDH's
1192-1 in
the Iocal market to which the driver travels) to let them know that an empty
tractor-trailer
(200 & 202) has arrived. The driver can refuel the tractor-trailer (200 &
202), while a RDC
worker loads a full-trailer-load of delivery shipments onto the driver's
tractor-trailer (200 &
202) from the local market shipping dock conveyor (48) at which the driver
arrived. The
worker who loads the trailer (202) can be the same worker who moved the full-
trailer-load
onto that dock conveyor (48). With reference to FIG. 11B, the worker can open
the local
', market shipping dock door (50) and initiate a Delivery Shipment Program
(342) by, for
example, scanning the barcode on their employee id card, scanning the Trailer
Id barcode on
the trailer door label, and scanning the Delivery Shipment Id barcode on the
label plate of the
delivery shipment farthest away from the shipping dock door (50). The Delivery
Shipment
Program (342) can read the CDC Id from the record on the Delivery Shipment
table 1238,
having the scanned Delivery Shipment Id and can use it to retrieve the values
of the Type,
CDC Server Connection Script, Primary Contact Number, Secondary Contact
Number, and
Temp Code Reservation Override fields from the CDC table 1252. If the Type
value
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retrieved is a value such as "LDDH", the Delivery Shipment Program (342) can
determine the
quantity of mufti-item packages (in cargo cages) and single-item packages by
selecting
records from the Package table 1234 having the scanned Delivery Shipment Id,
and grouping
and subtotaling those records by Package Size. This calculated package count
information
can be saved along with the Delivery Shipment Id by the Delivery Shipment
Program (342).
This saved information can later be printed on the Delivery Shipments Report.
If the Type
value retrieved is a value such as "CDC", the Delivery Shipment Program (342)
can use the
retrieved CDC Server Connection Script value to establish a remote connection
to the
database on the server of the destination CDC 1190-1. The Delivery Shipment
Program
(342) can use the remote connection to retrieve that CDC's 1190-1 available
SBU bin
capacity for each Bin Size, from the Unreserved Bins data view.
With reference to FIG. 10A, an Unreserved Bins data view 1305, can be created
by
subtracting the Quantity of bins of each Bin Size-Temperature Code combination
on a
Reserved Bins data view 1303 from the Quantity of the corresponding Bin Size-
Temperature
Code combination on a Bin Availability data view 1301, and then adding the
Quantity
Adjustment of the corresponding Bin Size-Temperature Code combination on a
Pending Bin
Configuration Adjustments table 1304. The Bin Availability data view 1301 can
be created
from an underlying Bin Tnventory table 1300 by selecting records having a
Status such as
"available", grouping those selected records by Bin Size and Temperature Code,
and then
subtotaling a count of the records within each group. The Reserved Bins data
view 1303 can
be created from an underlying Bin Reservation table 1302, for example, by
selecting,
grouping, and subtotaling the Quantity on records of each Bin Size-Temperature
Code
combination that do not have a Status such as "filled".
After retrieving the available bin capacity for each Bin Size-Temperature Code
combination from the Unreserved Bins data view 1305, the Delivery Shipment
Program (342)
can compare it against the number of packages of each Package Size-Temperature
Code
combination in the current delivery shipment to determine the extent of the
CDC's 1190-1
available bin capacity to receive the packages of the current delivery
shipment. The Delivery
Shipment Program (342) can select and group Package records 1234 having the
scanned
Delivery Shipment Id by Package Size and Temperature Code. The program (342)
can
subtotal the record count of each group of Package records 1234 to determine
the number of
packages of each Package Size-Temperature Code combination in the current
delivery
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shipment. The Delivery Shipment Program (342) can add a new record to the Bin
Reservation table 1302 (on the current CDC's 1190-1 database server) to
reserve, for the
current shipper, the Quantity of each Bin Size-Temperature Code combination
needed to
receive the bulk delivered packages of the delivery shipment, up to the
available bin capacity
found on the Unreserved Bins data view 1305. Each new Bin Reservation record
1302 can be
created with, for example, the Bin Size, Temperature Code, and Quantity being
reserved, the
ePD Shipper Id of the current shipper, a Reservation Date/Time equal to the
current
date/time, Trailer Loading Employee Id equal to the value scanned from the
worker's
employee id card, and a Status value such as "new". The Delivery Shipment
Program (342)
can track the bin capacity shortage of each Bin Size-Temperature Code
combination in a
program variable. If bins are available to be reserved for the entire Quantity
of a Package
Size-Temperature Code combination, the program variable holding the bin
capacity shortage
for the corresponding Bin Size-Temperature Code combination can be zero. The
ePD
Delivery Application can allow different shippers to reserve bin space in a
CDC 1190-1, as
there may be multiple shippers shipping bulk delivered packages from different
destination
RDC's (the RDC's of shippers other than the one shipper depicted in the
illustrative example
of FIG. 2 are not shown) to the same CDC 1190-1. In another embodiment of the
invention,
a given CDC can be run by a single shipper, and can receive delivery shipments
from one
destination RDC 1180-1 only, negating the need to reserve bin space.
The Delivery Shipment Program (342) can also update the Delivery Shipment
record
1238 of the scanned delivery shipment on the current RDC's 1180-1 database
server by, for
example, changing its Status to a value such as "in-transit", writing the
scanned employee id
into the Trailer Loading Employee Id field, writing the scanned trailer id
into the Trailer Id
field, and writing the current date and time into a Delivery Shipment Loading
Date/Time
field. The update can associate the delivery shipment (and all the packages of
ordered items
contained therein) with the trailer (202) upon which it will be loaded.
If the Delivery Shipment Program (342) does not find enough unreserved SBU
bins
having a Temperature Code value such as "standard" to receive all the packages
having a
Temperature Code value such as "standard", it may attempt to reserve SBU bins
having a
Temperature Code value such as "refrigerated" to receive "standard"
Temperature Code
packages. To determine whether it is able to reserve "refrigerated"
Temperature Code SBU
bins for "standard" Temperature Code packages, the program (342) can check the
Temp Code
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Reservation Override field that was retrieved from the CDC table 1252 for
current CDC
1190-1 and can compare the percentage listed against the unreserved
refrigerated bins ratio.
The unreserved refrigerated bins ratio can be calculated by dividing the sum
of the Quantity
values on the Unreserved Bins data view records 1305 having a Temperature Code
value such
as "refrigerated" by the total count of bins on the Bin Inventory table 1300
having a
Temperature Code value such as "refrigerated". If the Temp Code Reservation
Override
percentage is less than the unreserved refrigerated bin ratio, then the
Delivery Shipment
Program (342) can begin to reserve "refrigerated" Temperature Code bins up
until the
unreserved refrigerated bins ratio becomes less than or equal to the Temp Code
Reservation
Override value for the current CDC 1190-1. The unreserved refrigerated bins
ratio can be
decreased as "refrigerated" bins are reserved.
If the Delivery Shipment Program (342) cannot reserve enough bins to receive
all the
bulk delivered packages of the delivery shipment, it can initiate or cause to
be initiated, a
Configuration Adjustments Report Program (344) to determine the SBU bin
configuration
1 S adjustments that should be made to increase the number of bulk delivered
packages from the
current delivery shipment which are able to be received into the CDC 1190-1.
When the
Delivery Shipment Program (342) calls or causes the Configuration Adjustments
Report
Program (344) to be called, it can pass its program variables containing the
bin capacity
shortage of each Bin Size-Temperature Code combination as inputs. The
Configuration
Adjustments Report Program (344) can use the bin capacity shortage information
and its
program rules to effectively make configuration adjustments by updating the
Pending Bin
Configuration Adjustments table 1304, and in some situations updating the Bin
Inventory
table 1300. While the Configuration Adjustments Report Program (344) does not
make the
actual bin configuration adjustments, it can effectively make the adjustments
by updating the
2S data views used to determine bin availability, to take into account the bin
configuration
adjustments that will be made. The actual bin configuration, adjustments can
be physically
made to SBU's in the CDC 1190-l, in step 1140, by CDC workers using the
Configuration
Adjustments Report. The Configuration Adjustments Report Program (344) can
also add
records to the Bin Reservation table 1302 to reserve the bins made available
by its
configuration adjustments for the packages of the current delivery shipment.
The program rules of the Configuration Adjustments Report Program (344) can be
followed to effectively make bin configuration adjustments and bin
reservations to resolve the
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bin capacity shortage of each Package Size-Temperature Code combination in a
serial
manner. The bin capacity shortage of each Package Size-Temperature Code can be
processed
one at a time, in the sequence of the Configuration Adjustments Report
Program's (344)
priority rules, and each subsequent bin configuration adjustment can be
calculated based upon
prior bin configuration adjustment updates and bin reservation updates.
Package Size-
Temperature Code bin capacity shortages can be processed in priority sequence
by
Temperature Code, starting with a value such as "freezer", then a value such
as
"refrigerated", and finishing with a value such as "standard". Within
Temperature Code
priorities, Package Size-Temperature Code bin capacity shortages can be
processed by a.pre-
defined Package Size priority sequence, for example, "4", "3", "6", "2", "5",
"1 ". To resolve
each shortage, the Configuration Adjustments Report Program (344) can attempt
to make a
division configuration adjustment before making a consolidation configuration
adjustment.
Bin Sizes such as "5" and "6" can be considered separately from the other Bin
Sizes when
making bin configuration adjustments, as they can be part of separate master
bins.
To effectively make a division configuration adjustment, the Configuration
Adjustments Report Program (344) can search the Unreserved Bins data view 1305
for the
Quantity of Bin Size-Temperature Code combinations larger than the Package
Size of the
Package Size-Temperature Code bin capacity shortage that it is trying to
resolve. It can start
with the next largest bin size, greater in size than the Package Size for
which it is searching,
before searching for larger Bin Sizes in increasing size sequence. The
Configuration
Adjustments Report Program (344) can determine how many bins, of the Bin Size
corresponding to the current Package Size, it can make from dividing one bin
of the selected
Bin Size. It can, for example, multiply the total number of bins, of the
selected Bin Size
found on the Unreserved Bins data view 1305, by the number of bins, of the Bin
Size
corresponding to the current Package Size, that can be created from each one
of those
selected bins. The Configuration Adjustments Report Program (344) can also
determine if
there can be a remainder Bin Size left after dividing the selected unreserved
bins. The
Configuration Adjustments Report Program (344) can update the existing record
1304 or
create a new record on the Pending Bin Configuration Adjustments table 1304 to
account for
a positive adjustment to the Quantity of bins of the Bin Size-Temperature Code
combination
that will be created when the bin configuration adjustment is physically made
at the CDC
1190-1. The Configuration Adjustments Report Program (344) can also, update or
create
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another record on that table 1304 to account for a negative adjustment to the
Quantity of bins
of the Bin Size-Temperature Code combination that will be divided to create
the additional
smaller bins. If a number of bins will be created from the remainder of each
bin
configuration adjustment, a new record can be added or a Quantity update to an
existing
record can be made to the Pending Bin Configuration Adjustments table 1304 to
account for
the positive adjustment to the Quantity of bins of the Bin Size-Temperature
Code
combination of the remainder Bin Size. The Configuration Adjustments Report
Program
(344) can also create a new record on the Bin Reservation table 1302 to
reserve bins for the
Quantity of additional packages, of each Package Size-Temperature Code
combination in the
current delivery shipment, that will be able to be delivered because of the
newly made
pending bin configuration adjustments.
If the Configuration Adjustments Report Program (344) was unable to resolve
the
entire bin capacity shortage of the Package Size-Temperature Code combination
using the
first Bin Size-Temperature Code combination it selected from the Unreserved
Bins data view
1305, it can select the Unreserved Bins record 1305 having the next largest
Bin Size for the
same Temperature Code, and can follow the same processing logic to resolve the
remaining
shortage. If there is still a shortage after trying to divide the largest
possible Bin Size
applicable to that Package Size (single-item packages for stationary bins can
be considered
separate from multi-item packages for revolving bins), the Configuration
Adjustments Report
Program (344) can attempt to effectively make a consolidation configuration
adjustment to .
resolve the remaining shortage. To effectively make a consolidation
configuration
adjustment, the Configuration Adjustments Report Program (344) can select all
the records
from the Bin Inventory table 1300 having the Temperature Code of the current
Package Size-
Temperature Code combination and a Status such as "available" in a subquery.
It can then
select the records from that subquery for which there is more than one record
having the same
Master Bin Id. The Configuration Adjustments Report Program (344) can read
through the
Configuration Codes of those selected subquery records to determine if the
selected bins can
be consolidated together to receive a package of the current Package Size. If
the
Configuration Adjustments Report Program (344) determines, using its
configuration logic
rules, that two or more selected Bin Inventory records 1300 having the same
Master Bin Id
can be consolidated together to create a bin to meet the size of the current
Package Size, then
the Configuration Adjustments Report Program (344) can search the Unreserved
Bins data
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view 1305 to make sure that the selected Bin Inventory records 1300 are not
already reserved
indirectly on the Bin Reservation table 1302. If the Configuration Adjustments
Report
Program (344) is able to find a bin on the Unreserved Bins data view 1305 to
match the Bin
Size of each Bin Inventory record 1300 involved in the possible bin
configuration adjustment,
then there can be enough unreserved bins to accept incoming packages without
the selected
Bin Inventory records 1300. The program (344) can update the Status of the
selected Bin
Inventory records 1300 to a value such as "configuration reserved". The
program (344) can
also make updates to the Pending Bin Configuration Adjustments table 1304 to
account for
both the positive and negative adjustments to the Quantity of the Bin Size-
Temperature Code
combinations that will be created and removed when the consolidation bin
configuration
adjustment is physically made at the CDC 1190-1. A new Bin Reservation record
1302 is not
created to reserve bins for a consolidation bin configuration adjustment,
since a "hard
allocation" reservation was made directly to the Bin Inventory table 1300
through the Status
update. The Status update that can be made to the selected Bin Inventory
record 1300 for a
pending consolidation bin configuration adjustment can automatically, flow
through to the
Bin Availability data view 1301 that is created from the Bin Inventory table
1300 and the
Unreserved Bins data view 1305 that is created from the Bin Availability data
view 1301. A
Loading Program (356), which can be run in a CDC 1190-1 when packages are
being loaded
into SBU bins, will not allow packages to be loaded into bins that have a
Status value such as
"configuration reserved". A "hard allocation" (a reservation of specific bins)
can be made for
consolidation bin configuration adjustments, because unlike a division bin
configuration
adjustment in which any available bin of a larger size can be divided into
smaller bins, a
consolidation bin configuration adjustment can require that two or more
available smaller
bins be adjacent to each other within the same master bin to be configured
together into a
larger bin. Reserving specific bins can prevent a bulk delivered package from
being loaded
into a bin, and can thus preserve that bin's ability to be consolidated with
one or more
adjacent bins to create a larger bin.
Once the Configuration Adjustments Report Program (344) finishes a
consolidation
adjustment for a given Package Size-Temperature Code combination, it can
attempt to find
another set of selected Bin Inventory records 1300 to effectively make another
consolidation
adjustment until the entire bin capacity shortage for that Package Size-
Temperature Code
combination is fully resolved, or until it is unable to find a set of Bin
Inventory records 1300
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which can be consolidated to hold a package of the current Package Size-
Temperature Code.
Once either of these two situations occurs, the Configuration Adjustments
Report Program
(344) can begin to process the bin capacity shortage of the next Package Size-
Temperature
Code combination. As it finishes effectively making all the bin configuration
adjustments
that it is able to make to resolve a bin capacity shortage, the Configuration
Adjustments
Report Program (344) can continue to save the remaining bin capacity shortage
value for each
Package Size-Temperature Code combination in a program variable.
The Configuration Adjustments Report Program (344) can print, or caused to be
printed, a hard copy report for the CDC workers of the ePD shipper on, for
example, a report
printer in the CDC 1190-1. It can also send, or cause to be sent, an e-
mail/text pager message
to the primary and secondary cell phone/text pager device associated with that
CDC 1190-1
to notify the CDC workers of that CDC 1190-1 that a Configuration Adjustments
Report has
printed. Configuration Adjustments Reports for different shippers can be
printed on the same
CDC report printer, but a shipper's CDC workers can identify which report to
use by looking
for the ePD Shipper Id in the report header. Each Configuration Adjustments
Report can
contain only the bin configuration adjustments needed to receive the packages
of that shipper.
After the Configuration Adjustments Report Program (344) finishes its bin
configuration processing, it can initiate a Shipment Adjustments Report
Program (345),
passing the remaining bin capacity shortage values to the program (345) as
program inputs. If
all of the remaining bin capacity shortage values equal zero, the Shipment
Adjustments
Report Program (345) can send a message to the Delivery Shipment Program (342)
to
confirm that no shipping adjustments are required. If there is at least one
remaining bin
capacity shortage value greater than zero, the Shipment Adjustments Report
Program (345)
can create a report listing the total quantity of packages of each Package
Size-Temperature
Code combination that should be removed fiom the current delivery shipment to
prevent
sending more packages than the CDC 1190-1 has the capacity to accept. A
barcode
containing an identifier of the program variable holding the bin capacity
shortage value of
each Package Size-Temperature Code combination can be printed with each report
line. The
barcodes can be used to initiate the action of removing packages from the
delivery shipment.
The Shipment Adjustments Report Program (345) can, for example, sound an error
tone,
and/or light the local market shipping dock workstation warning light (located
at the local
market shipping dock workstation (220) processing the current delivery
shipment), print a
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hard copy of the report at, for example, the workstation's (220) printer, and
send a message
to the Delivery Shipment Program (342) to confirm that the report has been
sent to the
printer.
A worker can retrieve the Shipping Adjustments Report from the workstation's
printer (220) and can scan the barcode on the report next to the first report
detail line. The
worker can pick the number of packages, of the Package Size-Temperature Code
combination
listed on that report line, out of the current ~'°~livery shipment,
scanning the package label
barcode of each one as the worker places it aside the local market shipping
dock conveyor
(48). The Shipment Adjustments Report Program (345) can use the scanned
Package Id to
~ validate that the Package Size and Temperature Code of the scanned package
match the Bin
Size and Temperature Code of the last identifier scanned on the Shipment
Adjustments
Report. If the scanned package fails validation, the program (345) can, for
example, sound an
error tone, light the local market shipping dock workstation warning light,
and/or display a
message on the workstation's program display monitor (220) that the scanned
package does
I S not match the delivery shipment adjustment scanned on the report. If the
scanned package
passes validation, the Shipment Adjustments Report Program (345) can, for
example, sound a
confirmation tone and can update the Package record 1234 of the scanned
package, setting
Status from a value such as "delivery shipment" back to a value such as
"closed" and deleting
the Delivery Shipment Id. The program (345) can also decrement the bin
capacity shortage
value of the barcode indicator scanned on the report by one for each package
successfully
removed from the delivery shipment. The removed packages which have been set
aside can
later be moved back to the CDC feed conveyor (47A) from which those package
came, after
the worker is finished loading all of the delivery shipments into the outbound
trailer (202).
The worker can continue to scan the barcodes listed on the report and remove
packages as
required until the entire quantity of packages of each Package Size-
Temperature Code listed
on the Shipping Adjustments Report has been removed from the delivery
shipment. After
finishing working through the report, the worker can, for example, scan a
confirmation
barcode at the bottom of the report to confirm that all the adjustments have
been made. The
Shipment Adjustments Report Program (345) can validate that the value of each
bin capacity
shortage program variable has been decremented to zero and can sound a
confirmation tone.
If there is more than one delivery shipment on the local market shipping dock
conveyor (48), the worker can scan the Delivery Shipment Id barcode on the
cargo cage of the
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next delivery shipment to repeat the delivery shipment loading process
previously described,
for the remaining delivery shipments. The delivery shipments can be scanned in
a sequence
starting with the one farthest from the local market shipping dock door (50).
After all the
delivery shipments have been processed, the worker can select the program menu
option to
end the Delivery Shipment Program (342) and the Delivery Shipments Report can
print on
the workstation's report printer (220). The Delivery Shipments Report can list
the delivery
shipments that will be physically loaded onto the trailer (202) in the
sequence in which they
were scanned (which can also be the sequence in which they will be unloaded).
The Delivery
Shipments Report can provide guidance to the driver transporting delivery
shipments to
CDC's 1190-1 and/or LDDH's 1192-1 within a local market, by listing the
destination CDC
1190-1 or LDDH 1192-1 of each delivery shipment on the tractor-trailer in
unloading order.
The CDC Id, CDC Description, CDC address related fields (for example, an
Address 1 field,
an Address 2 field, a City field, a State field, and a Zip field), Primary
Contact Number,
Secondary Contact Number, the total number of mufti-item packages in the
delivery
shipment, and the total number of single-item packages in the delivery
shipment can be listed
on the Delivery Shipments Report in a readable format for each CDC 1190-1/LDDH
1192-1
listed on the report. The Delivery Shipment Id, Temperature Code and the total
number of
packages of each Package Size in the delivery shipment can be printed, for
example, in a
single parseable barcode on the Delivery Shipments Report for each CDC 1190-
1/LDDH
1192-1 report item. The total number of packages of each Package Size and the
total number
of mufti-item packages and single-item packages for a delivery shipment can
have been
calculated when the program (342) originally selected records from the Package
table 1234
for that delivery shipment. CDC related information can have been retrieved
from the CDC
table 1252 using the CDC Id embedded in the scanned Delivery Shipment Id
barcode.
After retrieving the Delivery Shipments Report from the report printer (220),
a worker
can open the trailer door, move the conveyor extension of the local market
shipping dock
conveyor (48A) into the horizontal loading position, start the trailer
conveyor (204) in the
loading direction, and then start the local market shipping dock conveyor (48)
in the loading
direction. The system of conveyors can move the delivery shipments onto the
trailer
conveyor (204). The RDC worker can stop the conveyors (204, 48A & 48),
reposition the
conveyor extension (48A) to the vertical delivery preparation position, and
close the trailer
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door. The worker can hand the Delivery Shipments Report to the tractor-trailer
driver, and
the driver can depart for the first CDC 1190-1 or LDDH 1192-1 listed on the
report.
In a further aspect of the invention an illustrative embodiment of a process
used to
recycle packing materials can be shown. Recipients can be asked to voluntarily
return
package bags to CDC's 1190-1 for recycling. Referring to FIG. 6, recipients
can place empty
package bags, including the package ties and packing sheets that came with
each package
bag, in a package bag recycling chute (138) at a CDC 1190-1. Returned package
bags can be
left t~ °~~,;ccumulate in a package bag recycling collection tank (140)
of a CDC 1190-1, until a
large volume of them has accumulated. Periodically, large batches of returned
package bags
can be taken from package bag collection tanks (140), in CDC's 1190-1 that do
not have a
package bag recycling machine (142), and transported to a CDC 1190-1 in the
same local
market that does have a package bag recycling machine (142). A package bag
recycling
machine (142) can be located in at least one CDC 1190-1 within a local market.
Workers at a
CDC 1190-1, where package bags can be recycled, can separate package ties from
package
bags, and load the package bags and packing sheets into a package bag
recycling machine
(I42). A package bag recycling machine (142) can condense bubble wrap package
bags and
packing sheets into blocks of recycled plastic source material which can be
used later to make
new package bags and packing sheets.
CDC workers can break down the empty cargo cages, that were received into a
CDC
1190-1, for shipping, by unlatching enough of the cargo cage linking clasps to
fold the sides
of the cargo cages, down on top of each other, to create flat condensed cargo
cage units.
Tractor-trailers can be used to transport condensed cargo cage units, package
bag ties, and
blocks of recycled plastic source material from a local market to its RDC 1180-
1. While
package bags, packing sheets, and package bag ties can be grouped together to
one or a few
CDC's in a local market before being recycled and shipped to a RDC, cargo
cages can be
transported directly from CDC's 1190-1 and LDDH's 1192-1 to a RDC 1180-1. The
package
bags used in traditional deliveries to customer-specified addresses from
LDDH's 1192-1 can
be returned to a CDC I 190-
1. With reference to FIG. 8, after blocks of recycled plastic source material,
package bag ties,
' and disassembled cargo cages arrive at a RDC 1180-1 on a tractor-trailer
(200 & 202), the
different materials can be unloaded from the trailer (202) onto the local
market receiving
dock conveyor (14) and moved through the RDC 1180-1. The packing materials can
travel to
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the local market sort conveyor (24) along the same path as inbound cases from
retailers.
From the local market sort conveyor (24), the blocks of recycled plastic
source material can
be moved to a bubble wrap bag production machine (58), which can be located
adjacent to
the local market sort conveyor (24). The recycled plastic source material can
be fed into the
. bubble wrap bag production machine (58) to make new bubble wrap package bags
and bubble
wrap packing sheets. Newly created package bags can be packed into totes
carrying a
standard quantity. The totes can be labeled with a barcode containing a
special Case Id that
can identify the tote as one containing packing materials. A Packing Materials
Supply
Program (346) can be used to generate a Case record 1208 and a case label for
each tote. The
Case Id of packing material totes (cases) can consist of, for example, the
current RDC Id + a
value such as "pm" + the current date + a sequential seven digit number.
Status can be set to
a value such as "destination RDC". SKU can be set to a value corresponding to
the type of
packing material - large package bags, small package bags, package bag ties,
or packing
sheets. Quantity can be set to the standard quantity packed in each tote
for.either small or
large package bags. Quantity can be set to a value such as "1" for package bag
ties or
packing sheets (the exact quantity of package bag ties and packing sheets in a
tote may not be
tracked). ePD Retailer Id can be set to a value such as "pack". The
Temperature Code can be
set to a value such as "standard". Other fields on the Case record 1208 can
have no value
when the record 1208 is created. The totes containing packing materials can be
placed onto
the local market sort conveyor (24). Although not absolute, cargo cages can be
preferably not
labeled or placed into totes.
RDC workers performing the local market sort 1118 and CDC sort 1120 can be
responsible for picking totes of packing materials, as well as item SKU cases,
for the packing
stations (45) which they support. There can be special Order Header 1200 and
Order Detail
records 1202 for packing materials that define the safety stock for each type
of packing
material. There can be a separate set of Order Header 1200 and Order Detail
1202 records for
each type of packing material, for each CDC 1190-1 or LDDH 1192-1. Each set of
packing
material Order Header 1200 and Order Detail 1202 records can establish a
continual request
for a supply of a packing material to meet the predefined safety stock of that
packing
material. Safety stock levels can be defined for each CDC 1190-1 or LDDH 1192-
1 based for
example, upon the number of packing stations (45) normally in use for that CDC
1190-1 or
LDDH 1192-1. The safety stock level quantities required for each CDC 1190-1 or
LDDH
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1192-1 can be adjustable through a menu option function of the CDC Sort
Program (328).
Package bag safety stock levels can be set, for example, to require two totes
of the standard
quantity of each package bag size per packing station (45) -- one full tote
quantity for
working stock and another one for safety stock. Package bag tie, packing
sheet, and cargo
cage safety stock levels can be set relative to the number of package bags or
totes of package
bags in package bag safety stock levels. For example, one tote of package bag
ties can be
required for every 20 totes of package bags, 1.5 totes of packing sheets can
be required for
each tote of package bags, 2.5 cargo cages can be required for each tote of
small package
bags, and 6 cargo cages can be required for each tote of large package bags.
The Order
Header records 1200 for packing materials can be defined, for example, as
follows: Order Id
consists of RDC Td + a value such as "pack" + CDC Id + a filler value such as
"010101" + a 3
digit number representing the type of packing material; Status can be set to a
value such as
"open"; Local Market Id can be set to the value associated with the current
CDC Id; CDC Id
can be set to the value of the current CDC 1190-1 or LDDH 1192-1 related to a
group of
I S packing stations (45); Customer Id can be set to a value such as "packing-
m"; ePD Retailer Td
can be set to a value such as "pack"; and all other fields can have no value.
Order Detail
records 1202 for packing materials can be defined, for example, as follows:
Order Id can be
the same as the value on the corresponding packing material Order Header
record 1200;
Status can be set to a value such as "destination RDC"; SKU can be set to the
value
representing the type of packing material (consistent with the SITU values
used on Case
records 1208 for each type of packing material); Quantity can be set to the
safety stock value
as previously described; Temperature Code can be set to a value such as
"standard"; and all
other fields can have no value.
As packages are created by workers at packing stations (45), the Package
Creation
Program (330) can decrement the Quantity on the packing material Case record
1208 of the
current CDC 1190-1 or LDDH 1192-l, for the package bag size that was used in
creating the
package. The Package Creation Program (330) can also increment the Quantity on
the
Packing Material Restocking Counter table 1262 for the records having a Type
value such as
"package bag tie" and "packing sheet" and a CDC Id value equal the current
packing station
CDC Id, as each new package is created. The Packing Material Restocking
Counter table
1262 can serve as a counter, relative to package bag consumption, which can be
used to
determine when to decrement the Quantity of a packing material Case record
1208, of
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package bag ties or packing sheets, from one to zero. Since the exact counts
of package bag
ties and packing sheets are not tracked, when the Packing Material Restocking
Counter record
1262, tracking either package bag ties or packing sheets for packing stations
(45) of the
current CDC 1190-1 or LDDH 1192-1, reaches a predefined level, the Quantity of
a packing
material Case record 1208, having the current packing station CDC Id and the
SKU of the
packing material reaching the predefined level, can be decremented from one to
zero. The
predefined level can be based upon the ratio of the consumption of that
packing material
relative to the consumption of package bags. Since Case records 1208 are not
used to track
the supply of cargo cages; the CDC Sort Program (328) can use the Packing
Material
Restocking Counter table 1262 as the supply count of cargo cages for the
packing stations of
the current CDC 1190-1 or LDDH 1192-1.
Unlike normal Order Detail records 1202, packing material Order Detail records
1202
are not updated as packing material items are picked from totes to create
packages, so the
safety stock demand, against which the packing materials supply can be
measured, can
remain constant. As the Quantity on a packing material Case record 1208 for
the packing
stations of the current CDC 1190-1 or LDDH 1192-1 decreases below the safety
stock level
defined on its Order Detail record 1202, the CDC Sort Program (328) and Local
Market Sort
Program (326) can indicate to pick a tote of that packing material, when the
case label of one
of those packing material totes is scanned. The sorting programs (326 ~z 328)
can also
display a restocking alert message on a program display monitor of
workstations used by the
workers performing the CDC sort 1120 and local market sort 1118 for the
packing stations of
the CDC 1190-1, LDDH 1192-1, or the local market of the CDC 1190-1 or LDDH
1192-1 for
which the packing material demand has been realized. As the Quantity of a
Packing Material
Restocking Counter record 1262 of the packing stations of a CDC 1190-1 or LDDH
1192-1,
having a Type value such as "cargo cage", decreases below the safety stock
level defined on
its Order Detail record 1202, the sorting programs (326 & 328) can also
display restocking
alert messages on the appropriate workstation program display monitors. Upon
seeing the
restocking alert message, workers performing the local market sort 1118 and
CDC sort 1120
can pick cargo cages from the local market sort conveyor (24) and CDC sort
conveyor (42)
respectively, to meet the demand. Workers performing the CDC sort 1120 can
enter the
picked quantity into the CDC Sort Program (328) on their workstation
keyboards, updating
the cargo cage supply on the Packing Material Restocking Counter table 1262.
Workers
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performing the local market sort 1118 can pick cargo cages from the CDC sort
conveyor (42).
A cargo cage does not have to be scanned and an update does not have to be
made to the
Packing Material Restocking Counter table 1262 as cargo cages are picked from
the local
market sort conveyor (24) to a CDC sort conveyor (42).
Referring to FIG. 12, there is shown an exemplary SmartBin Unit (SBU)
consisting of
revolving bins and stationary bins that can be subsections of a physical bin
structure which
can be conf gurable, and which can be divided into two or more subsections. A
SmartBin
Unit can include a front exterior panel 230, side exterior panels 232,
revolving bin doors 234,
revolving bin door handles 236, stationary bin doors 238, stationary bin door
handles 240, a
I O scanner port 242, a keypad 244, a display screen 246 and an exterior
wiring duct 248.
Each subsection of a physical bin structure can be referred to as a bin and
the physical
bin structure can be referred to as a master bin. Thus with reference to the
Bin Inventory
table 1300 of FIG. 10A, if a master bin is divided into two or more bins, each
subsection or
bin can have the same Master Bin Id for one of its data attributes. The bins
can also have
Configuration Codes and Bin Sizes that identify the manner in which they have
been divided.
A Configuration Code can numerically describe which subsections comprise a
bin, of the
possible number of subsections within a master bin. Each subsection of a
revolving master
bin can be numbered, for example, from left to right starting with a value
such as "1". Each
subsection of a stationary master bin can be numbered from left to right
starting with the 1
number equal to the highest revolving bin subsection number, plus one. A
Configuration
Code can, for example, consist of only the numbers of the master bin
subsections that
comprise the bin, moving from left to right. The Bin Size of any revolving bin
can be equal
to the number of its subsections. For example, a bin with a Configuration Code
of "234" can
have a Bin Size of "3". The Bin Size of any stationary bin can be equal to its
number of
subsections + the largest possible Bin Size of a revolving bin. For example,
if the largest
possible Bin Size of a revolving bin is "4", a stationary bin with a
Configuration Code of "6"
can have a Bin Size of "5". Each bin within a CDC 1190-1 can be tracked on the
Bin
Inventory table 1300 in the database of that CDC's 1190-1 processing server.
The Bin
Inventory record 1300 of each bin can contain a unique Bin Id, which can be
derived by
concatenating, for example, its SBU Id + its Master Bin Id + its Configuration
Code.
The following two illustrative examples can illustrate how different
configurations of
a master bin can be tracked on the Bin Inventory table 1300. In the first
illustrative example,
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a revolving master bin -- Master Bin Id "02" of SBU Id "A01" -- can be divided
into three
bins. Bin Id "A01-02-0012" can encompass the left half of the master bin and
can have a Bin
Size of "2". Bin Id "A01-02-0003" can encompass the third quarter of the
master bin, just to
the right of Bin Id "A01-02-0012", and can have a Bin Size of "1". Bin Id "A01-
02-0004"
can encompass the right-most quarter of the master bin and can have a Bin Size
of "1". The
Configuration Codes of the three bins respectively can be as follows: "12",
"3", "4". In the
second illustrative example, a stationary master bin -- Master Bin Id "SI" of
SBU Id "A01" --
can be configured as one bin, consisting of both master bin subsections. Bin
Id "A01-S1-
0056" can encompass the whole stationary bin, can have a Bin Size of "6", and
a
Configuration Code of "56".
SBU master bins can have one or more two-section panels, called configuration
dividing panels (CDP's), hinged on one side to the top surface of their bottom
panels. Each
CDP can be locked into one of two different positions. For example, a
consolidating position
or the dividing position. The two sections of the CDP can be attached to each
other by
folding hinges. The section which is not hinged to the bottom panel of the
master bin can
have, for example, four CDP cam locks, each of which slide a CDP bolt 90
degrees to lock or
unlock the CDP into one of its two positions. CDC workers can use, for
example,
configuration keys to lock a CDP into or unlock a CDP out of the dividing
position or the
consolidating position. The CDP cam lock and configuration key can be similar
to the lock
and key mechanism used to open and close vending machines. Configuration keys
can be
constructed in such a manner as to be used interchangeably between all CDP cam
locks and
bin door cam locks of any SBU. The design of the configuration key can allow a
worker with
a key to make bin configuration adjustments to any SBU, while preventing
someone without
a configuration key from changing a bin's configuration, even if the door of
the bin has been
opened.
When a CDP is in the consolidating position, a first panel section of the CDP,
which
is hinged to the bottom of the master bin, can rest horizontally in a recessed
area on top of the
master bin's bottom panel. The second panel section of the CDP can rest
horizontally on top
of the first panel section, and can also be recessed so that the top surface
of the second panel
section is level with the surface of the rest of the master bin's bottom
panel. The CDP bolts
of the four CDP cam locks can be locked into locking slots, built into the
sides forming the
recessed area within the master bin's bottom panel. When a CDP is in the
dividing position,
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the two panel sections of the CDP can both be vertical, sitting on top of each
other, with the
first panel section perpendicular to the bottom panel, of the master bin to
which it is attached,
and the second panel section perpendicular to the top panel of the master bin,
into which it
can be locked in place by two of its CDP bolts. Two of the second panel's CDP
bolts can
lock into locking slots in the top panel of the master bin, while the two CDP
bolts on its other
side can lock into locking slots built into the side of the first panel
section. The CDP bolts
which can lock down into the side of the first panel section can provide
structural support to
form a single, solid dividing panel. The CDP bolts which can lock into the top
panel of the
master bin and the hinges which can attach the first panel section to the
bottom panel of the
master bin can secure the CDP as the side wall between two adjacent bins of a
master bin.
If bin configurations are required to receive a delivery shipment, CDC workers
covering a CDC 1190-1 can be alerted that a Configuration Adjustments Report
is printing on
the CDC printer, while bins in that CDC 1190-1 are being reserved for the
delivery shipment.
Upon arriving at the CDC 1190-1 where the Configuration Adjustments Report
printed, CDC
workers can use the report to make the necessary configuration adjustments,
step 1140, before
the delivery shipment which triggered the report is received. The
Configuration Adjustments
Report can guide a CDC worker to the SBU's, upon which the worker will make
configuration adjustments, by listing them in SBU Id order. A CDC worker can,
for example,
wear a hands-free barcode scanning device as the worker takes the report to
each listed SBU.
The CDC worker can, for example, connect the scanning device into the scanner
port (242) of
the first SBU listed on the report, scan their employee id card to identify
themselves as the
worker configuring the current SBU, and scan the first barcode next to a
Master Bin Id, listed
underneath the SBU Id on the report. The scanner could also be a wireless
scanner, which
can communicate to a remote device or server. A SBU Configuration Program
(352) of the
ePD SBU Application can be initiated on the CDC's 1190-1 processing server.
Under each
SBU Id on the Configuration Adjustments Report, Master Bin Id's can be listed
in ascending
order, with stationary master bins preceding revolving master bins. In one
embodiment of a
SBU, the SBU can have only one stationary master bin, which can contain only
one CDP, but
because other embodiments may feature more than one stationary master bin
and/or may
feature stationary master bins with more than one CDP, in this disclosure both
stationary
master bins and their CDP's will be referred to in a more general plural
sense, rather than as
one specific master bin or CDP. If more than one bin configuration adjustment
is to be made
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to one master bin, each bin configuration adjustment can be listed separately.
For example,
the Master Bin Id can be listed more than once under its SBU Id. The new
Configuration
Codes of the bins to be created within the master bin can be listed next to
each Master Bin Id
on the report, along with a barcode that can be used to trigger the database
changes associated
with the configuration action.
There can be many possibilities of forming a new bin configuration from an
existing
one, but no matter what the bin configuration is at the start and end of a bin
configuration
adjustment, every bin configuration adjustment can be classified as either a
dividing bin
configuration adjustment or a consolidating bin configuration adjustment. The
barcode of a
dividing bin configuration adjustment can contain, for example, a.
configuration type
identifier, followed by the Bin Id of the bin to be divided, followed by the
Configuration
Code of each bin resulting from the bin configuration adjustment, in a barcode
format which
can be parseable. When the barcode of a dividing bin configuration adjustment
is scanned,
the SBU Configuration Program (352) can parse the data in the barcode, use the
configuration
type identifier to determine that the configuration action is a dividing one,
and use the Bin Id
to select the Bin Inventory record 1300 of the bin being divided. The program
(352) can
create two or more new Bin Inventory records 1300 from the selected
Bin~Inventory record
1300, before deleting the selected record 1300. Each new Bin Inventory record
1300 can
have the same values as the deleted Bin Inventory record 1300, except for the
Configuration
Code, Bin Id, and Bin Size fields. The Configuration Code on the first record
1300 created
can be set to the value of the first Configuration Code, listed after the Bin
Td, in the scanned
report barcode. The Configuration Code on subsequently created records 1300
can be set to
the value of each subsequent Configuration Code, listed after the first one,
in the scanned
report barcode. The Bin Id on each new record 1300 can be derived, for
example, by
concatenating SBU Id + Master Bin Id + Configuration Code. Bin Size on new
records 1300
created for revolving bins can be set to the number of digits in the
Configuration Code. Bin
Size on new records 1300 created for stationary bins can be set to the number
of digits in the
Configuration Code added to the value of the largest possible revolving~Bin
Size.
The parseable barcode of a consolidating bin configuration adjustment can
contain, for
example, a configuration type identifier, followed by the Configuration Code
of the new bin
resulting from the bin configuration adjustment, followed by the Bin Id of
each bin within the
master bin to be consolidated, in a barcode format. When the barcode of a
consolidating bin
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configuration adjustment is scanned, the program (352) can parse the data in
the barcode, use
the configuration type identifier to determine that the conf guration action
is a consolidating
one, and use the Bin Id's to select the Bin Inventory records 1300 of the bins
being
consolidated. The program (352) can create one new Bin Inventory record 1300
from the
S selected Bin Inventory records 1300, before deleting the selected records
1300. The new Bin
Inventory record 1300 can have the same values as the deleted Bin Inventory
records 1300,
except for the Configuration Code, Bin Id, Bin Size, and Status fields. The
Configuration
Code on the new record 1300 can be set to the value of the Configuration Code,
listed after
the configuration type identifier, in the scanned report barcode. The Bin Id
on the new record
1300 can be derived, for example, by concatenating SBU Id + Master Bin Id +
Configuration
Code. Bin Size on the new record 1300 can be set for a revolving or stationary
bin based on
the Configuration Code in a manner that can be consistent with the way it can
be set for a
dividing bin configuration adjustment. Status can be set to a value such as
"available".
As each dividing bin configuration adjustment is made to the Bin Tnventory
table
1300, the program (352) can update the Pending Bin Configuration Adjustments
table 1304
to offset the amount of pending bin configuration adjustments by the amount of
bin
configuration adjustments actually made. It can reduce the Quantity of the
Pending Bin
Configuration Adjustments record 1304, having the Bin Size and Temperature
Code of the
newly created Bin Inventory records 1300, by the number of new bins created.
It can increase
the Quantity of the Pending Bin Configuration Adjustments record 1304, having
the Bin Size
and Temperature Code of the deleted Bin Inventory records 1300, by the number
of records
deleted. The Pending Bin Configuration Adjustments table 1304 does not have to
be updated
as consolidating bin configuration adjustments are made, because pending
consolidating bin
configuration adjustments can be tracked by the Status on specific Bin
Inventory records
1300, instead of on Pending Bin Configuration Adjustments records 1304. With
reference to
FIG. l OB, the program (352) can also add a new record to a Configuration
Adjustment Log
table 1306 to track each bin configuration adjustment made, using the data
from the scarred
report barcode and the scanned employee id. A Configuration Adjustment Id can
be derived,
for example, by concatenating the value of the first Bin Id listed in the
scanned report barcode
+ the current date. Configuration Type can be set to the value of the
configuration type
identifier. The value of Bin Id 1 through Bin Id 4 can be set to the value of
each Bin Id listed
in the barcode, in the sequence that it is listed. The value of Configuration
Code 1 through
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Configuration Code 4 can be set to the value of each Configuration Code listed
in the
barcode, in the sequence that it is listed. Employee Id can be set to the
value'on the scanned
employee id card, and Configuration Date/Time can be set to the current
date/time.
When the barcode of a stationary master bin listed on a Configuration
Adjustments
Report is scanned, the program (352) can unlock the bin doors (238) of the
stationary master
bin and display the Master Bin Id and the desired Configuration Codes on the
SBU display
screen (246). The program (352) can separate the Master Bin Id and each
individual
Configuration Code with, for example, hyphens, when displaying them on a SBU
display
screen (246). The worker can hold the stationary bin doors (238) open while
using a
configuration key to reposition the CDP's of the stationary master bin to
achieve the bin
configuration dictated by the Configuration Codes listed on the Configuration
Adjustments
Report and the SBU display screen (246). The worker can also use a
configuration key to
reposition bin door configuration bolts into either a dividing or
consolidating position to align
the configuration of the stationary bin doors (238) with the new bin
configuration. Unlike bin
door configuration bolts on revolving bin doors (234), which can be moved
electronically by
ePD SBU Application programs, bin door configuration bolts on a stationary bin
door (238)
can be moved manually using a bin door cam lock, located near the bottom of
the inside of a
stationary bin door (238). When a CDP has been moved in place to divide a
stationary bin,
the bin door configuration bolt between the two bin doors (238) on either side
of that CDP
should be in the dividing position -- for example, vertical, completely within
the structure of
one of the two stationary bin doors (238). When a stationary bin CDP is folded
down and
locked into the consolidation position, the bin door configuration bolt,
between the two
stationary bin doors (238) on either side of where that CDP is hinged, should
be in the
consolidating position -- for example, horizontal, overlapping into the
locking slot within the
structure of the stationary bin door (238) adjacent to the stationary bin door
(238) into which
it is built.
With reference to FIG. l OC, when the barcode of the first revolving master
bin of a
SBU listed on a Configuration Adjustments Report is scanned, the program (352)
can move
the master bin of the scanned report barcode into the unloading position (the
unloading/loading position of a SBU bin or master bin can be with the open
front side of the
master bin lined up with the SBU's revolving bin doors (234)), move the bin
door
configuration bolts to consolidate the revolving bin doors (234) to form one
solid bin door
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across the entire revolving master bin, update the values on a SBU Settings
record 1314 of
the current SBU, and unlock the revolving bin doors (234). The SBU
Configuration Program
(352) can call or cause to be called, a Bin Positioning Program (372) and can
use program
logic similar to an Unloading Program (370) to position and unlock revolving
bins. A
difference between how the SBU Configuration Program (352) works as compared
to the
Unloading Program (370) can be in how it determines which bins to move and
unlock. The
SBU Configuration Program (352) can determine which bins to move from the
Master Bin Id
associated with one or more of the Bin Id's in the scanned report barcode, and
it can unlock
all the revolving bin doors (234). The Unloading Program (370) can determine
which bin to
move and which revolving bin doors (234) to unlock from the information
entered on the
SBU keypad (244) by the package recipient. After moving the master bin into
the unloading
position and unlocking the revolving bin doors (234), the SBU Configuration
Program (352)
can display the Master Bin Id and the desired Configuration Codes on the SBU
display screen
(246). The worker can open the consolidated bin doors (234), lift them up
against the front
panel (230) of the SBU, and use a configuration key to lock them into an open
position. The
locking bolt of a revolving bin door cam lock, which can be located on the
inside of one of
the revolving bin doors (234), can slide into a locking slot on the front
panel of the SBU to
lock the bin doors (234) into an open position. The worker can use a
configuration key to
reposition the CDP's of the revolving master bin to achieve the bin
configuration dictated by
the Configuration Codes listed on the Configuration Adjustments Report and the
SBU display
screen (246).
Like the Unloading Program (370), whenever the SBU Configuration Program (352)
moves the revolving bins and the revolving bin door configuration bolts, it
can update the
current SBU's record on the SBU Settings table 1314 to account for the
movements. It can
set Load Position Master Bin Id to the Master Bin Id of the bin moved to the
unloading
position and Door Configuration Code to the value that describes the current
setting of each
revolving bin door configuration bolt. The Door Configuration Code can be an
alphanumeric
value, consisting of zeros and ones. It can have as many characters as there
can be bin door
configuration bolts, and each character can represent a bin door configuration
bolt starting
from left to right. Zeros can be used, for example, to denote that a bin door
conf guration bolt
is in the dividing position. Ones can be used, for example, to denote that a
bin door
configuration bolt is in the consolidating position.
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The worker can continue to scan the barcodes underneath the SBU Id on the
report
and make the bin configuration adjustments to each master bin as directed on
the
Configuration Adjustments Report and the SBU display screen (246). The SBU
Configuration Program (352) can move a SBU's bins regardless of whether the
revolving bin
doors (234) of that SBU are closed. After all bin configuration adjustment
changes for a SBU
are complete, the worker can, for example, scan a confirmation barcode, which
can be listed
on the last report line underneath the SBU Id, to confirm that all the bin
configuration
adjustments listed for that SBU have been made. Upon receiving a confirmation
tone and a
confirmation message on the SBU display screen (246) for example, the workex
can use a
configuration key to unlock the revolving bin doors (234) from the open
position. The
worker can then lock the revolving bin doors (234) by firmly pushing them
closed. The
worker can then proceed to the other SBU Id's listed on the Configuration
Adjustments
Report, scanning their employee id card and making bin configuration
adjustments on each
one until the end of the report is reached. After all the bin configuration
adjustments listed on
the Configuration Adjustments Report have been made and confirmed, the SBU
Configuration Program (352) can end.
The Configuration Adjustments Report for one delivery shipment may be split
between two or more CDC workers making the bin configuration adjustments. Each
worker
can scan their employee id card before starting to make configurations to a
SBU, allowing the
program (352) to track the worker who made each bin configuration adjustment
on the
Configuration Adjustment Log table 1306. '
In a further aspect of the invention, the tractor-trailer driver can stop at
the CDC's
1190-1 and/or LDDH's 1192-1 listed on their Delivery Shipments Report in the
sequence in
which they can be listed. Prior to arriving at the CDC's 1 I90-1, the driver
can use a
communication means such as a cellular phone to call a Primary Contact Number
for each
CDC 1190-1 in order to alert CDC workers that a delivery shipment will arrive,
give, for
example, an estimated time of arrival, and let the workers know whether the
incoming
delivery shipment encompasses more or less than half of the trailer (202). If
the attempt to
reach the team of CDC workers covering the CDC 1 I90-1 using its Primary
Contact Number
fails, the driver can attempt to call the CDC's 1190-1 Secondary Contact
Number (both
numbers can be listed on the Delivery Shipments Report with each CDC Id). In
one
embodiment, the Primary Contact Number and Secondary Contact Number of a CDC I
190-1
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do not dial telephones located in the CDC facility 1190-1. Instead, the
contact numbers can
dial cellular phones designated to those CDC's 1190-1. As a team of CDC
workers begins its
work shift to cover a group of CDC's 1190-1, the CDC workers of the prior work
shift can
transfer the cellular phones, designated to the CDC's 1190-1 they are
covering, to the team of
CDC workers accepting coverage responsibility for those CDC's 1190-1.
Depending upon
the designation of the CDC coverage routes within a local market, there can be
a group of
CDC's 1190-1 which share the same contact numbers. Upon receiving a call from
a tractor-
trailer driver, the team of CDC workers can travel to the identified CDC 1190-
1 to meet the
delivery shipment. In one embodiment, a tractor-trailer driver does not need
to call ahead to
alert a LDDH 1192-1 when making a delivery there, as LDDH's can have dedicated
workers
on site to receive delivery shipments.
The CDC workers can arrive ahead of the delivery shipment in order to minimize
the
time (and the costs associated with that time) the tractor-trailer and its
driver spend away ,
from their primary function of transporting cases and packages. With reference
to FIG. 6,
prior to the arrival of the delivery shipment, CDC workers can position a
number of mobile
putaway conveyor units (143) on the receiving dock area, in front of the CDC
receiving dock
conveyor extension (145). In one embodiment, either four or eight mobile
putaway conveyor
units (143) can be used depending upon the size of the delivery shipment.
Eight conveyor
units (143) can be set up, if the driver indicated that the delivery shipment
for the CDC 1190-
1 encompassed more than half of the trailer. Four conveyor units (143) can be
set up, if the
driver indicated that the delivery shipment encompassed less than half of the
trailer. Some of
the conveyor units (143) may have already been positioned and prepared to
receive the next
delivery shipment by the CDC workers who last used them. Although specified
units can be
described, other quantities can b~e used without departing from the spirit of
the invention.
For illustration, each mobile putaway conveyor unit (143) can have an electric
power
outlet on the side of its base component, below a rotating conveyor component,
above where
wheels can be attached to the base, at each of the corners of the base
component. Each
conveyor unit (143) can be as wide as half the width and as long as one-fourth
of the length of
a trailer conveyor (204). When positioning the conveyor units (143), the
workers can connect
power cables between the power outlets of adjacent conveyor units (143),
forming a
horseshoe shaped chain, for example, starting from the front-left unit. The
power cable
connections between the conveyor units (143) can extend back the left side to
the unit farthest
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away from the CDC delivery dock door (144), across to a back-right unit, and
back up the
right side to the unit positioned to the right of the front-left unit. The
power cables used to
connect the units (143) to each other can normally sit with one end plugged
into one of the
power outlets of the unit (143), and the other plug end, for example, fastened
under a holding
clip built into the side of that unit (143). The power cable at the front-left
corner of the front-
left unit (143), can be plugged into an electrical power outlet, located for
example, on the
base of the CDC receiving dock conveyor extension (145), underneath its
pivoting conveyor
component. Since the CDC receiving dock conveyor extension (145) can be
plugged into an
electric power outlet of the CDC facility 1190-1, electric power can be
supplied to each of the
mobile putaway conveyor units (143) linked together by the power cables.
Another step in
positioning conveyor units (143) to receive a delivery shipment can be locking
their wheels to
prevent the conveyor units (143) from moving, as cargo cages get loaded onto
them. Each
mobile putaway conveyor unit (143) can have a wheel locking mechanism that can
be set to
either lock all of its wheels or allow them to move freely. CDC workers can
engage the
wheel locking mechanism on each conveyor unit (143) after that conveyor unit
(143) has been
aligned in position to receive a delivery shipment. Yet another step in
preparing the conveyor
units (143) to receive a delivery shipment can be to raise a cargo stop wall
on the two units
farthest from the CDC delivery dock door (144), to prevent cargo cages from
moving off of
the end of the conveyor unit (143) as they are loaded onto the conveyor units
(143). Cargo
stop walls can be slightly less than the width and height of the backside of
the base of the
conveyor unit (143) into which they can be built. Cargo stop walls can be
contained within a
rectangular frame that can be built into the backside of the base of the
conveyor unit (143)
just beyond the edge of the end of the conveyor component. The cargo stop
walls can be
positioned either in the inactive position -- down inside its base frame -- or
in the active
position -- extended upward from the top of the frame, forming a wall that
extends beyond
the top of the conveyor component. A spring-loaded locking pin can be used to
keep a cargo
stop wall in one of the two positions and must be disengaged to allow the
cargo stop wall to
be moved from one position to the other. The mobile putaway conveyor units
(143) can be
designed to be interchangeable with each other. That can simplify the steps
involved in
positioning them by removing the possibility of positioning one in the wrong
place. The
conveyor units (143) do need to be positioned in the correct direction,
however, to enable. the
movement of their conveyors to be in synchronization with each other, the dock
conveyor
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extension (145), and the trailer conveyor (204). A correctly positioned
conveyor unit (143)
can have its cargo stop wall end away from the CDC delivery dock door (144).
After the
mobile putaway conveyor units (143) axe positioned and ready to receive a
delivery shipment,
one of the CDC workers can open the CDC delivery dock door (144). The CDC
workers can
then await the aiTival of the tractor-trailer (200 & 202) carrying the
delivery shipment.
In step 1142, a delivery shipment can be received into a CDC 1190-1. When the
tractor-trailer (200 & 202) arrives and finishes backing up to the CDC
delivery dock door
(144), a CDC worker can open the door of the trailer and lower the CDC
receiving dock
conveyor extension (145) to the horizontal unloading position. The lowered
conveyor
extension (145) can bridge the gap between the trailer conveyor (204) and the
mobile
putaway conveyor units (143) to form one continuous set of conveyor sections.
One of the
CDC workers can switch on the conveyors of the mobile putaway conveyor units
(143) and
the CDC receiving dock conveyor extension (145) to move in the unloading
direction (away
from the trailer (202)). A CDC worker can then switch the trailer conveyor
(204) to move in
the unloading direction (toward the trailer door) and the cargo cages and
single-item packages
can be moved from the trailer conveyor (204) across the conveyor extension
(145), and on to
the conveyor units (143). If the driver had informed the CDC workers that the
delivery
shipment encompassed less than half of the trailer (202), for example, only
four conveyor
units (143) would be positioned to receive the delivery shipment, and the
trailer conveyor
(204), conveyor extension (145), and conveyor units (143) can be stopped after
a delivery
shipment the size of approximately half of the contents of the trailer is
moved onto the
conveyor units (143). If the driver had informed the CDC workers that the
delivery shipment
encompassed more than half of the trailer (202), for example, eight conveyor
units (143)
would be positioned to receive the delivery shipment, and the trailer conveyor
(204),
conveyor extension (145), and conveyor units (143) can be stopped after a
delivery shipment
the size of approximately all of the contents of the trailer (202) is moved
onto the conveyor
units (143). While the number and the design of conveyor units (143) required
can be
specified, other numbers of conveyor units (143) and variations in the design
of those
conveyor units (143) can appropriately be used without departing from the
spirit of the
invention. The cargo cages and single-item packages at the leading end of the
delivery
shipment can move across the conveyor units (143) closest to the trailer
(202), and then back
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onto the ones farthest away from the trailer (202), until they hit up against
the cargo stop
walls at the back end of the conveyor units (143) farthest away from the
trailer (202).
The CDC workers can look at the delivery shipment label plate on one of the
first
cargo cages at the lead end of the delivery shipment to confirm that the
delivery shipment
unloaded is for the current CDC 1190-1. They can then work their way back
looking for
another delivery shipment label plate on the other cargo cages to determine
where the current
CDC's 1190-1 delivery shipment ends and another CDC's 1190-1 delivery shipment
begins.
If the contents of the trailer (202) contains more than one delivery shipment,
the workers can
see a delivery shipment label plate with a different CDC Id listed on it,
marking the cut off
point between two different delivery shipments.. If the CDC workers do find a
second
delivery shipment label plate, they can switch the trailer conveyor (204), the
conveyor
extension (145), and the conveyor units (143) in the loading direction to move
the cargo
cages and single-item packages of the second delivery shipment back onto the
trailer
conveyor (204). If necessary, the appropriate sections of the coordinated
system of conveyors
-- trailer conveyor (204), CDC receiving dock conveyor extension (145), and
mobile putaway
conveyor units (143) - can be controlled separately from each other in a
coordinated manner
to move cargo cages and single-item packages back onto the trailer (202). Once
the delivery
shipment for the current CDC 1190-1 has been unloaded onto the conveyor units
(143) and
any parts of other delivery shipments, which may have been partially unloaded,
have been
reloaded back onto the trailer conveyor (204), the different components of the
coordinated
system of conveyors can be switched off. A CDC worker can, for example,
manually move
the conveyor extension (145) into the vertical non-loading position, close the
trailer door, and
close the CDC delivery dock door (144).
The driver of the tractor-trailer can give one of the CDC workers the Delivery
Shipments Report for the current CDC 1190-1. In one embodiment, the CDC worker
can
connect a hands-free barcode scanning device to a workstation running the
current CDC's
1190-1 instance of the ePD SBU Application. The worker can, for example,
initiate a
Loading Guide Report Program (354) to run on the workstation and use the hands-
free .
barcode scanning device to scan their employee id card and the report barcode
underneath the
current CDC 1190-1 on the Delivery Shipments Report to accept the delivery
shipment. The
Loading Guide Report Program (354) can read the report barcode and parse the
information it
contains according to its standard format. The barcode on the Delivery
Shipments Report can
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contain the Delivery Shipment Id, the Temperature Code, and the number of
packages in the
delivery shipment of each Package Size. The number of packages of each size
can be
listed in the barcode, in increasing Package Size sequence, using a standard
number of digits
per Package Size. Due to the nature of how packages can be transported,
packages received
in the same delivery shipment can have the same Temperature Code. Packages
having a
Temperature Code value such as "refrigerated" or "freezer" can arrive in
temperature-
controlled vehicles that can maintain the temperature conditions required by
each of those
types of packages, while packages having a Temperature Code value such as
"standard" can
arrive in non-temperature controlled tractor-trailers. The Loading Guide
Report Program
(354) can search the Bin Inventory table 1300 for the count of records of each
Bin Size
having the Temperature Code of the delivery shipment and a Status such as
"available", and
can compare that count of available bins against the package counts of each
corresponding
Package Size from the Delivery Shipments Report barcode to create a Loading
Guide Report.
The Loading Guide Report Program (354) can read a High-Availability Bins data
view 1307
before searching the Bin Inventory table 1300, so that it can search the Bin
Inventory table
1300 for SBU's having a large number of available bins, first, before
searching for other
SBU's having less availability. Both data sets (SBU Id's with high
availability and other
SBU Id's) can be selected in SBU Id sequence. The ePD SBU Application can
maintain the
High-Availability Bins data view 1307 dynamically as the underlying Bin
Inventory table
1300 is updated. The High-Availability Bins data view 1307 can list, for
example, the SBU
Id, Temperature Code, and Available Quantity of bins for SBU's which have a
quantity of
available bins greater than a target number considered to indicate high
availability (such as
more than 50°10 of its bins are available). The setting for the number
or percentage of bins
available to be considered as indicating a high availability can be
configurable and can be set
differently at each CDC 1190-1. As the Loading Guide Report Program (354)
creates the
Loading Guide Report, it can save the listing of SBU Id's needed to accept the
packages of
the smallest Package Size. In searching for SBU Id's to accept packages of
each increasing
Package Size, the Loading Guide Report Program (354) can search the saved list
of SBU Id's
first, before searching selected SBU Id's with high bin availability, and then
searching other
SBU Id's. SBU Id's can be added to the list being saved for the report, during
the search for
bins of each Package Size, if the search for that Package Size is not
satisfied by the existing
saved list. The program (354) can print the Loading Guide Report as the final
saved list of
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SBU Id's, in SBU Id sequence, once the program (354) has finished its search
for all Package
Sizes of the delivery shipment. The Loading Guide Report can list, for
example, the total
quantity of available bins of each Bin Size for each SBU Id that it lists.
In addition to printing the Loading Guide Report, the Loading Guide Report
Program
(354), can for example, open a remote dial-up connection with the RDC server,
of the
destination RDC 1180-1 serving the current CDC 1190-1, and update the Delivery
Shipment
table 1238 of the ePD Delivery Application. The following updates can be made
to the
Delivery Shipment record 1238 having the Delivery Shipment Id of the scanned
report
barcode: Status can be set to a value such as "received"; Delivery Shipment
Arrival
Date/Time can be set to the current date/time; and CDC Employee Id can be set
to the value
of the scanned employee id card. The update to the Status of the Delivery
Shipment record
1238 by the ePD SBU Application can trigger, or cause to be triggered, the ePD
Delivery
Application, which can be running on the RDC server, to automatically update
the Status to a
value such as "in CDC" on all Package table records 1234 having a Delivery
Shipment Id
equal to the value in the updated Delivery Shipment record 1238. As the ePD
Delivery
Application updates the Status on each Package record 1234, it can also update
the Order
Detail records 1202 that contain that Package Id, setting their Status to a
value such as "in
CDC".
After scanning the barcode on the Delivery Shipments Report, the CDC worker
can
hand the report back to the driver and the driver can depart for the next CDC
1190-1 listed on
the report. CDC workers can disconnect the power cables between the mobile
putaway
conveyor units (143), unlock the wheels of the conveyor units (143), and move
the conveyor
units (143) into a holding cage (134) designated to the shipping organization
for which they
work. With reference to FIG. 6, a holding cage (134) can be an area within the
backroom
area (154) of a CDC 1190-1, which can be secured by a fence-like structure,
which can have a
lockable door. The CDC workers can lock the holding cage (134) and travel to
the next CDC
1190-1 listed on the Delivery Shipments Report to meet the tractor-trailer
driver. The CDC
workers can continue to unload the trailer (202) until it becomes empty or
contains only
delivery shipments for LDDH's 1192-1. When the workers get finished unloading
the
trailer's (202) last CDC delivery shipment, the CDC workers can begin to load
the packages
of the delivery shipment into SBU's in whichever CDC 1190-1 they are currently
in. After
disconnecting the power cables and unlocking the wheels of the conveyor units
(143), the
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CDC workers can begin to move the conveyor units (143) throughout the CDC 1190-
1 to
load the packages of the delivery shipment into SmartBin Units (SBU's) (158),
as illustrated
in step 1144. The workers can then travel back to the other CDC's 1190-1 in
which they
received a delivery shipment to load the packages of the delivery shipments,
which they had
previously placed into the holding cages (134). In one embodiment, multiple
shippers can
deliver to the same CDC's 1190-1, and different holding cages (134) can
correspond to
different shippers and can have security to restrict access to only workers of
that shipper. In
another embodiment, an entire CDC 1190-1 can be run by one shipper and mobile
putaway
conveyor units (143) can be left in the back room area (154) of the CDC 1190-
1, eliminating
the need for holding cages (134). In either embodiment, the entire back room
area (I54) of a
CDC 1190-1 can be secured to allow access to shipper workers only.
After a driver unloads all of their delivery shipments, the driver can leave
for a retailer
site or can load up CDC reverse shipments and/or recycled materials depending
upon their
next scheduled run. At this point in the ePD Delivery Process, the packages of
a delivery
shipment have been delivered in bulk and received into a CDC location 1190-1
as illustrated
in step 1142. The bulk delivered packages of the delivery shipment can later
be retrieved by
many different recipients, in step 1150.
Following step 1142, the packages can be loaded into the SBU's (158) as
illustrated in
step 1144 of FIG. 1. After the CDC workers unload the last delivery shipment
from a trailer
into a CDC 1190-1, they can use the Loading Guide Report to guide them as they
move
mobile putaway conveyor units (143) from the CDC back room area (154) or
holding cage
(134) through the main room delivery entrance door (146), into the CDC's main
aisle (170),
cross aisles (162), and side aisles (160) to the SBU's (158) listed on the
report. To load the
bulk delivered packages into a SBU (158), a CDC worker can connect, for
example, a hands-
free scanning device into a SBU's scanner port (242) and can scan, for
example, their
employee id card to activate the Loading Program (356) of the ePD SBU
Application. The
Loading Program (356) can determine which revolving master bin is closest to
the loading
position and has at least one available bin, so that it can move that bin into
the loading
position. To select the closest bin with a Status value such as "available",
the Loading
Program (356) can select the record from the SBU Settings table 1314 having
the SBU Id of
the current SBU (158). With reference to FIG. 10D, the Loading Program (356)
can use, for
example, the value in the Load Position Master Bin Id field of the selected
SBU Settings
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record 1314, to select all the Master Bin After Movement values for that
master bin from a
Master Bin by Movement table 1316. The Loading Program (356) can use each
selected
Master Bin After Movement value, in the sequence the fields can be listed on
the Master Bin
by Movement table 1316 (which can be sequenced by the lowest absolute value of
a
movement), to search the Bin Inventory table 1300 for the first record having,
for example,
the current SBU Id, a Status value such as "available", and a Master Bin Id
value matching
the selected Master Bin After Movement value. The first Bin Inventory record
1300 it finds
meeting that criteria can contain the closest available bin. Once the Master
Bin Id of the
closest available bin is determined, the Loading Program (356) can call or
cause to be called,
a Bin Positioning Program (372) to determine the movement needed to position
the selected
master bin into the loading position. The Loading Program (356) can pass the
Load Position
Master Bin Id value for the current SBU (158) and the Master Bin Id value of
the selected
master bin (the one for the closest available bin) to the Bin Positioning
Program (372) as
inputs. The Bin Positioning Program (372) can use the input values to search a
Bin
Movement table 1315 for the movement required to move the selected master bin
into the
loading position. The Loading Program (356) can send a motor command to the
SBU motor
to move the revolving bins by the movement value returned from the Bin
Positioning
Program (372). Upon receiving the motor command, the SBU motor can move the
revolving
bins to position the selected master bin into the loading position.
The Loading Program (356) can read a Door Configuration Code value from the
SBU
Settings record 1314 it had selected for the current SBU (158) and can
determine the bin door
configuration commands needed to move the bin door configuration bolts to
consolidate all
the revolving bin doors (234) to form one solid bin door across the entire
revolving master
bin. The Loading Program (356) can send the needed bin door configuration
commands to
the bin door configuration mechanisms on the revolving bin doors, and the bin
door
configuration bolts can be moved accordingly. In referring to sending a bin
door
configuration command to a bin door conftguration mechanism in this
disclosure, a program
can be sending the command directly to the bin door configuration mechanism
through a
local area network connecting each SBU (158) to the CDC processing server or
it can actually
be sending the command to a bin door configuration bolt controller, which in
turn, can
. interpret the command and initiate the action through a wired connection to
the bin door
configuration mechanism. If a bin door configuration bolt controller is used,
it can be
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centralized to control all the bin door configuration mechanisms in a CDC 1190-
1 or specific
to a single SBU (158) or a group of SBU's (158). The program (356) can update
the values
on the SBU Settings record 1314 of the current SBU (158) to reflect the bin
movement and
the bin door configuration bolt movement. The program (356) can send an unlock
command
to the bin door locking mechanism of each revolving bin door to unlock all of
the revolving
bin doors (234). In referring to sending an unlock command to a bin door
locking mechanism
in this disclosure, a program can be sending the command directly to the bin
door locking
mechanism through a local area network connecting each SBU (158) to the CDC
processing
server or it can actually be sending the command to a lock controller, which
in turn, can
interpret the command and initiate the action through a wired connection to
the bin door
locking mechanism. If a lock controller is used, it can be centralized to
control all the bin
door locking mechanisms in a CDC 1190-1 or specific to a single SBU (158) or a
group of
SBU's (158). The program (356) can also send, for example, a display command
to display
the Master Bin Id and Configuration Codes of the master bin in the loading
position, on the
SBU display screen (246). The Loading Program (356) can also check the Status
of the Bin
Inventory records 1300 for the current SBU's (158) stationary bins to
determine if one or
more of them have a Status such as "available". The Loading Program (356) can
send an
unlock command to the bin door locking mechanism of one or more of the
stationary bin
doors, as needed, to unlock the bin doors (238) corresponding to available
stationary bins.
A CDC worker can open consolidated revolving bin doors (234), lift them up
against
the front panel (230) of the SBU (158), and use a configuration key to lock
them into the
open position -- fully open, against the SBU (158), above the bin door
openings of the
revolving bins. The worker can pick a bulk delivered multi-item package from
one of the
cargo cages on the mobile putaway conveyor unit (143), scan the barcode on its
package
label, and place it into the left-most available bin with the package tie
handle facing out or to
one side of the bin. The worker can then scan the bin door label barcode
located on the inside
of the bin door (234) of the bin in which the bulk delivered multi-item
package was loaded.
In one embodiment, if a bin is configured to span across more than one
revolving bin door
(234), the bin door label on the Left-most bin door (234) corresponding to the
bin must be
scanned. The Loading Program (356) can, for example, sound an error tone
and/or display an
error message, if a bin door label other than the left-most one of an
available bin gets
scanned, or if a bin door label of a bin that already contains a package gets
scanned, or if two
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package labels get scanned consecutively, or if two bin door labels get
scanned consecutively.
When a loading error occurs, the program (356) can also clear its memory of a
Package Id
that may have been scamied in the transaction prior to the error. If the bulk
delivered package
gets loaded successfully when a package label and then a bin door label are
scanned, the
Loading Program (356) can for example, sound a confirmation tone and/or
display a message
on the SBU's display screen (246), confirming that the package was loaded
successfully.
As each bulk delivered package gets loaded into a SBU bin, the Loading Program
(356) can update the Bin Inventory 1300 and Bin Reservation tables 1302 of the
SBU
Application, and can create a new record on a Notification Check table 1310 of
the SBU
Application. The Loading Program (356) can read, for example, a Customer Id,
embedded in
the Package Id on the scanned package label, and can use it to select the
Customer table
record 1256 corresponding to the bulk delivered multi-item package. The
Loading Program
(356) can use the Employee Id on the scanned employee id card to select the
ePD Shipper Id
from the Employee table 130. The Loading Program (356) can read the SBU Id and
a Bin
Door Identifier, in the barcode on the scanned bin door label, and can use
that SBU Id to
search the SBU Settings table 1314 to determine which master bin is in the
loading position.
The Loading Program (356) can then select the Bin Inventory record 1300 of the
bin in which
the bulk delivered mufti-item package was loaded, by selecting the Bin
Inventory~record 1300
having the SBU Id of the scanned bin door label, a Master Bin Id equal to the
value of the
Load Position Master Bin Id field on the SBU Settings record 1314 having that
SBU Id, and a
Configuration Code that contains the Bin Door Identifier of the scanned bin
door label. The
Loading Program (356) can update the selected Bin Inventory record 1300, for
example:
Package Id can be set to the value of the barcode scanned on the package
label; Customer Id
can be set to the Customer Id value embedded in the Package Id; PIN can be set
to the value
on the selected Customer record 1256; Status can be set to a value such as
"loaded"; Delivery
Employee Id can be set to the value scanned from the barcode on the employee
id card; ePD
Shipper Id can be set to value from the selected Employee record 1308; and
Delivery
Date/Time can be set to the current date/time. The Loading Program (356) can
select, for
example, the Bin Reservation record 1302 having the Bin Size, Temperature
Code, and ePD
Shipper Id of the Bin Inventory record 1300 which it just updated and a Status
such as "new",
and can decrement its Quantity by one. If more than one Bin Reservation record
1302 gets
selected using Bin Size, Temperature Code, and ePD Shipper Id, the Loading
Program (356)
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can update the one with the earliest Reservation Date/Time. When the Quantity
of a Bin
Reservation record 1302 reaches zero, the Loading Program (356) can set its
Status to a value
such as "filled". The Loading Program (356) can also create a new record on
the Notification
Check table 1310 by writing the Customer Id that was embedded in the Package
Id on the
new record 1310.
If there is another available bin in the master bin in the loading position,
after a bulk
delivered mufti-item package gets loaded, the worker is able to load another
bulk delivered
mufti-item package using the same steps just described. When all the bins in
the current
master bin are filled after a bulk delivered mufti-item package is loaded, the
Loading Program
(356) can move the revolving bin structure to position the closest remaining
master bin,
having at least one available bin, into the loading position. The Loading
Program (356) can,
for example, repeat the processing performed to move the first closest
available bin into the
loading position, when determining the movement needed to position the closest
remaining
available bin into the loading position. In one embodiment, the program
commands are not
issued to move bin door configuration bolts or unlock revolving bin doors as
the Loading
Program (356) subsequently positions each master bin into the loading
position, because the
revolving bin doors (234) can already be locked into the open position. The
worker can
continue to load bulk delivered mufti-item packages into available bins in
this mamier until
the SBU (158) no longer has any available revolving bins.
Workers can also load bulk delivered single-item packages into a SBU's (158)
stationary bins by placing the bulk delivered single-item package in the
stationary bin,
scanning its package label, and scanning the bin door label of the bin. In one
embodiment,
stationary bin doors (238) are not locked into or out of a loading position
using a
configuration key. When loading bulk delivered single-item packages into a
stationary bin, a
worker can hold the stationary bin doors (238) open while placing the package
into the
stationary bin. Unlike the loading of bulk delivered mufti-item packages into
revolving bins,
the Loading Program (356) does not confirm the bulk delivered single-item
package as being
successfully loaded into a stationary bin until its stationary bin door (238)
gets pushed closed
to lock the stationary bin. After the program makes the updates to the Bin
Inventory 1300
and Bin Reservation 1302 records and creates the new Notification Check record
1310 for the
bulk delivered single-item package (in the same manner as described for
updating/creating
records when mufti-item packages are loaded into revolving bins), it can
display a message to
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prompt the worker to close the bin door, and it can check the state of a bin
door sensor (of the
bin in which the bulk delivered single-item package was loaded) to determine
if the bin door
has been closed. The Loading Program (356) can, for example, sound an error
tone and
display an error message if any scanning action is done before the bin door of
the stationary
bin into which the bulk delivered single-item package was loaded, has been
closed. When
that bin door (238) gets closed, the Loading Program (356) can, for example,
sound a
confirmation tone and display a confirmation message on the SBU display screen
(246).
Other audio, or visual alerts may be utilized. A worker is not required to
close the bin doors
(238) of a stationary bin, unless a package has been loaded into that
stationary bin. A
stationary bin can be allowed to remain empty as the program (356) ends.
When the Loading Program (356) unlocks bin doors (234 or 238) at its start,
the bin
doors (234 or 238) can be pushed out to rest upon locking mechanisms, and the
locking
mechanisms can be set back into a locked position. The SBU bin door lock (for
both
revolving bins and stationary bins) can consist of, for example, three
components: a two-
pronged bin door locking mechanism which can extend from the SBU frame, a
catch slot in
the bin door (234 or 238) into which the bin door locking mechanism can fit to
form the lock,
and a spring-loaded bin door opening mechanism which can extend outward from
the SBU
frame in its natural state when it is not compressed. In one embodiment, the
SBU bin door
locks may only be capable of unlocking a bin door (234 or 238). In this
embodiment, a
closed bin door can always be a locked bin door, and the lock movements which
can be
triggered by programs of the ePD SBU Application do not actually perform the
locking
function. A person applying pressure to the bin door (234 or 238) to close it
can be the action
that locks a bin door (234 or 238). It should be noted while the embodiment of
the locking
mechanism described can contain the specified components, other combination of
components can be possible without departing from the spirit of the invention.
When a SBU bin door (234 or 238) gets closed and Locked, the prongs of the
locking
mechanism can fit inside the bin door catch slot and the heads of each prong
can extend
around the side edges of the catch slot hooking it into a locked position. The
spring action of
the bin door opening mechanism can be constantly trying to extend outward into
its natural
uncompressed position. Because the bin door opening mechanism can be situated
between
the bin door (234 or 238) and the SBU frame, when the bin door opening
mechanism moves
from a compressed state into its natural uncompressed state, it can push the
bin door (234 or
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238) away from the SBU frame. The bin door locking mechanism prongs, when
hooked
around the side edges of the catch slot, can prevent the bin door opening
mechanism from
extending into an uncompressed state, as they hold the bin door (234 or 238)
into place
against the SBU frame, forcing the bin door opening mechanism to be
compressed. When the
bin door lock receives an unlock command from the CDC server, it can contract
the two
prongs of the locking mechanism toward each other, into an unlocked position,
where the
prong heads can be completely within the catch slot, no longer extending
beyond the catch
slot's side edges. Since the prongs no longer remain in position to secure the
bin door (234 or
238), the spring action of the bin door opening mechanism can then extend away
from the
SBU frame pushing the bin door (234 or 238) away from the SBU frame and beyond
the front
end of the prong heads. When the unlock command has finished contracting the
prongs, the
prongs can be released back into the locked position. Even though the prongs
can be in the
locked position, however, the bin door (234 or 238) can be unlocked because it
can already
have been pushed out beyond the front edge of the prong heads and can be
resting in an
unclosed position against the prongs and the bin door opening mechanism. When
a person
applies pressure to push the bin door (234 or 238) closed, the catch slot of
the bin door can
push against the angled front edges of the prong heads, forcing them to
contract in toward
each other until they are narrow enough to fit inside the side edges of the
catch slot. As the
bin door (234 or 238) continues to move toward the SBU frame and the prong
heads have
passed completely inside the catch slot, the prong heads can extend outward to
their normal
position hooking around the inside edges of the catch slot in the locked
position. The bin
door opening mechanism can become compressed as the bin door (234 or 238) is
closed. The
bin door sensor, which can have a component located in the bin door, can for
example, make
an electrical connection to a sensor component located within the SBU frame to
register a
closed status once the bin door (234 or 238) is flat against the SBU frame.
While a sensor
utilizing an electrical connection between a sensor component located within
the bin door and
another sensor component located within the SBU frame can be a preferred
option of
detecting that the revolving bin doors of a SBU are closed, other
sensing/detecting
technologies can be employed without departing from the spirit of the
invention. It should be
understood by one skilled in the art that other sensor arrangements are
possible without
departing from the spirit of the invention.
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When there are no available revolving or stationary bins remaining in a SBU
(158),
the Loading Program (356) can, for example, sound a message alert tone and
display a
message requesting the worker to close the revolving bin doors (234). The
action of closing
the revolving bin doors (234) of a SBU (158) while the Loading Program (356)
is running for
that SBU (158), can end the Loading Program (356) for that SBU (158). A CDC
worker can
use a configuration key to unlock the revolving bin doors (234) from the open
position, and
the revolving bin doors (234) can fall against their corresponding bin door
locking
mechanisms. The worker can push the revolving bin doors (234) firmly against
their locking
mechanisms until they get locked into place. As the Loading Program (356)
determines that
all the revolving bin door sensors are registering a closed status, it can,
for example, sound a
confirmation tone, display a confirmation message that the program has ended
successfully,
and end. A worker can then disconnect their hands-free scanning device or
other suitable
scanning device from the SBU scanner port (242) and can proceed on to the next
SBU (158)
listed on the Loading Guide Report. If the worker did not close all of the
revolving bin doors
to end the program (356) successfully, the Loading Program (356) can, for
example, sound an
error tone and display an error message, indicating that one of the revolving
bin doors (234)
has not been closed properly. In one embodiment, this validation step can
occur when that
worker tries to scan their employee id card to log into another SBU (158). In
another
embodiment, a worker can scan a SBU Id barcode on a label affixed to the
exterior of a SBU
to switch from loading one SBU to another instead of scanning an employee id
card, and the
Loading Program (356) can perform the validation step to ensure that all the
revolving bin
doors (234) of a SBU (158) have been closed properly at the time the SBU Id
barcode of
another SBU (158) is scanned. CDC workers do not have to be restricted to
loading bulk
delivered packages into SBU bins in any particular order. Although a Loading
Guide Report
can be used as a guide to make the package loading process more efficient by
pointing
workers toward the SBU's (158) with the most available bins, CDC workers can
load
packages into any available SBU bin, whether or not it is listed on a Loading
Guide Report.
SBU's (158) can be loaded in the same manner regardless of where they can be
located in a CDC 1190-1. Some SBU's (168 and 188 respectively) can be located
in
refrigerated or freezing temperature controlled areas within the CDC I 190-I.
Others can be
located outside the air-conditioned space of a CDC facility 1190-1, for
example, on trailers or
under covered areas in a CDC's parking lot. The practice of using SBU's (158)
outside of a
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CDC 1190-1 in a temporary fashion can be employed to provide additional bin
capacity to
accommodate extremely high seasonal volumes of packages delivered in bulk.
After the team of CDC workers finishes loading all the bulk delivered packages
of a
delivery shipment in one CDC 1190-1, the team can travel to another CDC 1190-1
where a
S delivery shipment was received, to load the packages of that delivery
shipment. Optionally, a
program can be used to create an exception report that can compare the Package
Id's having a
particular Delivery Shipment Id (the bulk delivered packages in a particular
delivery
shipment) against the Package Id's on the Bin Inventory table 1300 of the CDC
1190-1
having the CDC Id embedded within that Delivery Shipment Id (the bulk
delivered packages
that have been loaded into bins at the CDC 1190-1 where that delivery shipment
was
delivered). This exception report can be created at either the CDC 1190-1 by a
CDC worker
before leaving for another CDC 1190-1 or by a RDC worker at the destination
RDC 1180-1
from which the delivery shipment was sent. The exception report can be used to
help ensure
that the bulk delivered packages of a delivery shipment are accounted for and
to identify and
1S investigate packages that are shipped from a destination RDC 1180-1 but not
loaded into a
SBU (1S8).
Following the loading of bulk delivered packages into SBU's (1S8) as described
in
step 1144, notification contacts can be made according to step 1148.
Recipients can receive
electronic notification messages to alert them that bulk delivered packages
have been
delivered to a CDC 1190-1 for them. The electronic notification can be an
automated
message delivered by a telephone call, e-mail, facsimile machine, or an
alphanumeric pager.
Several programs and tables can be employed by the ePD Delivery Process to
provide
flexibility in the method and timing of sending electronic notification
messages to recipients
to alert or remind them that they have one or more bulk delivered packages
ready to be picked
2S up from a CDC 1190-1. Recipients can be given a great number of choices in
how and when
they wish to be contacted by an ePD shipper for bulk delivered package
delivery notification.
At a minimum, a recipient (which may or may not be the customer who ordered
the items of
the bulk delivered package) can be required to provide at least one phone
number or e-mail
address as their primary contact. A recipient can also provide secondary
contact information
and can choose to be contacted by both the primary and secondary contacts each
time, or to
be contacted using the secondary contact only when the primary contact fails.
For each
contact that a recipient provides to an ePD shipper, the recipient can specify
the type of
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contact (for example, a value such as "phone" for telephone, facsimile, or an
alpha-numeric
pager reached via a telephone number or a value such as "e-mail" for e-mail or
an alpha-
numeric pager reached via an Internet address), the contact phone number or e-
mail address,
the frequency of which the recipient wishes to receive reminder messages after
the initial
notification message (which can be measured for example, in the number of
hours between
reminder messages), and if the contact type is a value such as "phone", the
recipient can
specify a calling window start time and end time. A recipient's notification
preference
information can be stored on their Customer record 1256, and can be updated
through an
interface connected to the ePD Billing & Maintenance application, for example,
a web-page-
based interface accessible by customers and recipients
A New Package Notification Program (358) can run as a service on a CDC's 1190-
1
processing server or a remote server, to set up the information needed to
trigger an electronic
notification to a recipient. The New Package Notification Program (358) can
work with the
Notification Check 1310 and Customer 1256 tables to create new and update
existing records
on a Notification Queue table 1311. Records on a Notification Queue table 1311
can be used
later by a Notification Program (360) to initiate an electronic notification
to notify or remind
a recipient to pick up at least one bulk delivered package at a CDC 1190-1.
The New
Package Notification Program (358) can continually monitor and read the
Notification Check
table 1310 to find the Customer Id on records that were written as bulk
delivered packages
were loaded into SBU's (158). One Notification Check record 1310 can be
created for each
bulk delivered package that was loaded into a SBU (158) at a CDC 1190-1. As
the New
Package Notification Program (358) reads each Customer Id on the Notification
Check table
1310, it can search the Notification Queue table 1311 for a record having that
Customer Id, to
determine whether the recipient already has a record on the Notification Queue
table 1311 or
whether a new record should be added to the table for him. A recipient can
already be on the
Notification Queue table 1311 if the recipient was added for a different bulk
delivered
package that the recipient has not yet picked up. In one embodiment, a
recipient may only
have one Notification Queue record 1311 for a CDC 1190-1 at one time, and that
record 1311
can remain until that recipient has unloaded all of their bulk delivered
packages from the
SBU's (158) of that CDC 1190-1. If a recipient already has a record on the
Notification
Queue table 1311 , the program (358) can update the recipient's existing
record 1311, for
example, by incrementing the Total Number of Packages field by one and setting
the New
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Indicator field to a value such as "yes". If the recipient does not already
have a record on the
Notification Queue table 1311, the New Package Notification Program (358) can
use the
Customer Id to select information from that recipient's record on the Customer
table 1256,
and create a new record for the recipient on the Notification Queue table
1311.
The new record can be created on the Notification Queue table 1311 for the
recipient,
fox example: the Customer Id can be set to the value on the current
Notification Check record
1310; Record Date/Time can be set to the current date/time; Total Number of
Packages can
be set to "1"; New Indicator can be set to a value such as "Yes"; First
Notification Date/Time,
Last Primary Contact Date/Time, Last Secondary Contact Date/Time, and Next
Contact
Date/Time can have no value (depending upon the database management system a
date/tirne
field having no value can actually have a null value or an initialized
date/time value); Number
of Primary Attempts and Number of Secondary Attempts can be set to "0"; Next
Primary
Contact Date/Time and Next Secondary Contact Date/Time can have no value or
can be set to
the value of the Primary Calling Window Start Time and the value of the
Secondary Calling
Window Start Time (both from the Customer record 1256) respectively, depending
upon the
current time. If the current time precedes, for example, the value of the
Primary (or
Secondary) Calling Window Start Time field on the selected Customer record
1256, the value
of the Next Primary (or Secondary) Contact DatelTime field on the Notification
Queue record
1311 can be set to a date/time value consisting of the current date and the
time of the Primary
(or Secondary) Calling Window Start Time. If the current time is later than
the Primary (or
Secondary) Calling Window End Time field on the selected Customer record 1256,
the value
of the Next Primary (or Secondary) Contact Date/Time can be set to a date/time
value
consisting of the following date and the time of the Primary (or Secondary)
Calling Window
Start Time. If the current time is between the Primary (or Secondary) Calling
Window Start
Time and the Primary (or Secondary) Calling Window End Time, or if the primary
(or
secondary) contact does not have a calling window defined, the Next Primary
(or Secondary)
Contact Date/Time can have no value.
Whether the New Package Notification Program (358) updates an existing
Notification Queue record 1311 or creates a new one when processing a
Notification Check
record 1310, it can delete the Notification Check record 1310 as part of its
processing. The
program (358) can continue to read Notification Check records 1310 and perform
the
processing as previously described until there are no remaining records on the
Notification
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Check table 1310. After it has processed and deleted all the records on the
Notification
Check table 1310, the New Package Notification Program (358) can monitor the
Notification
Check table 1310 for new records to process. The New Package Notification
Program (358)
can be configured to monitor the Notification Check table 1310 at
predetermined intervals of
time.
The Notification Program (360) is another program, which can run continuously
on
the CDC server or on a remote server as a service. It can read the
Notification Queue table
1311 and can, for example, compare the Next Contact Date/Time field of each
record against
the current date/time. If the Next Contact Date/Time has no value or a value
prior to the
current date/time, the Notification Program (360) can attempt to send an
electronic
notification to the recipient using the primary and/or secondary contact
information. If the
Next Contact Date/Time is later than the current date/time, the Notification
Program (360)
can skip the record and evaluate the next one. When the Notification Program
(360) finishes
reading the last Notification Queue record 1311 listed on the table, it can
return to the first
record on the table and repeat its processing to evaluate the remaining
records on the table. If
the Notification Program (360) is able to skip all the records listed on the
Notification Queue
table 1311 when making a full pass through the table to evaluate the records,
it can begin
another pass through the table to evaluate the records again, after optionally
pausing for a
predetermined amount of time. The length of time the Notification Program
(360) pauses, if it
pauses at all can depend upon how it is configured.
If the Notification Program (360) determines that an electronic notification
should be
sent to the recipient on a Notification Queue 1311 record, it can compare the
Next Primary
Contact Date/Time to the current date/time. If the Next Primary Contact
Date/Time has no
value or a value prior to the current dateltime, the program (360) can use,
for example, the
value of the Customer Id field to select the Customer record 1256 of the
recipient for which
the notification is being sent, and can then use the data on the Notification
Queue 1311 record
and the selected Customer record 1256 to compile the input data needed to run
either an
Auto-call Program (362) or an Auto-e-mail Program (364). Before compiling the
input data,
the Notification Program (360) can evaluate the values of the Primary Contact
Frequency
field on the selected Customer record 1256 and the Last Primary Contact
Date/Time on the
Notification Queue record 1311. If the value of Primary Contact Frequency is
zero and the
Last Primary Contact Date/Time field has a value, the Notification Program
(360) can skip
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the remaining processing steps involved in sending a notification message to
the primary
contact, and can evaluate the value of the Dual Notification Indicator on the
Customer record
1256 to deternzine if it should compare the Next Secondary Contact Date/Time
against the
current date/time or begin processing the next Notification Queue record 1311.
Recipients
that specify that they do not wish to receive reminder notification messages
after the first
primary or secondary contact is made, can have a value of zero in the Primary
(or Secondary)
Contact Frequency field on their Customer records 1256.
If the value of the Primary Contact Frequency is not zero or if the Last
Primary
Contact Date/Time field has no value, the Notification Program (360) can
calculate one input
data value -- the number of days since the first notification -- by
subtracting the First
Notification Date/Time on the current Notification Queue record 1311 from the
current
date/time and rounding down to the number of whole days. The program can
compile other
input data values by selecting, for example, the Primary Contact
Number/Address value from
the Customer record 1256, the First Notification Date/Time, Total Number of
Packages, and
New Indicator values from the Notification Queue record 1311, the current
date/time, and the
value of the current CDC's 1190-1 address. The value of the current CDC's 1190-
1 address
can be pre-configured for the instance of the program (360) running on the
current CDC's
1190-1 server. If the value of Primary Contact Type on the selected Customer
record 1256 is
a value such as "phone", the Notification Program (360) can initiate the Auto-
call Program
. . (362) and pass it the compiled input data values. The Auto-call Program
(362) can use the
Primary Contact Number/Address value to dial the recipient's phone number and
play a pre-
recorded message to notify or remind the recipient that there is at least one
bulk delivered
package at the CDC 1190-1, ready to be picked up. The pre-recorded message can
include at
least the value of the current CDC's 1190-1 address (the values in the Address
1 and Address
2 fields of the current CDC's 1190-1 record on the CDC table 1252), and can
also include,
but is not limited to, the current date/time, the value of the Total Number of
Packages, an
indication of whether or not a bulk delivered package has been delivered since
the last
notification message (determined from the New Indicator value), the number of
days since
the first notification (calculated as previously described), the First
Notification Date/Time,
general shipper policy information (including early pickup incentive discounts
and late
pickup penalties), contact information to submit questions, and other general
information.
After the Notification Program (360) calls the Auto-call Program (362), it can
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increment the value of the Number of Primary Attempts by one on the
Notification Queue
record 1311 and wait for the Auto-call Program (362) to finish its processing
and return a
confirmation output. If the Auto-call Program (362) returns an output
indicating that an
electronic notification message was sent successfully, the Notification
Program (360) can
update the Notification Queue record 131 l, for example: if the First
Notification Date/Time
has no value, it can be set to the current date/time; Last Primary Contact
Date/Time can be set
to the current date/time; Next Primary Contact Date/Time can be set to the
current date/time
plus the number of hours in the Primary Contact Frequency on the Customer
record 1256
(adjusted to the next earliest Primary Calling Window Start Time if the
calculated value does
not fall between the Primary Calling Window Start Time and the Primary Calling
Window
End Time); Number of Primary Attempts can be set to zero; and if the value of
the Dual
Notification Indicator on the selected Customer record 1256 is a value such as
"no", the Next
Contact Date/Time can be set to the same value as the Next Primary Contact
Date/Tirne field.
The updates which can be made to the Notification Queue 1311 record by the
Notification
Program (360) can reset the record to trigger the sending of another
electronic notification
message to the Primary Contact Number/Address after the Primary Contact
Frequency
interval elapses.
In addition to updating the other fields on the Notification Queue record 1311
'after
receiving a successful confirmation output, the program (360) can evaluate the
value of New
Indicator field on the Notification Queue record 1311. If it is set to a value
such as "yes", the
program (360) can reset it to a value such as "no" and select records from the
Bin Inventory
table 1300 having a Status value such as "loaded" and a Customer Id equal to
the value on the
Notification Queue record 1311. The program (360) can update each selected Bin
Inventory
record 1300, for example, setting the Status to a value such as "notified" and
Notiftcation
Date/Time to the value of the Last Primary Contact Date/Time. The program
(360) can also
create, for example, a new record in a Notification Update data file for each
Bin Inventory
record 1300 it updates, writing the Package Id and Notification Date/Time from
the updated
Bin Inventory record 1300 to the data file. If the New Indicator field being
evaluated has a
value such as "no", the program (360) can continue with its next processing
step.
After updating the Notification Queue table 1311, Bin Inventory table 1300,
and
Notification Update data file records following the receipt of a successful
confirmation output
for a primary contact, the value of the Dual Notification Indicator on the
selected Customer
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record 1256 can be evaluated. If the Dual Notification Indicator field has a
value such as
"no", the program (360) can proceed to process the next Notification Queue
record 1311. If it
has a value such as "yes" the Notification Program (360) can follow processing
steps that can
be similar to those described for sending an electronic notification message
to the primaiy
contact, except that the secondary contact information can be read and
updated. One
exception to secondary contact processing steps using secondary contact
information can be
that after a successful confirmation output is received by the Notification
Program (360) for a
secondary contact, the Notification Program (360) can update the Next Contact
Date/Time to
the same value as the Next Primary Contact Date/Time field, instead of the
value of the Next
Secondary Contact Date/Time field. In addition to when the Dual Notification
Indicator for a
recipient has a value such as "yes", there can be other situations in which
the Notification
Program (360) can use secondary contact information to send an electronic
notification
message. Those situations can include, but are not limited to: a situation
where the Next
Contact Date/Time and the Next Secondary Contact Date/Time are prior to the
current
date/time, but the Next Primary Contact Date/Time is later than the current
date/time; and a
situation where the output return received from the Auto-call Program (362)
indicates that the
primary contact attempt was unsuccessful.
If both the primary and secondary contact attempts are unsuccessful, the
Notification
Program (360) can proceed to process the next record listed on the
Notification Queue table
1311. The Notification Program (360) can attempt to process the unsuccessful
record 1311
again on each successive pass it makes through the Notification Queue table
1311, until the
record 1311 gets updated as successful or the Number of Primary Attempts and
Number of
Secondary Attempts on the record 1311 reach a predefined limit. Once the
predefined limits
in the number of attempts fields are reached, the Notification Program (360)
can reset the
values in both number of attempts fields to zero and can reset the Next
Contact Date/Time to
a future date/time, which can be a predefined time interval ahead of the
current date/time.
The Notification Program (360) can process primary and secondary contacts
having a
Primary (or Secondary) Contact Type value such as "e-mail" using the same
processing steps
as described for sending an electronic notification message for a contact
having a Primary (or
Secondary) Contact Type value such as "phone", except that it can initiate the
Auto-e-mail
Program (364) instead of the Auto-call Program (362) and it does not need to
wait for a
confirmation output return from the Auto-e-mail Program (364) before
continuing its
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processing. The Notification Program (360) can assume notification e-mail
messages to be
sent successfully, and can update the Notification Queue table 1311, Bin
Inventory table
1300, and Notification Update data file records in the same way as it would
after receiving a
successful confirmation output from the Auto-call Program (362), immediately
after it
initiates the Auto-e-mail Program (364). The Auto-e-mail Program (364) can use
the Primary
(or Secondary) Contact Number/Address to send an e-mail message to the
recipient. The
same data input variables that can be passed to the Auto-call Program (362)
can be passed to
the Auto-e-mail Program (364) and the text of the prerecorded script used for
the phone
message can be the text of the e-mail message. The same updates can be made to
the
Notification Queue table 1311, Bin Inventory table 1300, and Notification
Update data file
records during processing. Although e-mail notification messages can be
assumed to be sent
successfully when transmitted, an E-mail Error Checking Program (366) can
search the inbox
of the Internet account used by the Auto-e-mail Program (364) for returned e-
mail error
messages from unsuccessful e-mail transmissions. The E-mail Error Checking
Program
(366) can read the e-mail address reference in the returned e-mail error
message, select the
Customer table record 1256 containing that e-mail address value in either the
Primary
Contact Number/Address or Secondary Contact Number/Address, and create a
record in a
Notification Error data ftle containing the Customer Id, the e-mail address
causing the error,
and the Primary (or Secondary) Contact Number/Address that did not cause the
error. The
Notification Error data file can later be used to contact recipients to
correct invalid e-mail
addresses.
The ability for a customer and/or recipient to view the status and CDC
location 1190-
1 of items that have been ordered but have not yet picked up can be provided
using , for
example, a web-page-based interface, which can have read-only access to
information on a
shipper's RDC and/or CDC servers. In a one aspect of the invention, a customer
or recipient
can log into an Internet site specific to a shipper or one that is common
across many ePD
shippers to view delivery information including, but not limited to, the
number of bulk
delivered packages currently in a CDC 1190-1 for the recipient to retrieve,
the SBU Id's of
each SBU (158) containing a bulk delivered package for the recipient to
retrieve, the elapsed
time that each bulk delivered package has been in a CDC 1190-1 since
notification of
delivery was first made, the recipient's notification preferences, the
customer or recipient's
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ePD Account Balance, and the Status of any CDC outbound package sent by the
customer
which has not yet been picked up by its package recipient.
In FIG. 6, there is depicted an exemplary Customer Distribution Center (CDC).
The
CDC of FIG. 6 can comprise the following entities: backroom aisle (132),
holding cage (134),
backroom video surveillance camera (136), package bag recycling chute (138),
package bag
recycling collection tank (140), package bag recycling machine (142), mobile
putaway
conveyor unit (143), CDC delivery dock door (144), CDC receiving dock conveyor
extension
(145), main room delivery entrance door (146), returns processing entry point
(148), returns
video surveillance camera (150), customer service video conferencing station
(152),
backroom area (154), returns conveyor (156), SmartBin Unit machine (158),
outbound
package processing workstation (159), side aisle (160), cross aisle (162),
temperature
controlled storage room door (164), temperature controlled storage room wall
(166),
temperature controlled SmartBin Unit machine (168), main aisle (170), entrance
station/entrance station door (172), entrance station video surveillance
camera (174), exterior
entrance doors (176), inner entranceway area (177), exterior video
surveillance camera (178),
exit way video surveillance camera (180), exterior exit door (182), exit aisle
(184), interior
exit door (186), SmartBin Unit machine - frozen articles (188), returns
processing
workstation (189), interior video surveillance camera (190), and holding cage
door (192).
A further embodiment of the invention can include one or more customer service
video conferencing stations (152) located in a CDC 1190-1 that can be used by
a recipient to
contact a customer service worker specific to a shipper or one that supports
more than one
shipper. The recipient can ask questions or report a discrepancy involving a
bulk delivered
package, a CDC outbound package, or an item return package. The recipient can
have the
ability to see the customer service worker and their immediate surrounding
area and the
customer service worker can have the ability to see the recipient and the
immediate
surrounding area including any packages or nearby SBU's (158), outbound
package
processing workstations (159), or returns processing workstations (189).
Customer service
can be provided to recipients and customers across every CDC location 1190-1,
24 hours a
day, seven days a week by a centralized group of customer service workers
without incurring
the cost of staffing one or more customer service representatives in every
physical location.
Another aspect can include various interior video surveillance cameras (190)
and exterior
video surveillance cameras (178), located at a CDC 1190-1, that can be
monitored remotely
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by a security service or a shipper's in-house security personnel. Security
personnel based in
the local markets can be on call to respond as needed to situations, which may
require the
interaction of a security worker. Any improper actions can also be captured on
video for later
use in prosecuting a wrongdoer. Security services can be provided remotely to
all CDC
locations, 24 hours a day, seven days a week by a centralized security service
working in
conjunction with local on-call security response personnel without incurring
the cost of
staffing one or more security workers in every physical location.
Returning to the notification step 1148, the recipient can retrieve (or pick
up) one or
more bulk delivered packages as described in step 1150. After receiving one or
more
notification phone calls, e-mails, or text page messages, a recipient can
travel to the CDC
1190-1 identified in the notification message (the same CDC 1190-1 which the
customer
selected as the destination centralized pickup location when the customer
ordered the items
from retailers) to pick-up their bulk delivered packages. For illustration,
the recipient can
chose to park in the CDC's I 190-1 parking lot, walk to the closest package
cart keeper
machine near their parking space, run their ePD customer access card through
the package
cart keeper's card reader, and press the release button to release a package
cart from the
package cart keeper machine. The recipient can push the cart through the
parking lot and
through the CDC's 1190-1 exterior entrance doors (176), which can
automatically open for
the recipient as the recipient approaches them. A sensor can be used to
automatically open
the doors (176) using technology similar to the technology commonly found on
the automatic
opening doors of supermarkets and other public places. The recipient can push
their cart
through the exterior entrance doors (176) and up to one of the entrance
station doors (172) in
the CDC's 1190-1 inner entranceway area (177).
There can be one or more entrance stations (172) located in the inner
entranceway
area (177) of a CDC I 190-I. Each one can consist of the following components:
a card
reader, a keypad, a tape printer, a display screen, and an electronic locking
door. The
components can be wired to the CDC server through networking cables to pass
data from the
card reader and keypad components to the CDC server and to pass commands and
data from
the CDC server to the display screen, tape printer, and electronic locking
door components of
the entrance station (172).
The recipient can run their ePD customer access card through the entrance
station card
reader and can key in their personal identification number (PIN) on the
entrance station
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keypad. An ePD customer access card can have, for example, a magnetic data
strip that
contains at least the recipient's Customer Id and can optionally include other
data used for
security validation. The recipient's actions can initiate or cause to be
initiated, an instance of
a Package Location Report Program (368) to run on the CDC server. The Package
Location
Report Program (368) can validate the scanned card and entered PIN by using
the Customer
Id on the access card to select the Customer record 1256 and then comparing
the entered PIN
value against the PIN value on the selected Customer record 1256. If the
entered PIN does
not match, the Package Location Report Program (368) can, for example, sound
an error tone
and/or display an error message on the entrance station display screen to
indicate that the
entered PIN is not valid for the access card. Alternately, other audio and or
visual alerts can
be used. If the entered PIN matches, the Package Location Report Program (368)
can search
the Bin Inventory table 1300 for all the records that have a Customer Id equal
to the one read
from the access card. The Package Location Report Program (368) can generate
and assign,
for example, a Quick Code to all of the Bin Inventory records 1300 found for
the recipient
(having the Customer Id of the scanned access card). The Quick.Code can serve
as a
temporary alias for a recipient's Customer Id and can be a random number, for
example, four
digits in length. Prior to generating a new Quick Code for a recipient, the
Package Location
Report Program (368) can search a Quick Code table 1313 for the Customer Id
read from the
access card to determine if the recipient already has an active Quick Code. If
the recipient
had previously used their customer access card to enter the CDC, following the
last time a
Quick Code Reset Program (376) had been run for that CDC, the recipient can
already have
an active Quick Code. If a recipient already has an active Quick Code, instead
of generating
a new Quick Code for the recipient, the Package Location Report Program (368)
can read that
active Quick Code from the record on the Quick Code table 1313 having that
recipient's
Customer Id and can write that active Quick Code to the Bin Inventory records
1300 selected
using the recipient's Customer Id. If the recipient's Customer Id is not found
on the Quick
Code table 1313, by the Package, Location Report Program (368), 'the program
(368) can
generate a new random number as a Quick Code for the recipient. In generating
a random
number for the Quick Code, the Package Location Report Program (368) can
validate the
combination of the recipient's PIN and the generated random number against the
Quick Code
table 1313 to ensure that the generated random number and PIN combination is
not already
active for another recipient. If the Package Location Report Program (368)
finds the
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randomly generated number in combination with the same PIN number on the Quick
Code
table 1313 it can attempt to generate a different random number to combine
with the
recipient's PIN and can check it against the Quick Code table 1313 to ensure
that the
combination is not already in use for a different recipient. When the Package
Location
Report Program (368) generates a Quick Code number that is not already listed
in
combination with a PIN matching the current recipient's PIN on the Quick Code
table 1313,
it can create a new record on the Quick Code table 1313 by writing that number
in the Quick
Code field and writing the recipient's Customer Id and PIN to the Customer Id
and PIN fields
on the Quick Code table 1313. The Package Location Report Program (368) can
also write
that Quick Code number to the Quick Code table 1313 and to the Quick Code
field of each
Bin Inventory record 1300 it selected for that recipient. Recording assigned
Quick Code
numbers to the Quick Code table 1313 can ensure that no two recipients will
have the same
combination of Quick Code and PIN at a given CDC 1190-1 over a certain time
period until
Quick Codes are reset. A Quick Code Reset Program (376), which can be used to
reset
(delete all Quick Code records from) the Quick Code table 1313, can be
scheduled to run at a
different frequency in each CDC 1190-1. In one embodiment of the ePD Delivery
Process,
the Quick Code Reset Program (376) can be scheduled to reset the Quick Code
table 1313
each night.
After assigning Quick Codes to the Bin Inventory records 1300 selected for the
recipient, the Package Location Report Program (368) can create a Location
Report listing the
Quick Code and all the SBU Id numbers of the selected Bin Inventory records
1300. The
Location Report can be printed on the tape printer at the entrance station
(172) where the
recipient swiped their ePD customer access card and entered their PIN number.
The Location
Report can be fomnatted to have, for example, the Quick Code printed on the
top line next to
a heading such as "Quick Code = ", a blank second line, and a listing of each
SBU Id on a
separate line below an underlined header such as "SBU locations". The SBU
locations can be
listed in SBU Id sequence, and if a recipient has more than one bulk delivered
package in a
SBU (158), that SBU (158) can be listed once for each bulk delivered package
that it holds
for that recipient. After printing the report, the Package Location Report
Program (368) can
unlock and automatically open the entrance station door (172) for a short
period of time to
allow the recipient to grab the report from the tape printer and enter the CDC
1190-1 with
their package cart.
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Basic information about using an entrance station (172) can be posted in the
inner
entranceway area (177) near the entrance stations (172), including a message
to tell recipients
to press an instructions key on the entrance station keypad to print detailed
instructions on
how to operate an entrance station, read a Location Report, and operate a SBU
(158). When
recipients press the instructions key on the entrance station keypad, the CDC
server can print
a standard instructions report listing the basic instructions on how to
maneuver through the
CDC 1190-1. The printer could be, but is not limited to a tape printer, laser,
inkjet, or dot
matrix printer or any combination thereof.
Continuing with the illustrative example, after passing through the entrance
station
door (172), the recipient can walk through the aisles of the CDC 1190-1 using
posted SBU
location number range signs to guide them to the SBU's (158) listed on their
Location
Report. Upon arriving at each SBU (158) listed on their report, the recipient
can key in the
Quick Code listed on their report and their PIN using the SBU's keypad (244)
to retrieve each
bulk delivered package listed on.their Location Report from an SBU (158). When
the Quick
Code and PIN are keyed in, the information can be passed through the SBU (158)
and sent to
the CDC server along with the SBU Id of the SBU (158). An Unloading Program
(370) of
the ePD SBU Application can be initiated and it can search the records on the
Bin Inventory
table 1300 having the SBU Id of the SBU (158) from which the data was sent.
The
Unloading Program (370) can search the Bin Inventory records 1300
corresponding to that
SBU's bins for the Quick Code and PIN entered by the recipient. The Unloading
Program
(370) can search for the records 1300 corresponding to a SBU's stationary bins
before
searching for the records 1300 corresponding to its revolving bins. If the
Unloading Program
(370) finds a stationary bin's record 1300 having a Quick Code and PIN that
matches the
values entered by the recipient, it can send a display command to the SBU
display screen
(246) to display the bin door number or numbers corresponding to the bin
containing the
recipient's bulk delivered package. The Unloading Program (370) can also send
an unlock
command to the bin door locking mechanism of one or more of the stationary bin
doors
(238), depending upon the configuration of the stationary bins , to open the
bin doors (238) of
the bin containing the recipient's bulk delivered package. The Unloading
Program (370) can
also, for example, write a new record to a Package Pickup table 1312 and a
Pickup Update
data file, and can update the selected Bin Inventory record 1300 to initialize
it as an available
bin.
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The Package Pickup table 1312 of the SBU Application can have all the same
fields
as the Bin Inventory table 1300 except for Status. It can also have two
additional fields that
are not on the Bin Inventory table 1300 -- CDC Id and Pick-up Date/Tirne. To
create the new
Package Pickup record 1312, the Unloading Program (370) can copy all the data
from the Bin
Inventory record 1300 except for Status. On the new Package Pickup record, CDC
Id can be
set to the value of the current CDC 1190-1 in which the application is
running, and Pick-up
Date/Time can be set to the current date/time. The Unloading Program (370) can
create the
new Pickup Update data file record by writing the Package Id from the selected
Bin Inventory
record 1300 and the Pickup Date/Time as the current date/time. To initialize
the Bin
Inventory record 1300 as an available bin, the Unloading Program (370) can set
its Status
equal to a value such as "available" and can delete the values from the data
fields related to
the bulk delivered package -- Customer Id, PIN, Quick Code, Package Id,
Delivery Employee
Id, Shipper Id, Delivery Date/Time, and Notification Date/Time.
If the Unloading Program (370) finds a revolving bin record matching the Quick
Code
and PIN, it can call or cause to be called, the Bin Positioning Program (372)
to determine the
movement needed to position the master bin containing the recipient's bulk
delivered
package into the unloading position. Before calling the Bin Positioning
Program (372), the
Unloading Program (370) can determine which master bin is currently in the
unloading
position for the current SBU (15~) by selecting the Load Position Master Bin
Id value from
the SBU Settings table 1314. The Unloading Program (370) can pass the values
of the
selected Load Position Master Bin Id and the Master Bin Id (from the selected
Bin Inventory
record 1300) of the bin containing the recipient's bulk delivered package to
the Bin
Positioning Program (372). The Bin Positioning Program (372) can use the Load
Position
Master Bin Id value to search a Bin Movement table 1315 for the movement
required to move
the master bin containing the recipient's bulk delivered package into the
unloading position.
The Bin Movement table 1315 can show the movement needed to move the selected
bin into
the unloading position, relative to the unloading position if moving in the
clockwise direction
(when referring to bin movement in this disclosure, moving a SBU's front bins
upward and
back bins downward is considered a clockwise direction). For example, if the
selected
' Master Bin Id is "OS" and the Master Bin Id currently in the unloading
position is "03", the
movement needed to move Master Bin Id "OS" into the unloading position can be
"-2". Since
master bins can be numbered in the clockwise direction, Master Bin Id "OS" can
be two
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positions beyond the unloading position in the clockwise direction in this
example, and would
need to be moved counterclockwise for a distance of two positions. In another
example,
where the SBU (158) has a total of eighteen bins, the selected Master Bin Id
is "17" and the
Master Bin Id in the unloading position is "03", the required movement needed
to move
Master Bin Id "17" into the unloading position can be "4", because "17" can be
four positions
away from the unloading position in the counterclockwise direction and
therefore would need
to be moved four positions in the clockwise direction to reach the unloading
position. If the
master bin containing the recipient's bulk delivered package is already in the
unloading
position the Bin Positioning Program (372) can calculate the required movement
to be "0"
and bypass the step of sending a motor command to the SBU (158).
After determining the movement required to move the master bin containing the
recipient's bulk delivered package into the unloading position, the Unloading
Program (370)
can check all the bin door sensors on the revolving bin doors (234) to make
sure that all the
revolving bin doors (234) are in the closed position before moving the master
bins. If any of
the revolving bin doors (234) are not fully closed (and thus locked), the
Unloading Program
(370) can display message on the SBU's display screen (246) to request the
recipient to close
the revolving bin doors (234). The SBU (158) can continue to display the
message and
refrain from performing any other actions until the doors (234) are closed.
Once all the
revolving bin doors (234) are in the closed position, the Unloading Program
(370) can send a
motor command, with the bin movement calculated by the Bin Positioning Program
(372), to
the SBU motor to move the selected master bin into the unloading position. The
program
(370) can also send a display command to the SBU display screen (246) to
display the bin
door number or numbers corresponding to the bin containing the recipient's
bulk delivered
package, and it can send a configuration command to one or more of the bin
door
configuration mechanisms to move the bin door configuration bolts into the
correct sequence
for the Configuration Code of the selected bin. The Unloading Program (370)
can check the
value of the Door Configuration Code field on the SBU Settings record 1314
having the
current SBU Id to find the current configuration of the revolving bin doors
(234), and can
compare it to the Configuration Code on the Bin Inventory record 1300 of the
bin containing
the recipient's bulk delivered package to determine the needed configuration
commands. If
the configuration bolts are already in a workable sequence for the selected
bin, then
configuration commands may not need to be sent. When the SBU motor and bin
door
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configuration mechanisms have completed their actions successfully, the
Unloading Program
(370) can send an unlock command to one or more of the bin door locking
mechanisms to
open the bin doors (234) corresponding to the configuration of the selected
bin. After
successfully unlocking the revolving bin doors (234), the Unloading Program
(370) can create
and update records in a manner consistent with the way it does when it unlocks
a stationary
bin, writing a new record to the Package Pickup table 1312 and the Pickup
Update data file,
and updating the Bin Inventory record 1300 to initialize it as an available
bin. The Unloading
Program (370) can also update the SBU Settings table 1314 when it unlocks a
revolving bin,
setting the Load Position Master Bin Id equal to the Master Bin Id value of
the selected bin
and the Door Configuration Code to the value which describes the current
position of the bin
door configuration bolts.
If the SBU gets listed on the recipient's Location Report more than once,
indicating
that there is more than one bulk delivered package for that recipient in that
SBU (158), the
recipient can reenter the Quick Code and PIN for each bulk delivered package
listed to
retrieve the bulk delivered packages one at a time. This can ensure that the
recipient makes
an effort to receive each bulk delivered package and can eliminate the
potential problems of
opening several bins from one recipient action. An example of such a problem
being that a
recipient can retrieve fewer bulk delivered packages than the number released
from a SBU
(158) and can leave one or more bulk delivered packages behind, which could be
taken by
another person.
The ePD SBU Application's programs and tables can track information that can
be
used by shippers to administer financial incentives when bulk delivered
packages get picked
up early or financial penalties when bulk delivered packages get picked up
late. A financial
incentive is a discount which can include, but is not limited to, a refund of
money, a rebate, a
credit towards a future transaction, and a coupon. Each shipper can set their
own policies
regarding incentives and penalties, and those policies can be changed at the
discretion of each
shipper. The data used to track recipient pick up activity can be captured on
the Package
Pickup table 1312 as recipients remove their bulk delivered packages from SBU
bins. Pickup
Date/Time can be compared against Notification Date/Time on the Package Pickup
table
1312 to determine how long a bulk delivered package remained in a SBU bin
following
delivery notification. A running total of the net cumulative incentive
discount or penalty
charge can be calculated and tracked for each shipper or in total across all
shippers, for a
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customer or recipient, in a field such as an ePD Account Balance field on a
Customer record
1256. A penalty is a disincentive that can be used as a deterrent. A penalty
can be financial,
for example, a financial penalty can be assessed whenever a recipient fails to
remove a bulk
delivered package from a SBU after a certain date.
S If a recipient accidentally locks a SBU bin with their bulk delivered
package still
inside, for example, by pushing it closed when trying to retrieve the bulk
delivered package
from the SBU (1S8), the recipient can open the bin again, for example, by
pressing a "re-
open" key or key sequence on the SBU keypad (244) and then keying in their
Quick Code and
PIN again. The re-open feature can re-open a bin on a SBU (1S8) that the
recipient had
previously opened using the same entered Quick Code and PIN. When the
recipient presses
the "re-open" key or key sequence, the SBU (1S8) can send a re-open request
including the
SBU Id and the entered Quick Code and PIN to the CDC server. A Re-open Program
(374)
can be initiated and can search the Package Pickup table 1312 for a record
matching the SBU
Id, Quick Code, and PIN sent from the SBU (1 S 8). If the recipient had
retrieved more than
1S one bulk delivered package from the SBU (1S8), the Re-open Program (374)
can select all the
records 1312, and process them in sequence of Pick-up Date/Time starting with
the latest one.
The Re-open Program (374) can function in the same way as the Unloading
Program (370)
with some exceptions. Instead of reading data from the Bin Inventory table
1300, the Re-open
Program (374) can read data from the Package Pickup table 1312. The Re-open
Program
(374) doesn't need to update a Bin Inventory record 1300 to initialize it. The
Re-open
Program (374) doesn't write new records to the Package Pickup table or the
Pickup Update
data file. Also, after the Re-open Program (374) fords the Bin Id on the
Package Pickup table
1312, it can check the Status of that Bin Id on the Bin Inventory table 1300
prior to taking any
action. If the Status is a value such as "available", "re-open", or
"configuration reserved" the
2S Re-open Program (374) can perform the actions required to re-open the bin.
If the Status
does not equal a value such as "available", "re-open", or "configuration
reserved" the Re-
open Program (374) can check the next selected Package Pickup record 1312 if
more than
one was selected, until it finds one having a corresponding Bin Inventory
record 1300 with a
Status value such as "available", "re-open", or "configuration reserved". If
the Re-open
Program (374) cannot find a Bin Id on a selected Package Pickup record 1312
which has the
appropriate status on its corresponding Bin Inventory record 1300, the Re-open
Program
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(374) can, for example, sound an error tone and/or displays an error message
indicating that
there are no bins in the SBU (158) corresponding to the entered Quick Code and
PIN.
The re-open feature can be used when a recipient mistakenly pushes the bin
door (234
or 238) closed when trying to retrieve their bulk delivered package. In that
situation, the
result of the Re-open Program (374) can be to re-open a stationary bin or a
revolving bin that
is already in the unloading position. If the recipient does not use the re-
open feature
immediately after closing the bin door (234 or 238) (if they are unaware of
the re-open feature
and confused as to what to do), they can come back at a later time and use the
re-open feature
to retrieve their bulk delivered package. If a recipient does come back to use
the re-open
feature at a later time, the Re-open Program (374) can move the bin containing
the recipient's
bulk delivered package to the unloading position before unlocking the bin, if
the bins have
been moved since the recipient originally tried to retrieve the bulk delivered
package. When
loading bulk delivered packages into a SBU (158), if a CDC worker comes across
a bin
having a bulk delivered package in it and a Bin Inventory record 1300 with a
Status value
such as "available", the worker can update the Status of the Bin Inventory
record 1300
corresponding to the bin, changing it from a value such as "available" to a
value such as "re-
open". The worker can, for example, scan a "re-open" status update barcode on
their scan
commands sheet, the package label barcode of the bulk delivered package
already in the bin,
and the bin door label of the bin containing the bulk delivered package to
cause the Loading
Program (356) to update the Bin Inventory record 1300 corresponding to that
bin to reflect
that the bulk delivered package has been 'reloaded' with a Status value such
as "re-open". In
this situation, the CDC worker should not remove the bulk delivered package
and load
another bulk delivered package into the bin. If the bulk delivered package
becomes lost, the
next worker to load a bulk delivered package into a bin which previously
contained a bulk
delivered package that a recipient has claimed to have not retrieved can be
easily identified.
When the recipient has retrieved all of their bulk delivered packages from the
CDC
1190-1, the recipient can exit the CDC 1190-1 with their package cart of bulk
delivered
packages by walking through the interior exit door (186), the exit aisle
(184), and the exterior
exit door (182). Both the interior exit door (186) and the exterior exit door
(182) can have
sensors that can automatically open the door for persons exiting from the
inside. This makes
it easy for recipients to exit through the exit corridor, while making it
difficult for someone to
enter the CDC 1190-1 through the exit corridor. The recipient can push their
package cart to
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their car and unload their bulk delivered packages into their car. The
recipient can then return
the package cart to the package cart keeper machine closest to their car, for
example, by
pushing the package cart into the package cart keeper machine, running their
ePD access card
through the machine's card reader, and pressing a "return" button to credit
their account for
returning the package cart. The package cart keeper system can be similar to
the luggage cart
systems used in airports that charge customers a fee to use the carts, and in
some cases refund
part of the fee back to the customer upon returning the cart. In one
embodiment of the ePD
Delivery Process, recipients do not get charged for using package carts at
CDC's 1190-1 as
long as they return them to one of the package cart keeper machines. If a
recipient does not
return a cart, they can be charged a fee, for example, through their ePD
account. This type of
cart system can be used to provide recipients with the convenience of using a
cart to carry
their bulk delivered packages, at no cost. At the same time, it can discourage
recipients from
leaving carts randomly in the parking lot or CDC 1190-1 and can eliminate the
need (and the
associated labor cost) of having workers on site at each CDC 1190-1 to collect
and organize
the carts, as is done, for example at many supermarkets. It should be noted
that a recipient
does not have to acquire a cart to retrieve a package and a CDC can choose not
to employ a
package cart system without departing from the spirit of the invention.
Following the notification update step 1145, the retailer billing step 1135
can be
followed as described. A Notification Update data file can be sent from the
CDC server to
the RDC server at predefined intervals. The CDC Id and the current date/time
can be written
as part of the data file header information. A Notification Update Program
(347) can run on a
RDC server and can process each Notification Update data file received. As the
Notification
Update Program (347) reads through each record in the data file, it can select
all the Order
Detail records 1202 having the Package Id of the current Notification Update
data file record.
The Notification Update Program (347) can update the selected Order Detail
records 1202,
setting their Status to a value such as "notified" and their Notification
Date/Time to the value
on the current Notification Update data file record. After updating the
selected Order Detail
records 1202, the Notification Update Program (347) can use each unique Order
Id of the
updated Order Detail records 1202 to select all the Order Detail records 1202
having that
Order Id. From each group of Order Detail records 1202 selected by Order Td,
the
Notification Update Program (347) can attempt to select records that do not
have a Status
value such as "notified" or "picked up" to determine if there are any Order
Detail records
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1202 of that order, which are not in bulk delivered packages for which the
recipient has been
notified of delivery. If the Notification Update Program (347) can find a
group of Order
Detail records 1202 in which every record has a Status value such as
"notified" or "picked
up", it can select the Order Header record 1200 having the Order Id of the
group and update
that Order Header record's 1200 Status to a value such as "delivered".
A Billing Program (349) can run on the RDC server at each RDC to create a
billing
output data file for the shipper running that RDC. Billing output data files
created for a
shipper can be used by that shipper's billing application to bill retailers
for delivered orders.
To create the billing data file for a shipper, the Billing Program (349) can
select records from
the Order Header table 1200 having the ePD Shipper Id of that shipper and a
Status value
such as "delivered". Order Header records 1200 with a Status such as
"delivered" can
represent customer orders for which all ordered items have been loaded as bulk
delivered
packages into SBU's (158) at a CDC 1190-1, prior to at least one electronic
notification
message being sent successfully to the recipients to notify them of the bulk
delivered package
1 S delivery. As the Billing Program (349) processes each selected Order
Header record 1200, it
can use the Order Id, on the Order Header record 1200, to select the
associated Order Detail
records 1202. The Billing Program (349) can check the Status of the Order
Detail records
1202 to determine if the entire order has been picked up by the recipient (if
the Status of all
the selected Order Detail records 1202 has a value such as "picked up"). If
the Status of all
associated Order Detail records 1202 has a value such as "picked up", the
Billing Program
(349) can set the Status of the current Order Header record 1200 to a value
such as "picked
up". If the Status of any one of the associated Order Detail records 1202 does
not equal a
value such as "picked up", the Billing Program (349) can set the Status of the
current Order
Header record 1200 to a value such as "billed".
The Pickup Update data file can be sent from a CDC server to a RDC server at
predefined intervals. The CDC Id and the current date/time can be written as
part of the data
file header information. A Pickup Update Program (348) can run on a RDC server
and can
process each Pickup Update data file received. As the Pickup Update Program
(348) reads
through each record in the data file, it can select all the Order Detail
records 1202 having the
Package Id of the current Pickup Update data file record. The Pickup Update
Program (348)
can update the selected Order Detail records 1202, setting their Status to a
value such as
"picked up" and their Pickup Date/Time to the value on the current Pickup
Update data file
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record. The Pickup Update Program (348) can also select the Package record
1234 having
the Package Id of the current Pickup Update data file record and can update
its Status to a
value such as "picked up". After updating the selected Order Detail records
1202 and
Package record 1234, the Pickup Update Program (348) can use each unique Order
Id of the
updated Order Detail records 1202 to select all the Order Detail records 1202
having that
Order Id. From each group of Order Detail records 1202 selected by Order Id,
the Pickup
Update Program (348) can attempt to select records that do not have a Status
value such as
"picked up" to determine if there are any Order Detail records 1202 of that
order, which can
be in bulk delivered packages that have not been retrieved by the recipient.
If the Pickup
Update Program (348) can find a group of Order Detail records 1202 in which
every record
has a Status value such as "picked up", it can select the Order Header record
1200 having the
Order Id of the group and can update that Order Header record's 1200 Status to
a value such
as "picked up" if its existing Status is a value such as "billed". If the
existing Status on an
Order Header record 1200 is a value such as "delivered", the Pickup Update
Program (348)
can refrain from updating the Order Header record's 1200 Status. A Status such
as "picked
up" on Order Header 1200, Order Detail 1202, and Package 1234 records does not
affect the
billing process, but can provide information, which can be used in answering
package pickup
inquiries.
In another aspect of the invention, recipients can return ordered items back
to a
retailer using the infrastructure of the ePD Delivery Process. There is shown
in FIG. 13, an
illustrative embodiment depicting the steps that can be used to efficiently
return an ordered
item to a retailer. Recipients can return ordered items at a CDC 1190-2 by
initiating a CDC
Returns Program (378) of the ePD SBU Application which can be running, for
example, on a
returns processing workstation (189). To initiate the CDC Returns Program
(378) to process
the return of an ordered item and create an item return package, step 1400, a
recipient can
bring the ordered item and the packing list associated with the item to a
returns processing
workstation (189) in a CDC 1190-2. The recipient can run an ePD customer
access card
through a card reader and key in their PIN number. The card reader can be
located at the
workstation (189), and the workstation's keyboard can be used to key in the
PIN. This can
be used to initiate the item return transaction. The recipient can use, for
example, a hand-held
barcode scanning device that can communicate with the workstation (189) to
scan the item
return barcode on the packing list associated with the item being returned.
Such
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communication can be wireless or wired. The recipient can use the
workstation's keyboard to
key in the quantity of the item being returned, select a return reason from a
predefined list,
and type in a comment related to the returned item. Where no appropriate
option is available
in the list, the recipient can select a return reason such as "other" and can
enter a personal
reason in the comment field. The CDC Returns Program (378) can validate that
the entered
PIN matches the PIN on the Customer record 1256 having the Customer Id of the
ePD
customer access card which was read by the card reader, and that the Customer
Id from the
ePD customer access card matches the Customer Id embedded in the Package Id of
the
scanned item return barcode. An item return barcode can contain, but is not
limited to the
following: the Package Id, Order Id, and SKU of an ordered item. If one of the
CDC Returns
Program's (378) validation checks fails, the CDC Returns Program (378) can,
for example,
sound an error tone and/or display a message explaining which scanned and/or
entered
information failed its validation. With reference to FIG. 9F, if the entered
and/or the scanned
information passes the CDC Returns Program's (378) validation checks, the CDC
Returns
Program (378) can create a record on an Item Return Header table 1266 and an
associated
record on an Item Return Detail table 1268 for the item return transaction.
The term "retailer" can be referring to one of a retailer's or manufacturer's
or other
equivalent business' order fulfillment operations, if they operate multiple
order fulfillment
operations. If a retailer does operate multiple order fulfillment operations,
each one can be
identified by its own ePD Retailer Id. A retailer's item returns processing
facility can be
identified by a Returns Facility Id, can have a Returns Local Market Id
associated with it, and
can be assigned to each distinct ePD Retailer Id on the Retailer table 1246.
Before creating a
new Item Return Header 1266 and Item Return Detail records 1268, the CDC
Returns
Program (378) can select the ePD Shipper Id from the record on the RDC table
1258 having
~ the RDC Id embedded in the Package Id of the scanned item return barcode.
The CDC
Returns Program (378) can also select the Returns Local Market Id from the
record on the
Retailer table 1246 having the ePD Retailer Id embedded in the Order Id from
the scanned
item return barcode. After selecting the ePD Shipper Id (of the original bulk
delivered
package) acid the Returns Local Market Id (of the retailer of the original
bulk delivered
package) the CDC Returns Program (378) can select the RDC Id from the RDC-
Local Market
table 1264 having the selected ePD Shipper Id value and a Local Market Id
equal to the value
of the selected Returns Local Market Id (the RDC associated with the shipper
for that
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retailer's returns facility - referred to as the origination RDC for the
current item return
package). The new Item Return Header record 1266 can be created with, for
example, the
selected ePD Shipper Id, Returns Local Market Id, and RDC Id values, the
Customer Id from
the ePD customer access card, the current CDC Id, a Status value such as "in
CDC", the ePD
Retailer Id embedded in the Order Id from the scanned item return barcode, and
an Item
Return Creation Date/Time equal to the current date/time. The Item Return
Detail record
1268 can be created with, for example, the SKU, Package Id, and Order Id from
the scanned
item return barcode and the Return Quantity, Return Reason Code, and Return
Reason
Comment that the recipient entered and selected using the workstation
keyboard. The Item
Return Id on both new records can be set, for example, to a concatenation of
the ePD Retailer
Id + Customer Id + CDC Id + current date + a value such as "IR" + a sequential
3 digit
number.
After a recipient performs the actions to initiate the return of an item and
the CDC
Returns Program (378) successfully creates a new record on the Item Return
Header 1266 and
Item Return Detail 1268 tables, the CDC Returns Program (378) can, for
example, sound a
confirmation tone, display a confirmation message to confirm that the item
return transaction
has been recorded successfully, print an item return package label, and start
a returns
conveyor (156). The item return package label can include, but is not limited
to the following
information: the RDC Id, Returns Local Market Id, and Item Return Id printed
in readable
f0 format and the Item Return Id printed in barcode format.
The recipient can return another item from the same packing list or a
different packing
list by scanning its item return barcode, keying in the Return Quantity,
selecting a Return
Reason Code, and entering a Return Reason Comment. If a subsequent item being
returned is
from the same packing list or from a different packing list that is from the
same retailer, an
additional Item Return Detail record 1268 can be created for that item return
transaction with
the same Item Return Id as the records 1268 created for the previous item
return transaction
(since both transactions are for the same retailer). If a subsequent item
being returned comes
from a packing list of a different retailer, the CDC Returns Program (378) can
create a new
set of Item Return Header 1266 and Item Return Detail 1268 records and can
print a new item
return package label for the item return transaction. A new item return
package label can be
created for each new set of Item Return Header 1266 and Item Return Detail
1268 records.
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Recipients can be instructed to separate items being returned to different
retailers into
separate item return packages and to combine different items being returned to
the same
retailer into one item return package, as the size of a package bag allows. In
one aspect of the
invention, a recipient can place the items the recipient is returning, and
their associated
packing lists, into separate package bags by retailer, affix item return
package labels to the
item return packages to which they correspond, seal the item return packages,
and place them
through a returns processing entry point (148) and onto a returns conveyor
(156). Package
bags and package ties in which the recipient originally received the items the
recipient is
returning or new package bags and package ties available from packing
materials dispensers
at a returns processing workstation (189) can be used to create an item return
package. ~ An
item return label should be placed over top of an existing package label, if
one exists on a
package bag. A returns video surveillance camera (150) can be located at a
returns
processing workstation to record, in a digital data file, moving video or
still photos of a
recipient's actions in placing items being returned into package bags and
placing those
package bags through the returns processing entry point (148). A shipper's
return policy can
include requiring a recipient to clearly show their actions in processing an
item return in front
of a returns video surveillance camera (150).
An item return can be performed at any CDC 1190-2 running the CDC Returns
Program (378), regardless of to which CDC 1190-2 the bulk delivered package
that contained
the items was originally delivered. Even items, in packages that were moved
through a
LDDH 1192-2 and delivered directly to customer specified addresses, can be
returned using
the CDC Returns Program (378) at a CDC 1190-2.
In a further aspect of the invention, the ePD Delivery Process can also allow
a customer to
send a package to a CDC 1190-2 or a specific address for a recipient through a
method
similar to processing an item return. There is also shown in FIG. 13, an
illustrative
embodiment depicting the steps that can be used to enable a customer to
efficiently ship a
package from one CDC 1190-2 to another CDC 1190-3 for a recipient. A customer
or
someone sending a package, can create a CDC outbound package for a recipient,
step 1401,
for example, by putting items in an ePD package bag and sealing it using an
ePD package tie.
In step 1401, larger items suitable for shipping (packed in a large box or
container or wrapped
with protective material to prevent damage) can also be shipped as a CDC
outbound package,
provided the larger items are not larger than the largest configurable SBU
bin, if shipping to a
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CDC 1190-2. A package sender can use a package bag and package tie from a bulk
delivered
package the package sender had previously received, or the package sender can
take a new
package bag and package tie from the packing materials dispensers at an
outbound package
workstation (159). A package sender can bring a package that the package
sender wishes to
send, a CDC outbound package, to an outbound package processing workstation
(159) at any
CDC 1190-2 in which the shipper, that the package sender intends to deliver
their package,
accepts CDC outbound packages. An electronic scale can be connected to, for
example, an
outbound package processing workstation (159) and can be used to calculate a
package
sender's ePD shipping cost based upon several factors that can be defined
differently for each
shipper. Those shipping cost factors can include, but are not limited to
Delivery Type,
Weight, Package Size, Origination CDC Id, and Destination CDC Id. In one
aspect of the
invention, a credit card/bank debit card reader with a connection to a payment
transaction
validation service can be located at and connected to an outbound package
processing
workstation (159) to enable credit cards and debit cards to be authorized and
accepted as
payment options. In a further aspect of the invention, a package sender can
also have an ePD
account, which can be debited as a payment option for the cost of shipping a
CDC outbound
package.
The package sender can run an ePD access card through, for example, the
workstation's card reader, key in their PIN number on the workstation's
keypad, select a
shipper from a predefined list, select the type of delivery - either ePD
delivery to a CDC
1190-2 or LDDH delivery to a specific address -- and place their CDC outbound
package on
the outbound package processing workstation's electronic scale. If the
delivery type selected
was ePD delivery, the package sender can then key in or select the Customer Id
of their CDC
outbound package's recipient and select the CDC Id of the destination
centralized pickup
location (or CDC) 1190-2 where the package sender wants the package to be
delivered, from
a predefined list. A package sender can search through a listing of Customer
Id's on the
outbound package workstation (159) using other customer information related to
the package
recipient including, but not limited to Last Name to find the package
recipient's Customer Id.
The predefined list containing CDC Id's of potential CDC locations 1190-2 can
also be
narrowed using information related to the package recipient including, but not
limited to Zip
and City. If the LDDH delivery type was selected, the package sender can then
type in the
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name of the recipient and the specific address to which the package sender
wants the CDC
outbound package to be delivered.
A CDC Outbound Package Creation Program (380) of the ePD SBU Application can
validate the entered PIN against the Customer record 1256 of the Customer Id
read from the
ePD customer access card and can create a record on a CDC Outbound Package
table 1270.
Before creating the new CDC Outbound Package record 1270, the CDC Outbound
Package
Creation Program (380) can use, for example, the entered/selected information,
the electronic
scale reading, and a CDC Outbound Package Cost Calculation table 1317 to
determine the
cost the selected shipper will charge for shipping the current CDC outbound
package from the
current CDC 1190-2 to a selected CDC 1190-3 or specific address. If a shipper
bases the cost
on Package Size as well as weight, the CDC Outbound Package Creation Program
(380) can
prompt the package sender to enter the estimated size of the package based
upon guidelines
that the shipper can provide. The CDC Outbound Package Creation Program (380)
can, for
example, sound a message alert tone and display a message on the workstation's
display
monitor to communicate the shipping cost of the CDC outbound package and
prompt the
package sender to select a form of payment. The package sender can choose to
cancel the
transaction or select a form of payment and run their credit card or debit
card through the
credit card/bank debit card reader to initiate a payment authorization
request.
Upon receiving a successful credit/debit authorization or the selection of a
payment
option that does not require a payment authorization (such as an ePD account
or a shipper
account), the CDC Outbound Package Creation Program (380) can use the CDC Id
of the
selected destination CDC 1190-3 to select the Local Market Id associated with
the destination
CDC 1190-3 from the CDC table 1252, and can then use that selected Local
Market Id and
the ePD Shipper Id selected by the package sender to select the RDC Id from
the RDC-Local
Market table 1264 associated with the shipper and local market of the
destination CDC 1190-
3. If the Delivery Type of a CDC outbound package is a value such as "LDDH",
the CDC
Outbound Package Creation Program (380) can use the Delivery Zip entered by
the package
sender and the Zip Code-CDC 1254 and CDC 1252 tables to determine the CDC Id
and Local
Market Id associated with the LDDH 1192-3 that delivers to the delivery
address specified by
the package sender. The CDC Outbound Package Creation Program (380) can then
use that
determined Local Market Id and the selected ePD Shipper Id to determine the
RDC Id
associated with that LDDH 1192-3. In one aspect of the invention, the CDC
Outbound
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Package Creation Program (380) can create a new record on the CDC Outbound
Package
table 1270 for the CDC outbound package transaction, for example, as follows:
RDC Id can
be set to the value selected from the RDC-Local Market record 1264; Local
Market Id can be
set to the value selected from the CDC record 1252; CDC Outbound Package Id
can be set to
a concatenation of the Customer Id of the package recipient + the Origination
CDC Id (the
CDC Id of the current CDC 1190-2) + the current date + a sequential 3 digit
number; Status
can be set to a value such as "in origination CDC"; ePD Shipper Id can be set
to the value of
the shipper selected by the package sender; Shipping Customer Id can be set to
the value read
from the ePD customer access card; Delivery Type can be set to the value
selected by the
package sender; Origination CDC Id can be set to the value of the current CDC
1190-2;
Recipient Customer Id can be set to the value entered by the package sender or
can be created
with no value if Delivery Type has a value such as "LDDH"; Destination CDC Id
can be set
to the value selected by the package sender or can be selected from the Zip
Code-CDC table
1254 if Delivery Type has a value such as "LDDH"; Temperature Code can be set
to a value
such as "standard" (packages requiring refrigeration or freezer storage cannot
be shipped as
CDC outbound packages); Weight can be set to the value read from the
workstation's
electronic scale; Cost can be set to the value calculated by the CDC Outbound
Package
Creation Program (380) -- by comparing the information entered by the package
sender
against the CDC Outbound Package Cost Calculation table 1317; Delivery Name,
Delivery
Address 1, Delivery Address 2, Delivery City, Delivery State, and Delivery Zip
can be set to
the values entered by the package sender (or can be created with no value if
Delivery Type is
a value such as "ePD"); Payment Method can be set to the method selected by
the package
sender; Payment Card Number can be set to the card number of the credit or
debit card run
through the credit cardlbank debit card reader; and Payment Authorization
Number can be set
to the value returned from a successful credit card or debit card
authorization request.
After the customer performs the actions that can be used to ship a CDC
outbound
package and the CDC Outbound Package Creation Program (380) successfully
creates a new
record on the CDC Outbound Package table 1270, the CDC Outbound Package
Creation
Program (380) can, for example, sound a confirmation tone, display a
confirmation message
to confirm that the CDC outbound package has been recorded successfully, print
an outbound
package label, and start the returns conveyor (156). The exemplary outbound
package label
can include, but is not limited to, the following information: the RDC Id,
Destination CDC
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Id, CDC Outbound Package Id, Delivery Name, Delivery Address 1, Delivery
Address 2,
Delivery City, Delivery State, and Delivery Zip printed in readable format and
the CDC
Outbound Package Id printed in barcode format. The package sender can afftx
the package
label to the CDC outbound package (over top of any existing package labels)
and can place
S the CDC outbound package through the returns processing entry point (148)
and onto the
returns conveyor ( 1 S 6).
In one aspect of the invention, CDC workers can organize item return packages
and
CDC outbound packages into CDC reverse shipments using a CDC Reverse Shipment
Creation Program (382) in step 1402. The CDC Reverse Shipment Creation Program
(382)
can run, for example, on a workstation in the backroom area (1S4) of a CDC 1
I90-2. After
starting the CDC Reverse Shipment Creation Program (382) a CDC worker can scan
their
employee id card and begin scanning the barcodes on the labels of item return
packages and
CDC outbound packages as the worker puts them into cargo cages. A CDC worker
can look
for the RDC Id on the label of an item return package or a CDC outbound
package to
1 S determine if it is a package for the shipper for whom the worker works.
The CDC Reverse
Shipment Creation Program (382) can validate that the first scanned item
return package or
CDC outbound package is associated with the shipper with whom the CDC worker
is
employed, by using the Item Return Id of the scanned item return label or the
CDC Outbound
Package Id of the scanned CDC outbound package label to select the ePD Shipper
Id from the
Item Return header 1266 or CDC Outbound Package record 1270, and comparing it
against
the ePD Shipper Id selected from the Employee table record 1308 having the
Employee Id of
the scanned employee id card. If the first package, scanned after the employee
id card is
scanned, passes the CDC Reverse Shipment Creation Program's (382) validation,
the CDC
Reverse Shipment Creation Program (382) can create a new CDC reverse shipment
by
2S creating a new record on a CDC Reverse Shipment table 1274. In a further
aspect of the
invention, in order to create the new CDC Reverse Shipment record 1274, the
CDC Reverse
Shipment Creation Program (382) can select the Local Market Id from the CDC
table record
1252 of the current CDC 1190-2 and use it along with the ePD Shipper Id value,
selected
from the Employee table 1308 during the CDC Reverse Shipment Creation
Program's (382)
validation, to select a RDC Id from the RDC-Local Market table 1264. The CDC
Reverse
Shipment Creation Program (382) can create the new CDC Reverse Shipment record
1274,
for example, as follows: Origination RDC Id can be set to the selected RDC Id
value; CDC
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Reverse Shipment Id can be set to a concatenation of the current CDC Id + the
current date +
a value such as "RS" + a 3 digit sequential number; Status can be set to a
value such as "in
CDC"; CDC Id can be set to the value of the current CDC 1190-2; ePD Shipper Id
can be set
to the value selected from the Employee table 1308 during the program's (382)
validation;
and Shipment Creation Employee Id can be set to the value from the scanned
employee id
card.
As a CDC worker scans subsequent item return packages and CDC outbound
packages, the CDC Reverse Shipment Creation Program (382) can validate that
each scanned
item return package or CDC outbound package is associated with the shipper
with whom the
CDC worker is employed using the same validation that it used for the first
item return
package or CDC outbound package added to the CDC reverse shipment. If a
scanned
package does not pass the CDC Reverse Shipment Creation Program's (382)
validation, the
CDC Reverse Shipment Creation Program (382) can, for example, sound an invalid
tone and
display a message that the scanned package is for a different shipper. If a
scanned package
passes the CDC Reverse Shipment Creation Program's (382) validation, the CDC
Reverse
Shipment Creation Program (382) can update, for example, the Item Return
Header record
1266 or CDC Outbound Package record 1270 of the scanned item return package or
CDC
outbound package, to set its Status to a value such as "CDC reverse shipment"
and its CDC
Reverse Shipment Id field to the CDC Reverse Shipment Id of the current CDC
reverse
shipment being created.
The CDC worker can stop adding item return packages to a CDC reverse shipment
at
any time by, for example, selecting a program option to print a CDC reverse
shipment label.
A CDC worker can create different sized CDC reverse shipments depending upon
when the
worker decides to print the CDC reverse shipment label. The worker can, for
example, peel
the CDC reverse shipment label from its label stock, affix it to a label
plate, and slide the
label plate into the cargo cage label plate holder of one of the cargo cages
containing the item
return packages and CDC outbound packages that the worker grouped together
into a CDC
reverse shipment. Information printed on a CDC reverse shipment label can
include, but is
not limited to, the CDC Reverse Shipment Id and ePD Shipper Id in a readable
format and the
CDC Reverse Shipment Id in a barcode format.
In another aspect of the invention, after a tractor-trailer finishes unloading
all of its
delivery shipments in a local market, it can stop at one or more CDC's 1190-2
within that
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local market to pick up CDC reverse shipments, step 1404. A team of CDC
workers and a
tractor-trailer driver can coordinate with each other to meet at a CDC 1190-2
to load CDC
reverse shipments onto a tractor-trailer (200 & 202) bound for a RDC 1180-2
which serves
the local market in which that CDC 1190-2 is located. The CDC workers can
start a CDC
Reverse Shipment Program (384) of the ePD SBU Application on a workstation in
the
backroom area (154) of a CDC 1190-2. After starting the CDC Reverse Shipment
Program
(384), a CDC worker can scan their employee id card, the Trailer Id barcode on
the trailer
door label, and the label on each CDC reverse shipment being loaded onto the
trailer (202).
Mobile putaway conveyor units (143), a CDC receiving dock conveyor extension
(145), and
the trailer conveyor (204) of the tractor-trailer (200 & 202) can be used to
load the cargo
cages and large packages of CDC reverse shipments onto the tractor-trailer
(200 & 202).
As the label on each CDC reverse shipment is scanned, the CDC Reverse Shipment
Program (384) can update the CDC Reverse Shipment record 1274 of the scanned
label, for
example, as follows: Status can be set to a value such as "in-transit";
Loading Employee Id
can be set to the value from the scanned employee id card; Trailer Id can be
set to the value of
the scanned Trailer Id barcode; and CDC Reverse Shipment Date/Time can be set
to the
current date/time. After the updates are made to CDC Reverse Shipment records
1274, the
CDC Reverse Shipment Program (384) can create data files from the CDC Reverse
Shipment
-1274, Item Return Header 1266, Item Return Detail 1268, and CDC Outbound
Package 1270
tables on the CDC server. The data files can be created to move the records
from the
database on the CDC server to the database on the RDC server, and each data
file can have
the same fields as the table from which it can be created. In one aspect of
the invention, the
CDC Reverse Shipment Program (384) can create a CDC Reverse Shipment data file
by
selecting records from the CDC Reverse Shipment table 1274 using the CDC
Reverse
Shipment Id of each scanned CDC reverse shipment label as the CDC reverse
shipments are
loaded onto the tractor-trailer (200 & 202). After each CDC Reverse Shipment
data file
record is created, the CDC Reverse Shipment Program (384) can select all the
Item Return
Header records 1266 and CDC Outbound Package records 1270 having the CDC
Reverse
Shipment Id of the scanned CDC Reverse Shipment label and can create an Item
Return
Header data file and a CDC Outbound Package data file respectively. As the CDC
Reverse
Shipment Program (384) is creating the Item Return Header data file it can
also create an
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Item Return Detail data file by selecting records from the Item Return Detail
table 1268
having the Item Return Id of the records being written to the Item Return
Header data file.
A CDC reverse shipment containing item return packages and CDC outbound
packages can be shipped from an origination CDC 1190-2 to an origination RDC
1180-2 in
step 1406. After CDC reverse shipments have been loaded onto the trailer
(202), the tractor-
trailer (200 & 202) can leave the current origination CDC 1190-2 to proceed to
the current
shipper's origination RDC 1180-2 which serves the current CDC 1190-2, or to
another CDC
1190-2 in the local market to pick up more CDC reverse shipments, or to a
retailer fulfillment
site 1194-2 (FIG. 2) in the local market to pick up retailer shipments. Also
shown in FIG. 2,
is a retailer fulfillment site 1194-3 and a retailer fulfillment site 1194-4.
A CDC worker
running the CDC Reverse Shipment Program (384) can end the CDC Reverse
Shipment
Program (384) by, fox example, selecting an option to transmit the data files
related to the
CDC reverse shipment. The CDC Reverse Shipment Program (384) can transmit, for
example, the Item Return Header, Ttem Return Detail, CDC Outbound Package, and
CDC
Reverse Shipment data files via a file transport program to the RDC server of
the shipper's
RDC 1180-2 which serves the current CDC 1190-2 (the RDC Id selected from the
RDC-
Local Market table 1264 having the current ePD Shipper Id and the local market
of the
current CDC 1190-2). When the data files are received onto the RDC server, a
Receive RDC
Reverse Shipment Data Program (317) of the shipper's instance of the ePD
Shipping
Application can read each data file and write the data to the tables
corresponding to each data
file (having the same name) in the ePD Shipping Application's database on the
RDC server.
As the Receive RDC Reverse Shipment Data Program (317) reads through each
record in a
data file it can add a new record to the corresponding table and update the
Status on each data
file record to a value such as "record received". When processing Item Return
Header and
Item Return Detail data files to add records to their corresponding tables,
the Receive RDC
Reverse Shipment Data Program (317) can process the files together by first
writing an Item
Return Header record 1266 and then writing the Item Return Detail records 1268
that have
the Item Return Id of that Item Return Header record 1266. With reference to
FIG. 9G, as the
Receive RDC Reverse Shipment Data Program (317) writes the first Item Return
Detail
record 1268 corresponding to an Ttem Return Header record 1266, it can use,
for example, the
Order Id of that Item Return Detail record 1268 to select the Order Delivery
Type, CDC Id,
Retailer Order Number, and Order Date/Time values from either the Order Header
record
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1200 or an Order Header History record 1278 having that Order Id. In another
aspect of the
invention, a data archiving process can be employed to write Order Header 1200
and Order
Detail 1202 records to an Order Header History table 1278 and an Order Detail
History table
1280 respectively, after an entire order has been billed and picked-up. The
Receive RDC
S Reverse Shipment Data Program (317) can use the selected Order Header 1200
(or Order
Header History 1278) data to update the Item Return Header record 1266, for
example, as
follows: Original Order Delivery Type can be set to the Order Delivery Type
value selected
from the Order Header 1200 or Order Header History 1278 record; and Original
Order CDC
Id can be set to the CDC Id value selected from the Order Header 1200 or Order
Header
History 1278 record. The Receive RDC Reverse Shipment Data Program (317) can
use the
selected Order Header 1200 (or Order Header History 1278) data to update the
first record
written to the Item Return Detail table 1268 and each subsequent Item Return
Detail record
1268 written to the table having the same Item Return Id, for example, as
follows: Retailer
Order Number and Order Date/Time can be set to the values selected from the
Order Header
1 S 1200 or Order Header History 1278 record.
After reading through and updating the Status on all the records in each data
file, the
Receive RDC Reverse Shipment Data Program (317) can send the data file back to
the CDC
server from which it was received. Upon receiving each data file on the CDC
server, a CDC
Reverse Shipment Maintenance Program (386) can read each record in the data
file, verify
that its Status is a value such as "record received", and delete its
corresponding record in the
database, using its Item Return Id, CDC Outbound Package Id, or CDC Reverse
Shipment Id.
Item Return Header and Item ReturnlDetail data files can be processed after
both data files
have been received. If the Receive RDC Reverse Shipment Data Program (317) is
unable to
write a new record to the ePD Shipping Application's database from the data
file
2S successfully, the Receive RDC Reverse Shipment Data Program (317) can move
the
unsuccessfully written data file record from the data file to an error file or
table for later error
processing.
In a further aspect of the invention, RDC workers can use a Receive RDC
Reverse
Shipment Program (319) of the ePD Shipping Application to receive CDC reverse
shipments
into an origination RDC 1180-2, step 1408. The cargo cages and large item
return/CDC '
outbound packages making up the CDC reverse shipments can be physically moved
from a
trailer conveyor (204) onto a local market receiving dock conveyor (14) in a
manner
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consistent with the way retailer shipments can be received into a RDC 1180-2.
To start the
Receive RDC Reverse Shipment Program (319) a RDC worker can select the Receive
RDC
Reverse Shipment Program's (319) start option on a workstation upon which it
is located.
After starting the Receive RDC Reverse Shipment Program (319) a RDC worker
can, for
example, scan their employee id card and the CDC reverse shipment label on a
CDC reverse
shipment to trigger an update to the records related to the CDC reverse
shipment. The
Receive RDC Reverse Shipment Program (319) can select the record on the CDC
Reverse
Shipment table 1274 having the CDC Reverse Shipment Id of the scanned CDC
reverse
shipment label and can update it, for example, as follows: Status can be set
to a value such as
"received"; Receiving Employee Id can be set to the value from the scanned
employee id
card; and CDC Reverse Shipment Arrival Date/Time can be set to the current
date/time.
After updating the CDC Reverse Shipment record 1274, the Receive RDC Reverse
Shipment
Program (319) can use the CDC Reverse Shipment Id of that updated record 1274
to select
the Item Return Header records 1266 and CDC Outbound Package records 1270
having that
CDC Reverse Shipment Id. The Receive RDC Reverse Shipment Program (319) can
update
the Status on each selected Item Return Header record 1266 and CDC Outbound
Package
record 1270 to a value such as "destination RDC" and "origination RDC"
respectively.
Item return packages and CDC outbound packages can travel from a local market
receiving dock conveyor (14) onto the inbound section of the RDC sort conveyor
(16) and
then onto the outbound section of the RDC sort conveyor (18). As the item
return packages
and CDC outbound packages move past the teams of workers performing the RDC
sort
process, step 1112A (FIG. 13), those workers can look at the RDC Id on the
labels of the item
return packages and CDC outbound packages to identify the ones that can be
added to the
RDC shipment they are currently building. The RDC workers can, for example,
pick the item
return packages and CDC outbound packages matching their RDC shipment, scan
their labels
using the stationary scanner located next to the side of the RDC shipping dock
conveyor (22),
and place them into a cargo cage on the shipping dock conveyor (22). As each
item return
package or CDC outbound package is scanned, the RDC Shipment Program (318) of
the ePD
Shipping Application can write the RDC Shipment Id of the RDC shipment, being
built on
the shipping dock conveyor (22) associated with the stationary scanner used,
to the RDC
Shipment Id field on the Item Return Header record 1266 of the scanned item
return package
or the CDC Outbound Package record 1270 of the scanned CDC outbound package.
If a
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RDC worker scans an item return package or CDC outbound package to start a new
RDC
shipment, the RDC Shipment Program (318) can create a new RDC Shipment record
1216 in
the same way that it can create a new record when scanning a case of ordered
items, except
Destination RDC Id on the new RDC Shipment record 1216 can be set to the RDC
Id value
from the selected Item Return Header record 1266 or CDC Outbound Package
record 1270
instead of from a selected Case record 1208. Item return packages and CDC
outbound
packages that are labeled with the current RDC Id can be picked from the
outbound section of
the RDC sort conveyor (18) to the local market sort conveyor (24) by the same
team of
workers that is picking cases labeled with the current RDC Id from the
outbound section of
the RDC sort conveyor (18) to the local market sort conveyor (24).
In another aspect of the invention item return packages and CDC outbound
packages
can be shipped as part of a RDC shipment from an origination RDC 1180-2 to a
destination
RDC 1180-3 in step 1114A. A RDC shipment arriving at its destination RDC 1180-
3 may
contain item return packages and CDC outbound packages as well as cases of
ordered items.
The cargo cages containing the item return packages and CDC outbound packages,
as well as
the cases of ordered items, can be received into the destination RDC 1180-3 in
step 1116A,
and can be moved from the trailer conveyor (204) to the RDC inbound receiving
dock
conveyor (32), to the unloading section (34), case diverting section (38), and
local market
connection (36) of the RDC inbound conveyor, and up onto the local market sort
conveyor
(24) in the same way as described in step 1116 (FIG. 1). One difference
between step 11 I6A
and step 1116, can be that item return packages and CDC outbound packages
which were not
described in step 1116 can also be moved to the local market sort conveyor
(24) along with
the cases described in step 1116. In step 1116A, a RDC worker can perform the
same actions
as described in step 1116 to initiate the Receive RDC Shipment Program (324),
and the
Receive RDC Shipment program (324) can perform the same steps, as detailed in
step 1116,
to update, for example, the RDC Shipment record 1216 of the RDC shipment in
the database
on the origination RDC's 1180-2 server and the RDC Shipment Receiving record
1218 of the
RDC shipment in the database on the current destination RDC's 1180-3 server.
In addition to
updating and moving all the Case 1208, Order Header 1200, and Order Detail
1202 records
associated with the current RDC shipment from the database on the origination
RDC's I 180-
2 server to the database on the destination RDC's 1 I80-3 server, the Receive
RDC Shipment
Program (324) can also update and move the Item Return Header 1266, Item
Return Detail
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1268, and CDC Outbound Package 1270 records associated with the current RDC
shipment
from the database on the origination RDC's 1180-2 server to the database on
the destination
RDC's 1180-3 server. The Receive RDC Shipment program (324), running on the
destination RDC's 1180-3 server, can use the remote connection that it
established to the
origination RDC's 1180-2 server and the RDC Shipment Id, from the record on
the RDC
Shipment Receiving table 1218 having the Trailer Id that was scanned when the
RDC
shipment was received, to select the Item Return Header records 1266 and CDC
Outbound
Package records 1270 from the origination RDC's 1180-2 server having that RDC
Shipment
Id. The Receive RDC Shipment Program (324) can update the Status of the
selected Item
Return Header records 1266 to a value such as "origination RDC" and the Status
of the
selected CDC Outbound Package records 1270 to a value such as "destination
RDC". The
Receive RDC Shipment Program (324) can use the Item Return Id's of the Item
Return
Header records 1266 to select their associated Item Return Detail records
1268. The Receive
RDC Shipment program (324) can move the selected Item Return Header 1266, Item
Return
Detail 1268, and CDC Outbound Package 1270 records from the database on the
origination
RDC's 1180-2 server to the database on the current destination RDC's 1180-3
server. The
RDC into which a RDC shipment arrives can be referred to as its destination
RDC 1180-3,
even though it may have been the origination RDC for the items of a return
item package and
can be reflected as the "origination RDC" in the Status of item return
packages.
The item return packages and CDC outbound packages that were moved to the
local
market sort conveyor (24), during the RDC sort, step 1112A, or the receipt of
a RDC
shipment, step 1116A, can move around on the local market sort conveyor (24)
and pass by
the RDC workers performing the local market sort, step 1118A. In addition to
scanning case
labels to determine if a case should be picked from the local market sort
conveyor (24) to the
CDC sort conveyor (42) at which a RDC worker is stationed, a RDC worker can
Look at
labels on item return packages and CDC outbound packages to determine if they
should pick
them from the local market sort conveyor (24) to their CDC sort conveyor (42).
The worker
can pick an item return package that has a Returns Local Market Id printed on
its label that
matches the local market id of their CDC sort conveyor (42). Additionally, the
worker can
also pick a CDC outbound package that has a local market id, embedded in the
CDC Id
printed on its label, that matches the local market id of their CDC sort
conveyor (42). In one
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embodiment, item return packages and CDC outbound packages do not need to be
scanned
when picked from the local market sort conveyor (24).
In another aspect of the invention, a RDC worker performing the CDC sort, step
1120A, can scan the label of a CDC outbound package on the CDC sort conveyor
(42) to
determine if it is for the CDC 1190-3 associated with the CDC packing station
conveyor (44)
for which the RDC worker is picking cases of ordered items. The CDC Sort
Program (328)
can determine if the format of the data scanned from the label is for a case
or a CDC
outbound package. If an item return package label gets scanned, the CDC Sort
Program (328)
can determine that the scanned data was neither a Case Id nor a CDC Outbound
Package Id
and can, for example, sound an invalid pick tone. If a case label gets
scanned, the CDC Sort
program (328) can perform its processing as previously described in step 1120.
If a CDC
outbound package label gets scanned, the CDC Sort program (328) can use, for
example, the
scanned CDC Outbound Package Id to select the CDC Outbound Package record 1270
of the
CDC outbound package, can validate its RDC Id and Local Market Id values, and
can
compare its Destination CDC Id value against the CDC Id value of the current
instance of the
CDC Sort Program (328) (the instance associated with the current CDC packing
station
conveyor (44)). The RDC Id and Local Market Id values on the selected CDC
Outbound
Package record 1270 can be validated by the CDC Sort Program (328) in the same
way that
the RDC Id and Local Market Id values on the Case record 1208 of a scanned
case can be
validated. The worker who scanned the CDC outbound package can respond to a
validation
error tone, for example, a double invalid pick warning tone, from a scanned
CDC outbound
package in the same way the worker responds to a similar validation error tone
from a
scanned case. If the CDC Sort program (328) can determine that the CDC Id
associated with
the scanned CDC outbound package does not match the CDC Id associated with the
ciuTent
instance of the CDC Sort Program (328), it can indicate not to pick the
scanned CDC
outbound package, for example, by sounding an invalid pick tone. Upon hearing
an invalid
pick tone or another indication not to pick a scanned CDC outbound package, a
worker can
allow a CDC outbound package or an item return package to pass by them on the
CDC sort
conveyor (42). If the CDC Sort program (328) determines that the CDC Id
associated with
the scanned CDC outbound package matches the CDC Id associated with the
current instance
of the CDC Sort Program (328), it can indicate to pick the scanned CDC
outbound package,
for example, by sounding a pick confirmation tone. Upon hearing a pick
confirmation tone or
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another indication to pick a scanned CDC outbound package when scanning a CDC
outbound
package, the worker can pick the CDC outbound package from the CDC sort
conveyor (42)
and place it on the CDC packing station conveyor (44) at which the worker is
stationed.
In another aspect of the invention, CDC outbound packages can be added to a
delivery
shipment of packages designated for a particular CDC or LDDH, step 1418. A RDC
worker,
creating an ePD delivery shipment on the CDC feed of a CDC package conveyor
(47A)
associated with a particular CDC 1190-3 or LDDH 1192-3 by scanning packages
that were
created at the current destination RDC 1180-3 into cargo cages, step 1124, can
also pick and
scan CDC outbound packages from the CDC packing station conveyor (44)
associated with
that CDC 1190-3 or LDDH 1192-3 in step 1418. The worker can place each CDC
outbound
package picked from the CDC packing station conveyor (44) into a cargo cage of
the current
delivery shipment that the worker is creating. Upon scanning a CDC outbound
package label,
the worker's instance of the Delivery Shipment Creation Program (340) can, for
example,
recognize the format of the scamied value as a CDC Outbound Package Id instead
of a
I S Package Id, use the scanned CDC Outbound Package Id to select the
appropriate CDC
Outbound Package record 1270, display the Package Size of the selected record
1270 on the
workstation running the Delivery Shipment Creation Program (340), and prompt
the worker
to confirm or override the displayed Package Size. After the worker confirms
or overrides
the displayed Package Size, the Delivery Shipment Creation Program (340) can
update, for
example, the selected CDC Outbound Package record 1270 by setting its Status
to a value
such as "delivery shipment" and writing the Delivery Shipment Id, of the
current delivery
shipment being created, to its Delivery Shipment Id field. If the worker
overrode the
displayed Package Size value instead of confirming it, the Delivery Shipment
Creation
program (340) can also update the Package Size on the selected record 1270 to
the value
entered by the worker and can write data values from the selected record 1270
to a table or
file that can be used to create an exception report of CDC outbound packages
which have had
their Package Size overridden. The data fields which can be written to the
table or file can
include, but are not limited to the CDC Outbound Package Id, Shipping Customer
Id,
Delivery Type, original Package Size, overriding Package Size, and Employee Id
of the
worker creating the delivery shipment (this value is not read from the
selected CDC
Outbound Package record 1270, but can be scanned into the Delivery Shipment
Creation
program (340)). An exception report of CDC outbound packages, which have had
their
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Package Size overridden, can later be used for making billing adjustments to
the package
senders of the CDC outbound packages listed on that exception report.
After a CDC outbound package has been added to a delivery shipment in step
1418,
the CDC outbound packages can be shipped in bulk, as in step 1420, to the CDC
1190-3.
The method can follow the same physical movement from the CDC feed of a CDC
package
conveyor (47A) all the way to being retrieved from a SBU bin at a CDC 1190-3
by its
recipient in step 1150A. With reference to FIG. 13, these steps can be similar
to those
previously described for the CDC in FIG. 1. Hence, step 1140 can be equivalent
to 1140A;
step 1142 can be equivalent to step 1142A; step 1144 can be equivalent to step
1144A; step
1148 can be equivalent to step 1148A; and step 1150 can be equivalent to step
1150A. The
programs used to reserve SBU bins, make adjustments to delivery shipments, and
make SBU
configuration adjustments for the packages of a delivery shipment can account
for CDC
outbound packages in the same way as they account for packages created in a
destination
RDC 1180-3. The programs used to load packages into SBU bins, notify
recipients that
packages have been delivered to a CDC 1190-3, and unload packages from SBU
bins can
process the movement of CDC outbound packages in the same way that they
process the
movement of packages created in a destination RDC 1180-3, except that a CDC
Outbound
Package Td can be written to the Package Td field on a Bin Inventory record
1300 instead of a
Package Id, and updates can be made to the Status, Notification Date/Time, and
Pickup
Date/Time on a CDC Outbound Package record 1270 associated with a CDC outbound
package instead of the Package 1234, Order Detail 1202, and Order Header 1200
records
associated with a package (the programs can update the Status of a CDC
Outbound Package
record 1270 to the same values to which the Status of an Order Detail record
1202 can be
updated). CDC outbound packages which can be added to delivery shipments bound
for an
LDDH 1192-3 instead of a CDC 1190-3 can be physically moved and Logically
tracked in the
same way as packages created in a destination RDC 1180-3, except that data can
be read and
updated from CDC Outbound Package records 1270 instead of Order Header 1200,
Order
Detail 1202, and Package 1234 records. The billing process, step 1138 (FIG.
1), that follows
the notification of delivery of ordered items to a CDC 1190-3 or the actual
delivery of
ordered items to a specific address can be unnecessary after the delivery of
CDC outbound
packages, because the package sender had already been charged at the time the
CDC
outbound package was sent. If the original shipping charge for a CDC outbound
package was
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based upon a Package Size that was later overridden by a shipper, the package
sender can be
billed for additional shipping costs or refunded for an excessive shipping
payment. Billing or
refunding package senders for differences in shipping costs due to an
incorrect estimation of
Package Size can be facilitated by using an exception report of CDC outbound
packages
which have had their Package Size overridden. Following step 1418, CDC
outbound
packages bound for a CDC 1190-3 can be referred to collectively, along with
packages
created at a destination RDC 1180-3, as bulk delivered packages, since they
will both be
treated the same as they are delivered in bulk to a CDC 1190-3 and loaded into
SBU bins.
In a further aspect of the invention, RDC returns shipments can be created by
grouping item return packages by the retailer returns facilities for which
they are bound in
step 1410. One or more RDC workers creating RDC returns shipments bound for
the returns
facilities of retailers within a local market can be stationed at some point
along a CDC sort
conveyor (42) associated with that local market. The workers can, for example,
wear hands-
free scanners that can communicate with a workstation, which can run an
instance of the
RDC Returns Shipment Creation Program (341) of the ePD Delivery Application. A
RDC
worker can start the RDC Returns Shipment Creation Program (341) on the
workstation and
can scan their employee id card, before adding item return packages to a RDC
returns
shipment. Other RDC workers with hands-free scanners communicating with that
workstation can scan their employee id cards to sign on to the RDC Returns
Shipment
Creation Program (341) and can work as a team with the worker who started the
RDC
Returns Shipment Creation Program (341), to add item return packages to RDC
returns
shipments. As item return packages move past them on the CDC sort conveyor
(42), they can
scan the item return labels to pick them for the RDC returns shipments they
are creating. If a
CDC outbound package gets scanned instead of an item return package, the RDC
Returns
Shipment Creation Program (341) can, for example, sound an invalid pick tone
and display a
message on the workstation to indicate that the scanned package should not be
picked. When
a worker creating RDC returns shipments scans an item return package, the RDC
Returns
Shipment Creation Program (341) can select an Item Return Header record 1266
using the
Item Return Id value from the scanned item return package label. With
reference to FIG. 9G,
the RDC Returns Shipment Creation program (341) can use the ePD Retailer Id on
the
selected Item Return Header record 1266 to select a record from a RDC Returns
Shipment
table 1276 having that ePD Retailer Id and a Status value such as "open". If
the RDC
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Returns Shipment Creation Program (341) is able to select a record 1276 with
the ePD
Retailer Id of the scanned item return package and a Status such as "open", it
can, for
example, sound a pick confirmation tone, and display a message to
indicate°that the item
return package should be picked for the RDC returns shipment of the retailer
associated with
the scanned item return package (the retailer having an ePD Retailer Id
embedded in the Item
a Return Id of the scanned item return package label). The worker can, for
example, pick the
item return package from the CDC sort conveyor (42), scan the RDC returns
shipment label
of the RDC returns shipment for the retailer associated with the picked item
return package
(on a label plate on one of its cargo cages), and place the item return
package into one of the
cargo cages of that RDC returns shipment. The RDC Returns Shipment Creation
Program
(341) can validate that the RDC Returns Shipment Id on the scanned RDC returns
shipment
label matches the RDC Returns Shipment Id of the selected RDC Returns Shipment
record
1276. If the RDC Returns Shipment Id on the scanned RDC returns shipment label
passes
validation, the RDC Returns Shipment Creation Program (341) can update the
selected Item
Return Header record 1266, for example, as follows: Status can be set to a
value such as
"RDC returns shipment"; and RDC Returns Shipment Id can be set to the value of
the
selected RDC Returns Shipment record 1276. The RDC Returns Shipment Creation
Program
(341) can also compare the Employee Id of the worker who scanned the item
return package
against the values of the RDC employee id fields (RDC Employee Id #1 through
RDC
Employee Id #5) on the selected RDC Returns Shipment record 1276 and can add
the
worker's Employee Id to the first available RDC Employee Id field if it is not
already on the
record 1276. After making the record updates, the RDC Returns Shipment
Creation Program
(341) can, for example, sound a confirmation tone and display a message to
confirm that the
scanned item return package was added to the scanned RDC returns shipment
successfully. If
the scanned RDC returns shipment label does not pass validation, the RDC
Returns Shipment
Creation Program (341 ) can, for example, sound an invalid warning tone, and
display a
message to alert the worker that a RDC returns shipment label of a different
retailer's RDC
returns shipment was scamled and to indicate the ePD Retailer Id of the
scanned item return
package.
In a fixrther aspect of the invention, the instance of the RDC Returns
Shipment
Creation Program (341) that the workers can be logged into can track and
differentiate
between the scanning actions of one worker from the scanning actions of
another by
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associating a unique identifier of the scamiing device used by each worker
with the data
scanned by that device. For example, if the first scan registered by the RDC
Returns
Shipment Creation Program (34I) was from a first worker scanning an item
return package,
the second scan registered by the RDC Returns Shipment Creation Program (341)
was from a
second worker scanning an item return package, and the third scan registered
by the RDC
Returns Shipment Creation Program (341) was from the first worker scanning a
RDC returns
shipment label, the RDC Returns Shipment Creation Program (341) would be able
to
differentiate between the scans of the two different devices and would
validate the third scan
against the first scan; since that was the next sequential scan by that
scanning device.
If the RDC Returns Shipment Creation Program (341 ) was unable to find a
record
with the ePD Retailer Id of the scanned item return package and a Status value
such as
"open", when the item return package label was scanned, the RDC Returns
Shipment
Creation Program (341) can, for example, create a new RDC Returns Shipment
record 1276,
print a RDC returns shipment label, sound a pick confirmation tone, and
display a message on
the workstation's display monitor indicating that a new RDC returns shipment
should be
created for the scanned item return package. The new RDC Returns Shipment
record 1276
can be created, for example, as follows: RDC Returns Shipment Id can be
created by
concatenating the RDC Id of the current destination RDC 1180-3 + the ePD
Retailer Id from
the selected Item Return Header record 1266 + the current date + a three digit
sequential
number; Status can be set to a value such as "open"; ePD Shipper Id can be set
to the value of
the shipper operating the current destination RDC 1180-3; ePD Retailer Id can
be set to the
value from the selected Item Return Header record 1266; RDC Id can be set to
the value of
the current destination RDC 1180-3; Temperature Code can be set to a value
such as
"standard" (non-standard temperature items can be returned via a more direct
route to a
retailer's returns facility); and RDC Employee Id #1 can be set to the
Employee Id of the
worker who scanned the item return package (which can be associated with the
unique
identifier of the scanning device used to scan the item return package).
The RDC returns shipment label printed by the RDC Returns Shipment Creation
Program (341) can include, but is not limited to the following information:
RDC Returns
Shipment Id in both a readable format and a barcode format. The worker who
scanned the
item return package which initiated the new RDC returns shipment can take the
label from
the workstation's label printer, affix it to a label plate, place the label
plate in the label plate
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holder of an empty cargo cage, place the scanned item return package into the
cargo cage, and
scan the new label to add the scanned item return package to the new RDC
returns shipment.
Any one of the workers creating RDC returns shipments for the retailers of a
particular local
market can close a RDC returns shipment, by selecting a program option of the
RDC Returns
Shipment Creation Program (341), such as the "close shipment" option, and then
scamiing
the RDC returns shipment label of the RDC returns shipment to be closed. When
a program
option of the RDC Returns Shipment Creation Program (341) such as the "close
shipment"
option is selected, the RDC Returns Shipment Creation Program (341) can update
the Status
of the RDC Returns Shipment record 1276 to a value such as "closed". Because
RDC returns
shipment can be shipped with other RDC returns shipments or delivery shipments
bound for
the same local market, a worker can close a RDC returns shipment when it is
the size of a
full-trailer-load or at any time when it is smaller than the size of a frill-
trailer-load. A RDC
returns shipment can be built on top of a RDC returns shipment conveyor (62),
next to the
CDC sort conveyor (42) of the local market for which it is bound, or it can be
built near that
RDC returns shipment conveyor (62) and then positioned on that RDC returns
shipment
conveyor (62) with other closed RDC returns shipments, once it has been
closed. RDC
returns shipments can be moved from a RDC returns shipment conveyor (62) to a
package
conveyor (46A or 46B) in a coordinated manner to position them near one or
more delivery
shipments from the same local market to create a full-trailer-load.
In another aspect of the invention, RDC returns shipments can be moved through
the
destination RDC 1180-3 and loaded onto tractor-trailers (200 & 202) leaving
the destination
RDC 1180-3 for a local market in the same manner as described for (and
possibly along side
of) delivery shipments containing packages of ordered items and/or CDC
outbound packages.
Step 1412 shows this shipment of the item return packages to retailer returns
facility. One
difference in the process of loading a RDC returns shipment onto a tractor-
trailer (200 & 202)
as compared to a delivery shipment can be that the Delivery Shipment Program
(342) can
verify and reserve available bin space for the packages and CDC outbound
packages of a
delivery shipment, but the Delivery Shipment Program (342) does not need to do
so for the
item return packages of a RDC returns shipment. If a RDC returns shipment
label is scanned
by a worker running the Delivery Shipment Program (342), the Delivery Shipment
Program
(342) can select the RDC Returns Shipment record 1276 having the scanned RDC
Returns
Shipment Id and can update it, for example, as follows: Status can be set to a
value such as
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"reported"; Trailer Loading Employee Id can be set to the value of the
employee id card
scanned by the worker running the Delivery Shipment Program (342); Trailer Id
can be
updated to the value of the scanned Trailer Id barcode; and RDC Returns
Shipment Loading
Date/Time can be set to the current date/time. The Delivery Shipment Program
(342) can
store the RDC Returns Shipment Id from the scanned RDC returns shipment label
to be
printed in both a readable description and a barcode format on the Delivery
Shipments Report
when it is printed. The Delivery Shipment Program (342) can use the ePD
Retailer Id on the
selected RDC Returns Shipment record 1276 to select the retailer's record from
the Retailer
table 1246 and can store the ePD Retailer Description, Returns Facility Id,
and the address of
the retailer's returns facility (Returns Address 1, Returns Address 2, Returns
City, Returns
State, Returns Zip) from the selected Retailer record 1246 to be printed on
the Delivery
Shipments Report when it is printed. After a RDC worker scans all the delivery
shipments
and RDC returns shipments of the full-trailer-load and selects a program
option to end the
Delivery Shipment Program (342) and print the Delivery Shipments Report, the
delivery
shipments and RDC returns shipments can be loaded onto the tractor-trailer
(200 & 202) as
previously described in this disclosure.
In yet a further aspect of the invention, a RDC Returns Shipment Data Transfer
' . Program (343) can run as a service on the destination RDC's 1180-3 server
to monitor the
RDC Returns Shipment table 1276, searching for records with a Status value
such as
"reported". The RDC Returns Shipment Data Transfer Program (343) can select
RDC
Returns Shipment records 1276 having a Status value such as "reported", update
the Status of
each selected record to a value such as "in-transit", and use the RDC Returns
Shipment Id of
each selected record 1276 to select Item Return Header records 1266 having
that RDC
Returns Shipment Id. The RDC Returns Shipment Data Transfer Program (343) can
write the
selected Item Return Header records 1266 into a new Retailer Returns Header
data file, and
can use the Item Return Id's of the selected Item Return Header records 1266
to select their
associated Item Return Detail records 1268. The RDC Returns Shipment Data
Transfer
Program (343) can write the selected Item Return Detail records 1268 into a
new Retailer
Returns Detail data file. The RDC Returns Shipment Data Transfer Program (343)
can write
the ePD Retailer Id and RDC Returns Shipment Id of each selected RDC Returns
Shipment
record 1276 and the current date/time to the file header of both data files
created for that RDC
returns shipment. The RDC Returns Shipment Data Transfer Program (343) can
also use the
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ePD Retailer Id of each selected RDC Returns Shipment record 1276 to select
that retailer's
record from the Retailer table 1246 and can, for example, use the information
in its
Connection Script field to connect to the retailer's server and transfer the
Retailer Returns
Header and Retailer Returns Detail data files from the destination RDC's 1180-
3 server to the
retailer's server. A Receive RDC Returns Shipment Data Program (311 ) of the
retailer's
instance of the ePD Shipping Application can run as a service on a workstation
or server at a
retailer's returns facility to read Retailer Returns Header and Retailer
Returns Detail data files
as they are received and can create Item Return Header 1266 and Item Return
Detail 1268
records on the database of the retailer's instance of the ePD Shipping
Application.
In step 1414, workers at a retailer returns processing facility can receive
and process return
item packages. One of the workers at a retailer's returns facility can
initiate the Receive RDC
Returns Shipment Program (313) of the retailer's instance of the ePD Shipping
Application
on a workstation, can scan their employee id card, and can then scan the RDC
returns
shipment label on a RDC returns shipment arriving at the returns facility to
receive it from a
shipper. The Receive RDC Returns Shipment Program (313) can use the RDC
Returns
Shipment Id to select and update, for example, the Item Return Header records
1266
associated with the received RDC returns shipment, for example, as follows:
Status can be set
to a value such as "returned"; and Item Return Retailer Receipt Date/Time can
be set to the
current date/time. After updating the Item Return Header records 1266, the
Receive RDC
Returns Shipment Program (313) can create a simple RDC Returns Shipment
Receipt
Confirmation data file containing the RDC Returns Shipment Id of the received
RDC returns
shipment, the Employee Id value scanned from the retailer worker's employee id
card, and
the Item Return Retailer Receipt Date/Time. The Receive RDC Returns Shipment
Program
(313) can use the RDC Id from one of the Item Return Header records 1266
associated with
the current RDC returns shipment (each Item Return Header record 1266
associated with the
current RDC returns shipment should have the same RDC Id) to send the RDC
Returns
Shipment Receipt Confirmation data file to the destination RDC 1180-3 from
which the RDC
returns shipment originated.
Upon receiving a RDC Returns Shipment Receipt Confirmation data file from a
retailer's returns facility, a RDC Returns Shipment Update Program (388) of
the shipper's
instance of the ePD Delivery Application can use the RDC Returns Shipment Id
in the data
file to select the RDC Returns Shipment record 1276 and all of the Item Return
Header
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records 1266 associated with the RDC returns shipment. The RDC Returns
Shipment Update
Program (388) can update the selected RDC Returns Shipment record, for
example, as
follows: Status can be set to a value such as "received"; Retailer Employee Id
can be set to
the Employee Id in the received data file; and RDC Returns Shipment Arrival
Date/Time can
be set to the Item Return Retailer Receipt Date/Time in the received data
file. The RDC
Returns Shipment Update Program (388) can update, for example, the Status to a
value such
as "returned" on each selected Item Return Header record 1266. The data on the
Item Return
Header 1266 and Item Return Detail records 1268 with a Status value such as
"returned" can
be used by a shipper, in step 1416, to bill retailers for delivering item
return packages. The
Status of the Item Return Header record 1266 can be updated to a value such as
"billed" after
the billing step is complete. For example, shippers can bill retailers for
each item return
package or for the total number of items returned by using the data contained
in the Item
Return Header 1266 and Item Return Detail 1268 records associated with a
delivered
(returned) item return package.
In another embodiment of the invention, various entities can coordinate with
each
other to perform each of the different steps within the ePD Delivery Process.
For example, a
retailer can capture orders; a product fulfillment concern can pick cases of
ordered items and
prepare them for shipment to an origination RDC; a retailer, shipper, or other
organization
can transport cases of ordered items to an origination RDC; a separate
organization can
operate an origination RDC and forward cases of items to a destination RDC
operated by
another organization; bulk delivered packages can be delivered to CDC's by a
shipper; a
separate organization can operate a CDC; and yet another organization can bill
retailers,
customers or recipients for orders delivered to CDC's. Without departing from
the spirit of
the invention, there can be many different combinations of the various
entities being
responsible for the different steps within the ePD Delivery Process, from
having one
organization do everything to having a different organization responsible for
each step.
In another aspect of the invention, a shipper can operate CDC's exclusively
for the
bulk delivered packages it is delivering. The secured backroom area (154) of a
CDC may not
require the holding cages (134) since all bulk delivered packages which can be
left in the
backroom area (154) can be for the same shipper, and only the workers of that
shipper can
have access to that CDC's backroom area (154). Even though only one shipper
can be
sending packages to that CDC, the tables, data views, and programs that enable
the
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functionality of reserving SBU bins within a CDC can still function to reserve
bins for the
bulk delivered packages or CDC outbound packages of each delivery shipment in
the order in
which they are shipped. This can allow a shipper to make delivery shipment
adjustments to
ensure that a delivery shipment is not sent to a CDC, when that CDC does not
have the
capacity to accept all of the bulk delivered packages and/or CDC outbound
packages of that
delivery shipment.
In another embodiment of the invention, a customer order taken by a retailer
can be
fulfilled from more than one retailer fulfillment site. A retailer (or other
equivalent business
that can accept and fulfill orders) can accept an order from a customer for
various items that it
sells. The items to fill that order can be shipped in cases, organized by a
common item
identifier, from more than one fulfillment site to one or more origination
RDC's to fill that
order. One or more of the fulfillment sites can be owned and/or operated by
the retailer
accepting the order, or the fulfillment sites can be owned and/or operated by
a manufacturer,
another retailer, or another entity with which the retailer has contracted to
fulfill its orders. In
this embodiment, orders can be captured and recorded in Order Header 1200 and
Order Detail
records 1202 by the retailer in the same nature as described in the embodiment
depicted in
FIG. 2, except for the following differences related to the structure and data
contained on the
Order Header 1200 and Order Detail 1202 tables to enable this embodiment: the
ePD Retailer
Id field can be included on the Order Detail record 1202 instead of the Order
Header record
1200 to allow for more than one ePD Retailer Id to be associated with an
order, and an Order
Processing Retailer Id field can be included on the Order Header record 1200
to capture the
identifier associated with the one retailer having overall responsibility for
that order. The
ePD Retailer Id can identify the retailer fulfillment site (or other
equivalent business'
fulfillment site) from which the ordered items of a particular Order Detail
record 1202 can be
sourced. The Order Processing Retailer Id can identify the retailer,
manufacturer, or other
entity that can capture a customer's order in an Order Header record 1200 and
one or more
Order Detail records 1202. After capturing an order, the database of the
instance of the ePD
Shipping Application being run at each fulfillment site identified by an ePD
Retailer Id that is
listed on one of the Order Detail records 1202 of an order can be sent a copy
of that order's
Order Header record 1200 and a copy of each Order Detail record 1202 having
the ePD
Retailer Id associated with that fulfillment site. The copies of the
appropriate Order Header
1200 and Order Detail 1202 records can be sent at the time that the retailer
receives the order
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from the customer or at a later interval via a batch process. After receiving
the copies of the
Order Header 1200 and Order Detail 1202 records related to an order, a
fulfillment site can
pick cases of items to meet the orders it receives in the same manner as
described in the
embodiment depicted by FIG. 2. The cases of ordered items can be sent from
each retailer
fulfillment site to its associated RDC (depending upon the shipper being used
for the order),
and depending upon the location of the different retailer fulfillment sites
sourcing an order,
the items of that order may initially be received into several different
origination RDC's.
Processing steps consistent with the embodiment described for FIG. 2, can be
performed to
sort, transport, combine into packages, and deliver packages of the ordered
items to a CDC in
bulk or to customer-specified address, regardless of from how many retailer
fulfillment sites
those ordered items originated. The retailer responsible for the entire order
can be tracked
and billed using the Order Processing Retailer Id on the Order Header record
1200.
In yet another embodiment of the invention, there can be retailers creating
bulk
delivered packages at their fulfillment sites and shipping those retailer-
created bulk delivered
packages to a RDC. Retailers can pick items and create bulk delivered packages
at their
fulfillment sites to fill each customer order. Customer orders can either be
picked
individually or batch picked and sorted at a packing station to create bulk
delivered packages
to fill customer orders. A retailer can, for example, print a packing list and
a package label .
for each customer order, place the packing list inside the bulk delivered
package, and affix
the package label on the outside of the bulk delivered package. The package
label can
contain a Package Id in barcode format and a RDC Id and CDC Id in readable
format. The
bulk delivered packages created at the retailer fulfillment site can be
shipped to a RDC by the
retailer or a shipper on a tractor-trailer or other cargo carrying transport
for further processing.
Retailer-created bulk delivered packages labeled with a RDC Id different than
the RDC
which received the bulk delivered packages from the retailer fulfillment site
(the origination
RDC) can be sorted by RDC Id (in the RDC sort process) at the origination RDC,
forwarded
to the appropriate destination RDC as part of a RDC shipment, and shipped out
of the
destination RDC to a CDC or LDDH as part of a delivery shipment. Retailer-
created bulk
delivered packages labeled with the RDC Id of the origination RDC can pass
through the
RDC sort at the origination RDC, move into the local market sort, be picked
directly from the
CDC sort conveyor (42) into a delivery shipment, and be shipped out of the RDC
as a bulk
delivered package to a CDC or LDDH in one of the local markets served by that
RDC. In a
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further aspect of the invention, the retailer-created bulk delivered packages,
that have a CDC
Id, which is in the same local market as the retailer fulfillment site in
which that bulk
delivered package was created, can be grouped by CDC Id and shipped directly
to a CDC or
LDDH within that local market by the retailer or a shipper. In this
embodiment, all other
retailer-created bulk delivered packages can be shipped to a RDC. In a further
aspect of the
invention, the retailer-created bulk delivered packages having any CDC Id can
be grouped by
CDC Id at a retailer fulfillment site and shipped directly to the CDC or LDDH
to which it
should be delivered without first being shipped to a RDC.
The invention can further include more than one retailer-created bulk
delivered
package that can be combined together to create fewer, larger bulk delivered
packages.
Retailers can create bulk delivered packages at their fulfillment sites and
send them on
retailer shipments to an origination RDC. The processing at an origination RDC
can include
sorting the retailer-created bulk delivered packages by RDC Id and forwarding
them to their
destination RDC in RDC shipments. The processing at a destination RDC can
include
sorting the retailer-created bulk delivered packages by CDC Id, and then by
Customer Id
within the group of retailer-created bulk delivered packages organized by CDC
Id. Once
grouped by Customer Id within a CDC Id, multiple retailer-created bulk
delivered packages
can be combined into a larger package to be delivered for a package recipient
at a CDC or a
customer specified address. This embodiment can require an addition level of
sorting, but
can decrease the number of bulk delivered packages that need to be handled in
delivering
customer orders.
In a further embodiment of the invention, the programs used to sort cases and
create
bulk delivered packages at a RDC can function without using Temperature Code.
In this
embodiment, Temperature Code may not even be tracked on the tables and data
views upon
which it is tracked in the main embodiment, and the Package Creation Program
(330) can
create bulk delivered packages by grouping picked items into bulk delivered
packages by
CDC Id-Customer Id combination, instead of by CDC Id-Customer Id-Temperature
Code
combination.
Another aspect of the invention can include creating retailer-specific bulk
delivered
packages at a destination RDC. Retailers can ship cases of ordered items to an
origination
RDC to create bulk delivered packages at a destination RDC as described in the
main
embodiment. The receiving, inter-RDC shipping, and sorting processes described
in the main
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embodiment can occur in this embodiment, except that the Package Creation
Program (330)
can create retailer-specific bulk delivered packages by grouping picked items
into packages
by CDC Id-Customer Id-Temperature Code-ePD Retailer Id combination, instead of
by CDC
Id-Customer Id-Temperature Code combination. If Temperature Code is not an
active factor
' used to segregate items into bulk delivered packages for recipients, then
CDC Id-Customer
Id-ePD Retailer Id combination can be used instead of using CDC Id-Customer Id
combination. By adding ePD Retailer Id to the Package Creation Program's (330)
criteria for
determining whether to direct a worker to pick an item for a bulk delivered
package, a
- different bulk delivered package can be created to hold the items ordered
from each retailer,
to be delivered to a package recipient at a CDC or customer specified
location. Each bulk
delivered package can contain ordered items from only one retailer.
In yet a further embodiment of the invention, bulk delivered packages can be
sent
from more than one RDC to a CDC. This can increase the number of ordered items
that can
be shipped to a CDC from an origination RDC, rather than being shipped as part
of a RDC
shipment to a destination RDC, before being shipped to a CDC. By eliminating
the need to
transport some items on a RDC shipment, this embodiment could lower the
overall shipping
cost on some orders. Enabling this embodiment can be more complex than the
main
embodiment described, however, as the Pick List Report Program (310) would
need to be
able to determine if the shipper's origination RDC is a RDC which delivers to
the CDC or
LDDH associated with an order, and if it is not, the Pick List Report Program
(310) would
need to be able to determine which RDC Id, of more than one possible RDC, to
write to an
Order Header record 1200. To enable this embodiment, a decision table or a set
of processing
rules could be created for and utilized by the Pick List Report Program (310)
to compare one
of the possible RDC Id's against the RDC Id of the shipper's origination RDC
for that
particular retailer fulfillment site.
' In another aspect of the invention, a shipper can operate a distribution
network in
which one centralized RDC can be utilized to receive all retailer shipments
and CDC reverse
shipments and create bulk delivered packages and delivery shipments to be
shipped out to all
CDC's and LDDH's. This embodiment can be essentially the same as the main
embodiment
described in this disclosure, except that a shipper operates only one RDC, a
RDC sort sub-
process is not needed, RDC shipments do not need to be created, and all cases,
CDC
outbound packages, and item return packages can move directly into the local
market sort
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sub-process at that shipper's one central RDC following receipt. Assigning a
RDC Id to
orders for a shipper operating only one RDC can also be simplified by having
the programs,
which assign a RDC Id to the different records that contain a RDC Id, default
to the one RDC
Id for that shipper.
In a further embodiment, the local market sort step of the ePD delivery
process can be
bypassed. A RDC can contain only one CDC sort conveyor, which can be located
adjacent to
all the CDC packing station conveyors (44) in that RDC. Cases of ordered
items, CDC
outbound packages, and item return packages, having the RDC Id of the RDC in
which they
are located, can flow from a RDC sort conveyor (18) or a RDC inbound conveyor
(34)
directly onto one single CDC sort conveyor, which can be located adjacent to
aI1 the CDC
packing station conveyors (44) within that RDC to allow workers performing the
CDC sort to
scan and pick those cases and CDC outbound packages onto their CDC packing
station
conveyors (44). RDC workers creating RDC returns shipments can be grouped by
local
market or by groups of retailers and stationed along the one CDC sort conveyor
at different
points to scan and pick item return packages from the one CDC sort conveyor.
This can
result in a cost savings associated with not performing the local market sort
step, but the CDC
sort step may be less efficient and more costly.
Other aspects of the invention can include using multiple local market sort
conveyors
(24) to perform the local market sort step of the ePD delivery process. In
this embodiment, a
RDC can have more than one local market sort conveyor (not shown as
constructed for this
embodiment). Cases of ordered items, CDC outbound packages, and item return
packages
(having the RDC Id of the RDC in which they are located) can flow from the RDC
sort
conveyor (18) and the RDC inbound conveyor (34) onto one of the multiple local
market sort
conveyors. Each local market sort conveyor can move the cases and packages
past the CDC
sort conveyors (42), which can each represent a different local market. CDC
sort conveyors
(42) can be grouped together around one of the multiple local market sort
conveyors
randomly, by geographical location, or by some other logic. RDC workers
performing the
RDC sort for the current RDC would need to be able to determine to which local
market sort
conveyor to move the cases and packages. This could be accomplished by
scamling the case
or package label or reading the Local Market Id embedded in the CDC Id printed
on the
labels of CDC outbound packages and item return packages. A new RDC activity
would
need to be performed to enable this embodiment, requiring one or more workers
to scan and
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pick cases from the RDC inbound conveyor (34), and to scan and pick or look at
the labels on
CDC outbound packages and item return packages and pick them onto one of the
multiple
local market sort conveyors. In another aspect of the invention, when cases,
CDC outbound
packages, and item return packages can be separated by RDC Id during the RDC
sort at their
origination RDC, they can be grouped together into shipments specific to the
local market
sort conveyors of their destination RDC. The RDC Shipment Program (318) can
have the
ability to facilitate the creation of an RDC shipment for a subset of the
local markets served
by a RDC.
In a further embodiment of the invention, the RDC Id can be located on the
Order
Detail records 1202 instead of Order Header records 1200, or alternately, on
both records.
This embodiment can reduce or eliminate the number of times that programs need
to use the
Order Id on an Order Detail record 1202 to select the Order Header record 1200
associated
with an order to determine the RDC Id of that order.
Further aspects of the invention can include different methods of data
transfer that can
be utilized to copy or move data between two databases. Data records can be
copied or
moved from a table in one database to a table, having the same data structure
(and in many
situations the same name), in another database. The two databases involved in
a data transfer
can be located on the same server or on a plurality of servers. Different
methods of data
transfer can be employed within the ePD Delivery Process for transferring data
from a table
in a database on one server to a table in a database on another server. The
data transfer
opportunities can include, but are not limited to the programs that copy or
move data between
the tables of the database on a retailer server and a RDC server, between two
different RDC
servers, or between a RDC server and a CDC server. The differences in the
method of data
transfer can include copying data instead of moving data, moving data instead
of copying
data, and whether a program "pushes" the data to another program (which can be
initiated by
the program transferring the data) or "pulls" the data from another program
(which can be
initiated by the program receiving the data). For example, the Retailer
Shipment Program
(3 I2), running on a retailer server, can establish a connection to the server
of the RDC to
which a retailer shipment is headed, at the time the retailer shipment is
loaded onto an
outbound trailer. The Retailer Shipment Program (312) can move the Retailer
Shipment
record 1212 associated with that retailer shipment to the Retailer Shipment
table 1212 in the
RDC server's database. In this exemplary embodiment, the Retailer Shipment
Program (312)
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can also select the Case 1208 and Order Detail 1202 records having the
Retailer Shipment Id
of the retailer shipment and can move those records and the Order Header 1200
records
associated with the selected Order Detail records 1202 to the corresponding
tables in the
database on the RDC server. Thus, prior to the arrival of that retailer
shipment, the database
of the RDC to which the retailer shipment is being sent would have a Retailer
Shipment
record 1212 and one or more Case 1208, Order Detail 1202, and Order Header
1200 records
associated with that retailer shipment. The Status on those records would
reflect that the
retailer shipment is still in transit and has not yet been received -- the
Status field on those
records (on the RDC server's database), in the exemplary embodiment, would
have the same
values that the Status field on those records (on the retailer server's
database) would have in
the main embodiment. When the retailer shipment is received into the RDC, the
Status
values of the Retailer Shipment 1212, Case 1208, Order Detail 1202, and Order
Header 1200
records can be updated to reflect that the retailer shipment has been received
(the values in
the Status fields can be set to the same values, in the exemplary embodiment,
that those
records would have in the Status field, in the main embodiment, after the
retailer shipment
had been received). Although the method and timing of when the data can be
written to the
RDC server can be different in this exemplary embodiment, the material result
remains the
same, so that the records can be in the database of the RDC server with the
appropriate
values. Since the records were moved instead of copied, the retailer database
does not
contain a copy of the records.
In still a further embodiment of the invention, different means can be used to
transfer
data from one database to another including, but not limited to remote data
connections and ,
file transfer. A program of an application that can be connected to one
database can establish
a remote data connection to a different database, on a different server, to
copy or move data
from or to that database. Different types of remote data connections can be
established
between the programs and/or databases on a first server and the programs
and/or databases on
a second server including, but not limited to the following: a dedicated
network connection
can be continuously available between the two servers; a high-speed or
standard-speed direct
dial-up connection can be established; and a high-speed or standard-speed
connection can be
established through an intermediary service provider. In one aspect of the
invention, a first
program can create and send one or more files containing data from a first
database on a first
server (or a workstation connected to the first server) to a second server (or
a workstation
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connected to the second server). A second program can later read the files and
write the data
contained therein to a second database on the second server to complete the
action of copying
or moving data from the first database to the second database. The program
initiating the
creation of the f 1e can be on the first server or the second server. There
can also be a
separate program or service to initiate the transfer of the files from one
server to another,
instead of having one program create and send the files. The timing of the
file transfer can be
immediate (real-time) or scheduled (batch) for a specified future time or at a
regular interval.
The files can be sent over a private network, a public network, or the
Internet. Varying file
encryption/data encryption standards can be used to protect the data being
sent in the files.
In yet another embodiment of the invention, a wireless network architecture
can be
used at retailer fulfillment sites, RDC's, and/or CDC's to connect
workstations to servers,
servers to other servers, workstations and/or servers to various types of
scanning devices, and
workstations and/or servers to automated equipment and other peripheral
devices including,
but not limited to conveyors, printers, CDC packing stations (45), digital
video cameras,
. electronically locking doors, and SBU's. The type of technology enabling a
wireless network
at a retailer fulfillment site, RDC, and/or CDC can be radio frequency (RF),
home RF,
Bluetooth, WAP, and/or any other suitable type of wireless networking
technology. An in-
building wireless system employing, for example, TDMA, CDMA, AMPS or GSM can
be
used. One example of using a wireless network architecture can involve using a
RF system in
a CDC. In this exemplary embodiment, a CDC worker can use a hands-free scanner
connected to the CDC server of a CDC via a RF system. The worker can scan
their employee
id card to log in to the Loading Program (356) and a SBU label on the outside
of one of the
SBU's. SBU's can have labels) on their exterior with their SBU Id in barcode
format, and
scanning the label on a SBU (after having scanned an employee id Bard) can
trigger the same
actions that scanning an employee id card, with a scanner that is plugged into
a SBU, does in
the main embodiment - the Loading Program (356) can move the revolving bins to
position
the closest available bin in the loading position, unlock the SBU's bin doors,
and associate
the Employee Id that was previously scanned with any future loading actions
performed on
that SBU. Those main actions can be in addition to the validation, table
updates, and other
actions that the Loading Program (356) can perform. The worker can then scan
package
labels followed by bin door labels as the worker loads bulk delivered packages
into that SBU.
The Loading Program (356) can function in the same way in response to the
scans of a
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scanning device connected via a wireless network in this embodiment, as it
would to the
scans of a physically connected scanning device in the main embodiment. The
wireless
aspect of this exemplary embodiment can allow a CDC worker to load bulk
delivered
packages into the bins of many SBU's without needing to plug and unplug a
network
~ connector in and out of the scanner port of each SBU. The feature of being
able to capture a
unique identity and associate it with a scanning device can allow a CDC worker
to be able to
connect to different SBU's and associate the loading actions at each of those
SBU's with their
Employee Id without having to re-scan their employee id card at each new SBU.
These two
features can both be enabled as part of an embodiment in which a wireless data
architecture is
used in a CDC, or each feature can be enabled without the other in other
separate
embodiments.
In still a further embodiment of the invention, cases, CDC outbound packages,
item
return packages, and/or bulk delivered packages can be sorted, picked, and/or
redirected using
automated sorting and picking equipment and programs to move them through a
RDC to the
places where they can be loaded into RDC shipments, used to create bulk
delivered packages,
loaded into delivery shipments, or loaded into RDC returns shipments.
Automated
equipment including optical reading devices mounted near or on conveyors
carrying the cases
and different types of packages can read barcode or other imprinted formats on
the case labels
and different package labels to determine if a case or package should be
picked. If an
automated picking program determines that a case or package should be picked
from a
conveyor or redirected to another conveyor, based upon the data read from the
optical reading
device, it can initiate a mechanical device to pick or redirect the case or
package from the
conveyor. Tn this embodiment, automated programs and,machinery can be used,
for example,
in place of workers to perform the part of the RDC sort in which cases bound
for the current
' RDC can be picked from the outbound section of the RDC sort conveyor (18) to
the local
market sort conveyor (24). Another example, in which automated programs and
machinery
can be used is to replace one or more workers that regulate the flow of cases
from the RDC
inbound conveyor (34) to the local market sort conveyor (24) by moving the
case diverting
section of the RDC inbound conveyor (38) at the right times. Automated sorting
and picking
programs of this nature can also be used to perform the local market sort
function and CDC
sort function.
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In still a further embodiment of the invention, automated sorting programs and
equipment can be used to organize delivery shipments and RDC returns shipments
into full-
trailer-loads. Optical reading equipment to read the label plates containing
Delivery
Shipment Id's and/or RDC Returns Shipment Id's can provide the data inputs to
an
automated sorting programs that can move the CDC feed of a CDC package
conveyor (47A)
and the different independent conveyor sections of the local market feed of a
CDC package
conveyor (47B) to position different delivery shipments near each other to
create a full-
trailer-load. Similarly, an automated sorting program can initiate the RDC
returns shipment
conveyor (62) to move one or more RDC returns shipments into close proximity
of one or
more delivery shipments on a package conveyor (46A or 46B) to create a full-
trailer-load.
In yet another embodiment of the invention, sophisticated automated picking
and
packing equipment can be used to pick items from cases and redirect them into
the open
packages in which they should be packed. The automated equipment can be
integral part of
the physical hardware that makes up a CDC packing station and can function,
when directed
by the Package Creation Program (330), to insert printed packing Iists into
bulk delivered
packages, close and seal bulk delivered packages, open new bulk delivered
packages, and
label package bags. In a further aspect of the invention, additional equipment
can be added to
or changed on a CDC packing station (45) to aid a worker in setting up new
bulk delivered
packages and in closing and sealing bulk delivered packages, by automating the
process of
putting a new package bag in a package bag holder or sealing a package bag in
a more
automated manner. A package bag can be closed and sealed while still in its
package bag
holder (71 or 72) and the package sealing side of a CDC packing station (FIG
5) may not
need to exist separately from the package creating side of a CDC packing
station (FIG 4).
A further embodiment of the invention can include programs playing brief audio
messages~instead of sounding tones to convey a more descriptive message. This
embodiment
can include programs that run in a RDC, CDC, or retailer fulfillment site. The
workers using
the different programs may wear headsets or ear-bud headphone pieces to ensure
that they can
differentiate the audio messages intended for them from the ones created by
other instances of
the same program or other programs, which can be intended for other workers.
For example,
when a worker performing the local market sort in a RDC scans a case on the
CDC sort
conveyor (42), at which the worker is stationed, to pick and remove it from
the current local
market, back to the local market sort conveyor (24), the Local Market Sort
Program (326) can
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play a brief audio message to confirm that a reverse local market sort pick
has been processed
successfully, such as, "reverse pick confirmed". Any combination of tones,
brief audio
messages, text messages displayed on workstation display monitors, text
messages displayed
on scanning devices, andlor indicator lights can be used to alert a worker to
a message and
relay various messages including, but not limited to warning messages,
confirmation
messages, error messages, directions, suggestions, and commands.
A further embodiment of the invention can include employing a different amount
of
validation in the different programs. More validation steps can be added to
programs in
situations where errors can be more likely, more critical, and/or when the
processing required
to complete the additional validation does not adversely impact the speed and
ease of using
that program.
In a further embodiment of the invention, Bin Inventory table records 1300 can
exist
for every possible bin configuration. There can be an Active Status field on
the Bin Inventory
table 1300, which can be used to activate and deactivate each record by
changing its value
from a value such as "inactive" to a value such as "active" and vice versa. As
the SBU
Configuration Program (352) is run, in this embodiment, the Active Status
field on Bin
Inventory records 1300 associated with a master bin can be updated to reflect
the
configuration changes made to that master bin. For example, if a master bin
that is divided
into two bins, each with a Bin Size of "2", is configured to become one large
undivided bin, it,
will start with two Bin Inventory records 1300 that have an Active Status with
a value such as
"active" - one of those records having a Configuration Code value such as "12"
and the other
having a Configuration Code value such as "34". After the configuration
adjustment gets
made, both of the records which had an Active Status value such as "active"
will have an
Active Status value such as "inactive". The Active Status of the Bin Inventory
record 1300
' associated with that master bin that has a Configuration Code such as
"1234", can be updated
from a value such as "inactive" to a value such as "active". The number of
records on the Bin
Inventory table 1300 can be much larger than if inactive records were not
listed on the table
1300. Configuration adjustment changes can be made more easily, by updating
the Active
Status field on a few Bin Inventory records 1300 associated with a SBU master
bin, instead of
creating new Bin Inventory records 1300 and/or deleting existing ones.
In a further embodiment of the invention, each individual case can be scanned
to
associate it with a retailer shipment, when loading cases into a trailer at a
retailer fulfillment
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site. A Pick List Report does not need to be broken up into pick grouping
sections and a
worker loading a retailer shipment onto a trailer does not need to scan Pick
Grouping Id's as
the cases of a retailer shipment are loaded. The worker does need to scan each
case as it is
loaded onto a trailer to associate it with the retailer shipment. The Retailer
Shipment
Program (312) can update the Case record 1208 of each case as it is scanned
into a retailer
shipment by setting its Status to a value such as "on trailer" and writing the
Retailer Shipment
Id of the current retailer shipment to the Retailer Shipment Id field of the
record 1208, instead
of updating a group of Case records 1208 having a Pick Grouping Id, as that
Pick Grouping
Id is scanned on a Pick List Report. The Retailer Shipment Program (312) can
also update
Order Detail records 1202 with that Retailer Shipment Id and a Status value
such as "retailer
shipment - back order" or "retailer shipment - new" (depending upon whether
its Status was
"pick list - back order" or "pick list - new"), for Order Detail records 1202
having the SKU of
the scanned case, up to the Quantity of the scanned case.
In still a further embodiment of the invention, a group of cases with
sequential Case
. Id's can be associated with a retailer shipment by scanning the case Iabel
of the first and last
case in the retailer shipment. Cases can be picked in the sequence in which
they can be listed
on a Pick List Report and loaded as a retailer shipment in the sequence in
which they were
picked. In this embodiment, a set of sequential Case Id's can be loaded onto a
trailer as a
retailer shipment as the worker loading the cases onto the trailer can, for
example, scan the
case label of the first and last case being loaded, after scanning their
employee id card and the
trailer label. The Retailer Shipment Program (312) can update the Case record
1208 of the
two scanned cases and all of the Case records 1208 listed sequentially in
between those two
records on the Case table 1208. The Retailer Shipment Program (312) can update
the Case
records 1208, and can select and update Order Detail records 1202, in this
embodiment,
consistent with the way in which the Retailer Shipment Program (312) can
update Case
records 1208 and can select and update Order Detail records 1202 that can be
added to a
retailer shipment via a scanned Pick Grouping Id in the main embodiment.
In a further embodiment of the invention, cases of ordered items can be
labeled as
they are received at an origination RDC. The Pick List Report Program (310)
can print a Pick
List Report that lists the total number of cases of each SKU that should be
picked, but does
not contain case labels. The Pick List Report Program (310) can create Case
records 1208 in
the same way as described in the main embodiment. Workers at a retailer
fulfillment site can
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pick the total number of cases needed to f 11 the orders listed on the Pick
List Report and can
load them onto one or more trailers as retailer shipments. All the Case
records 1208 created
by the Pick List Report Program (310) can be sent in a data file or copied
through a remote
data connection to the database of the origination RDC, to which the retailer
shipments
containing the cases picked using that Pick List Report are being sent, when
the Pick List
Report Program (310) is run. Order Detail records 1202 can be selected and
sent/copied, so
that the total Quantity of all the selected Order Detail records 1202, that
have a particular
SKU, equals the total Quantity of all the Case records 1208 created by the
Pick List Report
Program (310), which have that same SKU. The Order Header records 1200
associated with
the selected Order Detail records 1202 can also be selected and sent/copied to
the RDC
database. In this embodiment, Retailer Shipment records 1212 are not created
and Case 1208
and Order Detail 1202 records are not updated with a Retailer Shipment Id or a
different
Status when the picked cases are shipped from the retailer fulfillment site as
a retailer
shipment. Workers at the RDC, receiving retailer shipments sent from retailer
fulfillment
sites, can run a program which can print case labels using the Case records
1208 sent/copied
from the retailer's database and can update the Status of the copied Case 1208
and Order
Detail 1202 records to a value such as "origination RDC". The RDC workers can
then label
each case as it is received into the origination RDC. The labeled cases can
then be processed
at the RDC consistent with the description of the main embodiment. This can
shift the effort
involved in labeling picked cases from workers at a retailer fulfillment site
to the workers at
an origination RDC, but it may be prone to labeling errors, and it does not
provide accurate
visibility as to the location of a picked case from the time it is printed on
a Pick List Report
until the time that it is labeled at the origination RDC.
A further embodiment of the invention can include, labeling cases when they
are
organized into a retailer shipment at the retailer fulfillment site, instead
of when they are
picked. The Pick List Report Program (310) can print a Pick List Report
containing case
labels, but the workers using the report to pick the cases can refrain from
labeling cases as
they are picked. The cases can be labeled at the shipping dock, after they
have been picked,
as they are being organized into a retailer shipment. In this embodiment, the
Retailer
Shipment Program (312) can update Case 1208 and Order Detail 1202 records to
associate
them with a retailer shipment in a way consistent with the main embodiment,
the embodiment
in which each case is scanned to associate it with a retailer shipment, or the
embodiment in
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which cases can be associated with a retailer shipment sequentially in between
two scanned
case records.
In a yet a further embodiment of the invention, the trailers upon which RDC
shipments have been loaded can be moved to a RDC inbound receiving dock (31)
or from a
RDC shipping dock (52) using loading equipment which can be found in an
intermodal rail
yard. The loading equipment can be located in between the RDC and a rail line
adjacent to
the RDC. In this embodiment, trailers can be moved from a train to the RDC
inbound
receiving dock (31) of a RDC, from the RDC inbound receiving dock (31) to the
RDC
shipping dock (52) of the RDC, and from the RDC shipping dock (52) to a train
using loading
equipment instead of a drayage vehicle (tractor).
In still a further embodiment of the invention, large conveyors, located
outside of a
RDC, can be used to move trailers to RDC inbound receiving docks (31), RDC
shipping
docks (52), and conveyor platforms located along side of a rail line. The
conveyor platforms
located next to the rail line can serve as loading and unloading points for
loading equipment
to move the trailers off of and onto a train. The other sections of the large
conveyors can be
used to move the trailers from the conveyor platforms next to the rail line to
conveyor
platforms next to the RDC inbound receiving docks (31) of the RDC, from the
conveyor
platforms next to the RDC inbound receiving docks (31) to conveyor platforms
next to the
RDC shipping docks (52) of the RDC, and from the conveyor platforms next to
the RDC
shipping docks (52) to the conveyor platforms next to the rail line.
In a further aspect of the invention, the Package Creation Program (330) can
consider
ordered items, which can be on RDC shipments heading for the destination RDC
in which the .
program (330) can run, when determining when to close a bulk delivered package
that can be
in the process of being created. In addition to creating a RDC Shipment
Receiving record on
the destination RDC database when a RDC shipment is sent from its origination
RDC, the
RDC Shipment Loading Program (320) can also copy the Case 1208, Order Header
1200, and
Order Detail 1202 records, that have the RDC Shipment Id of the RDC shipment
being sent,
from the origination RDC database to the destination RDC database. The Order
Detail 1202
and Case 1208 records can be copied with a Status value such as "RDC shipment"
and Order
. Header record 1200 can be copied with a Status value such as "open", but in
this
embodiment, the SKU by Customer Order List data view 1230 can be created by
selecting
fields from Order Detail records 1202 and their associated Order Header
records 1200 which
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have an Order Detail.Status value such as "destination RDC" or "RDC shipment"
and an
Order Header.RDC Id equal to the value of the current RDC. If items have been
picked and
packed into a bulk delivered package to meet the item quantities on all of the
Order Detail
records 1202 having a particular CDC Id-Customer Id-Temperature Code
combination and a
Status value such as "destination RDC", but there is still at least one Order
Detail record
1202 having that CDC Id-Customer Id-Temperature Code combination, a Status
value such
as "RDC shipment", and an associated Order Header record 1200 with an RDC Id
equal to
the value of the current RDC, the Package Creation Program (330) can refrain
from closing
that bulk delivered package.
A further embodiment can include a more automated CDC packing station (45)
featuring moving package bag holders that can move the package bag holder in
which a
worker is being directed to pack a picked item (the highlighted package bag
holder) in front
of the worker that is creating bulk delivered packages at that CDC packing
station (45). The
automated CDC packing station (45) can have, for example, large and small
package bag
holders arranged in a circular structure, which rotates to move the package
bag holders.
In a further embodiment, bulk delivered packages can be created in non-bubble
wrap
bags, boxes, or other suitable containers, in addition to bubble wrap bags.
The bags, boxes,
or other containers should be pre-sized to fit into the standard SBU bin
sizes, however.
In yet another embodiment of the invention, the RDC Returns Shipment Creation
Program (341) can allow workers to still work as a team to create RDC returns
shipments for
the retailers of a local market, even though each worker can be using a
different instance of
the RDC Returns Shipment Creation Program (341). There can only be one open
RDC
returns shipment for a retailer, and each worker on the team can add item
return packages to
any of the open RDC returns shipments. The scanning devices do not need to
have unique
identifiers and there can be a different display screen (which can include,
but is not limited to
a program display monitor, small LCD screen mounted to a fixed base, or a
small LCD screen
built into the scanning device) for each instance of the RDC Returns Shipment
Creation
Program (341). Each display screen can display the program messages specific
to the
instance of the RDC Returns Shipment Creation Program (341) associated with
that display
screen. In a further aspect of the invention, the RDC Returns Shipment
Creation Program
(341) can feature a Returns Shipment Creation Screen that can look and
function similar to
the Package Creation Screen - instead of having numbered shapes representing
package bag
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holders, it can have numbered shapes which represent conveyors, upon which
cargo cages
and single-item return packages can be organized into RDC returns shipments by
retailer. A
set of conveyors upon which RDC returns shipments can be created can be
located in
between a CDC sort conveyor (42) and a RDC returns shipment conveyor (62). The
set of
conveyors can be positioned so that a RDC returns shipment can flow from each
one onto the
RDC returns shipment conveyor (62). Each instance of the RDC Returns Shipment
Creation
Program (341) can guide a worker to pick scanned item return packages and can
add them to
an existing RDC returns shipment on a specific numbered conveyor or create a
new RDC
returns shipment for item return packages on one of the open numbered
conveyors. The RDC
10' Returns Shipment Creation Program (341) can associate a conveyor with the
RDC returns
shipment located on that conveyor, and workers can scan the RDC returns
shipment label of a
RDC returns shipment when adding a picked item return package to a RDC returns
shipment.
Although each worker can be using a separate instance of the RDC Returns
Shipment
Creation Program (341), workers can work in teams to create the RDC returns
shipments,
there can only be one open RDC returns shipment for a retailer, and each
worker on the team
can add item return packages to any of the open RDC returns shipments.
In a further aspect of the invention, the RDC Returns Shipment Creation
Program
(341) can feature a Returns Shipment Creation Screen, each worker can use a
separate
iystance of the RDC Returns Shipment Creation Program (341), and each worker
can create a
limited number of separate RDC returns shipments instead of working as a team
with other
workers to create RDC returns shipments. As a worker scans an item return
package, the
RDC Returns Shipment Creation Program (341) can check to see if that worker
has an open
RDC returns shipment for the retailer associated with the scanned item return
package. If the
worker has an open RDC returns shipment for the retailer associated with the
scanned item
return package, the RDC Returns Shipment Creation Program (341) can direct the
worker to
pick the item return package and place it into the RDC returns shipment on the
conveyor that
it highlights on the Returns Shipment Creation Screen. If the worker does not
have an open
RDC returns shipment for the retailer associated with the scanned item return
package, the
RDC Returns Shipment Creation Program (341) can check to see if another worker
has a
open RDC returns shipment for the retailer associated with the scanned item
return package.
If another worker has an open RDC returns shipment for that retailer, the RDC
Returns
Shipment Creation Program (341) can direct the worker not to pick the item
return package.
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If there is not an open RDC returns shipment fox that retailer, the RDC
Returns Shipment
Creation Program (341) can direct the worker to pick the item return package
and create a
new RDC returns shipment. In a further aspect of the invention, RDC workers
can use the
RDC Returns Shipment Creation Program (341) to create a limited number of
separate RDC
returns shipments, but the RDC Returns Shipment Creation Program (341) can
allow each
worker to create a new RDC returns shipment for a retailer, even if another
worker has an
open RDC returns shipment for that retailer. The processing step of checking
for which
retailers other instances of the RDC Returns Shipment Creation Program (341)
have an open
RDC returns shipment can be eliminated. RDC returns shipments bound for the
same retailer
can optionally be grouped together, before they are moved to a local market
shipping dock
(50), when full-trailer-loads of RDC returns shipments and delivery shipments
are created.
In a further embodiment of the invention, delivery shipments can be loaded
onto an outbound
trailer and shipped from a RDC without reserving bin space for the bulk
delivered packages
and CDC outbound packages of that delivery shipment. The Delivery Shipment
Program
(342) can still print a listing on a Delivery Shipments Report for each
delivery shipment
loaded onto a trailer, and when a delivery shipment is received into a CDC,
the barcode on
the Delivery Shipments Report associated with that delivery shipment can be
scanned and
used by the Loading Guide Report Program (354) to create a Loading Guide
Report. CDC
workers can use the Loading Guide Report to assist them as they load the bulk
delivered
. packages and CDC outbound packages of a delivery shipment into SBU bins. If
there are not
enough SBU bins available in the CDC to receive all of the bulk delivered
packages and CDC
outbound packages of a delivery shipment, the packages that are not able to be
loaded into
SBU bins can be stored in a holding cage (134) associated with the shipper
delivering the
delivery shipment.
In still a further embodiment of the invention, the Configuration Adjustments
Report
Program (344) is not initiated by the Delivery Shipment Program (342) as part
of loading a
delivery shipment onto a trailer, but it can be run periodically to adjust the
number of bins of
each bin size to meet the appropriate levels determined by bin usage trend
reporting. This
can be employed to set the number of bins of each bin size to an optimal
level, which can
reduce the effort that may be required to make bin configuration adjustments
to try to meet
the bin space requirements of every delivery shipment sent to a CDC. A bin
usage trend
report can be created from data snapshots of a CDC's available bin capacity,
the number of
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bulk delivered packages and CDC outbound packages shipped to a CDC in a day,
and the
number of bulk delivered packages and CDC outbound packages removed from
delivery
shipments of a CDC, to show the optimal numbers of bins of each bin size for a
CDC. The
bin usage trend reporting can be run separately for each CDC or across groups
of CDC's.
The Configuration Adjustments Report Program (344) can use the output from the
bin usage
trend report, a data view created from the Bin Inventory table of a CDC as a
summary of the
number of bins of each Bin Size, and the Unreserved Bins data view 1305 to
determine the
number of bin configuration adjustments to make in a CDC. In one aspect of the
invention, a
Configuration Adjustments Report can print in a CDC and can be used by a
shipper or the
entity running a CDC to make bin configuration adjustments in the same manner
as described
in the main embodiment. If there are not enough SBU bins available in a CDC to
receive all
of the bulk delivered packages and CDC outbound packages of a delivery
shipment, the
number of packages of each package size, above the amount which can be
reserved for the
current delivery shipment, can be removed from the current delivery shipment
by the
Shipment Adjustments Report Program (345) as described in the main embodiment.
A further embodiment of the invention can include using holding cages ( 134)
or
excess secured storage space in the backroom area (154) of a CDC to allow one
or more
shippers to deliver more bulk delivered packages and CDC outbound packages to
a CDC
before needing to make delivery shipment adjustments to the delivery shipments
it sends to
that CDC. The Shipment Adjustments Report Program (345) can be configured to
allow a
predetermined number or a percentage of bulk delivered packages above that
CDC's
remaining capacity of available SBU bins to be shipped.
A further embodiment of the invention can include cargo cages which can have
retractable wheels. These cargo cages can be received into a CDC onto a dock
conveyor and
. then pushed or pulled through the CDC by one or more CDC workers unloading
packages
from that cargo cage. The cargo cages can be linked together to form larger
groups of bulk
delivered packages that can be easily movable throughout a CDC, without the
use of mobile
putaway conveyor units (143).
In a further embodiment of the invention, package recipients can be notified
of the
receipt of a bulk delivered package or a CDC outbound package only once.
Although the
functionality to call/send reminder notifications to a recipient is not
available in this
embodiment, the New Package Notification Program (35~) and the Notification
Program
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(360) can still work together with the Customer table 1256 to notify a package
recipient
according to their recorded preferences and to prevent them from receiving a
separate
notification message fox each bulk delivered package received, if more than
one bulk
delivered package is received before the recipient retrieves their bulk
delivered packages.
In still a further embodiment of the invention, notification messages can be
customized by each shipper to include standard information, such as a
description of their
package retrieval policies, or situation specific information based upon
factors including, but
not limited to the time elapsed since the delivery notification of a bulk
delivered package, the
number of packages currently in a CDC for a package recipient, seasonal-based
factors, and
CDC location-based factors. A separate table can be used to store different
predefined
messages that can be selected for use in an electronic notification message
depending upon
the values of other fields on that table. This can provide shippers with the
capability to
change the content of notification messages sent to package recipients and can
allow them to
have several situational notification messages that can be selected and played
based upon
other factors.
A further embodiment can include sending a notification message to a package
sender
when a CDC outbound package that the package sender sent has been delivered to
a CDC. A
package sender can indicate the desire to be notified when the CDC outbound
package the
sender is sending is delivered - delivered to its destination CDC and loaded
into a SBU bin.
An indicator field on a CDC Outbound Package record 1270 can be used to track
whether a
package sender selected this feature and can be used by the New Package
Notification
Program (358) to create a Notification Queue record 1311 containing a field to
indicate that
the record is for notifying a package sender and not a package recipient. Upon
checking the
value of that indicator field when processing Notification Queue records 1311,
the
Notification Program (360) can initiate the Auto-call Program (362) and/or the
Auto-e-mail
Program (364) to contact the package sender. After one or more messages are
sent to the
package sender successfully, in accordance with the package sender's
notification
preferences, the Notification Program (360) can delete the package sender's
record from the
Notification Queue 1311. A different message can be played for notifying a
package sender
than a package recipient. If a customer is both a package sender and a package
recipient at
the same time, the customer can have more than one record on the Notification
Queue table
1311, and the customer can be contacted separately with each type of message.
A package
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sender notification message can include the package recipient's name, and a
package sender
can receive a distinct message for each CDC outbound package the package
sender sends,
regardless of when those packages are delivered. The Notification Program
(360) can be
configured to treat Notification Queue records 1311 for package senders with
the same
priority as Notification Queue records 1311 for package recipients, or they
can be treated with
a different priority.
In a further embodiment of the invention, a CDC can have separate returns
processing
entry points (14~) for each shipper accepting item return packages and/or CDC
outbound
packages at that CDC. This can result in customers/recipients naturally
segregating item
return packages and/or CDC outbound packages by shipper when they send an item
return or
a CDC outbound package, allowing for the CDC workers of each shipper to more
easily
identify item return packages and CDC outbound packages marked for their
shipping
organization when creating CDC reverse shipments.
Tn a further embodiment of the invention, an ePD customer access card can be
used at
a SBU along with an entered PIN to retrieve a bulk delivered package instead
of entering a
Quick Code and PIN on the SBU keypad (244).
In still a further embodiment of the invention, a Customer Id and PIN can be
entered
on a SBU keypad (244) to retrieve a bulk delivered package instead of entering
a Quick Code
and PIN on the SBU keypad (244).
In a further embodiment, shippers can bill the customers placing orders,
instead of the
retailers accepting those orders. The amount billed can be based upon factors
including, but
not limited to a flat shipping fee per order, a fee based upon the number of
items in an order,
a fee based upon the weight of an order, a fee based upon the value of an
order, a fee based
upon package size, a fee based upon the number of packages in an order,
location-based
storage rates, and seasonal-based storage rates.
Tn still a further embodiment, the entity operating a CDC can charge
retailers,
shippers, or customers a storage fee for each package or order delivered based
upon factors
including, but not limited to the number of SBU bins used to hold the packages
of an order,
the size of each SBU bin used to hold each package, the amount of time that a
package is in a
SBU bin after the package recipient was notified of delivery, a flat storage
charge per order, a
storage charge based upon the value of an order, a flat storage charge per
package depending
upon package size, location-based storage rates, and seasonal-based storage
rates.
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Yet another embodiment can include retailers creating temperature-controlled
bulk
delivered packages at their fulfillment sites for regional distribution to
CDC's and LDDH's in
the local markets served by a RDC. The retailers can create bulk delivered
packages that
require refrigeration or sub-freezing temperatures using a Retailer Package
Creation Program
(315) or a modified version of their own order fulfillment software. Each bulk
delivered
package created at a retailer fulfillment site can have an associated Package
record (which can
be of the same data structure as described in the main embodiment), a packing
list, and a
package label (which can be of the same format as described in the main
embodiment). The
temperature-controlled bulk delivered packages can be shipped to a shipper's
RDC in cargo
cages or any other suitable container on a temperature controlled tractor-
trailer or other cargo
carrying vehicle. The retailer shipment containing temperature-controlled bulk
delivered
packages can arrive at a RDC and can be unloaded from a trailer conveyor (204)
to a
temperature-controlled receiving dock in the same way that retailer shipments
of cases can be
unloaded from trailers and moved into a RDC in the main embodiment. The
Package 1234,
Order Header 1200, and Order Detail 1202 records associated with the
temperature-controlled
bulk delivered packages can be copied from the retailer's database to the
database on the
RDC server using a method similar to the one used to copy Case 1208, Order
Header 1200,
and Order Detail 1202 records associated with a retailer shipment of cases.
After the cargo
cages or other containers filled with the temperature-controlled bulk
delivered packages of
the temperature-controlled retailer shipment are moved onto a temperature-
controlled
receiving dock in the RDC, RDC workers can empty the cargo cages and/or other
suitable
containers filled with the temperature-controlled bulk delivered packages onto
the
temperature-controlled local market sort conveyor. RDC workers performing the
temperature-controlled local market sort can pick temperature-controlled bulk
delivered
packages from the temperature-controlled local market sort conveyor and place
them on the
temperature-controlled CDC sort conveyors at which they can be stationed by
reading the
Local Market Id embedded in the CDC Id printed on the package label or
scanning the
barcode on the package label using a program similar to the Local Market Sort
Program (326)
that is able to process scanned Package Id barcodes and direct a worker to
pick or ignore
temperature-controlled bulk delivered packages for the local market of the
temperature-
controlled CDC conveyor at which that worker is stationed. RDC workers
creating
temperature-controlled delivery shipments for a particular CDC or LDDH can
scan and pick
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temperature-controlled bulk delivered packages from the temperature-controlled
CDC sort
conveyor at which they are stationed and can place them into a temperature-
controlled
delivery shipment. The entire area where temperature-controlled bulk delivered
packages can
be received, sorted, and added to temperature-controlled delivery shipments
can be located in
a temperature-controlled area within a RDC, or at least the location in which
parts of that
process occur can be located in a temperature-controlled area of the R.DC.
Temperature-
controlled delivery shipments can be loaded onto temperature-controlled
tractor-trailers (or
similar vehicles), organized by local market, and shipped from the RDC to one
or more
CDC's or LDDH's in a local market. CDC workers meeting a temperature-
controlled vehicle
carrying temperature-controlled delivery shipments at a CDC 1190-1 can unload
the
temperature-controlled delivery shipment and immediately move through the CDC
1190-1 to
load the temperature-controlled bulk delivered packages into the bins of SBU's
located in a
temperature-controlled area of the CDC . '
In a further aspect of the invention, retailer-created temperature-controlled
bulk
delivered packages, shipped to a RDC for regional distribution to CDC's and
LDDH's in the
local markets served by that RDC, can be received into and moved through a RDC
using the
same conveyors and programs that can be used to move cases, bulk delivered
packages, and
CDC outbound packages through the RDC. The temperature-controlled retailer
shipments
can be received onto a RDC inbound receiving dock conveyor (32) and moved into
the local
market sort process. The retailer-created temperature-controlled bulk
delivered packages can
be labeled with color-coded labels or a label with a marking to indicate that
the package is a
retailer-created temperature-controlled bulk delivered package and not a
standard temperature
bulk delivered package, CDC outbound package or an item return package, to
allow RDC
workers to give first priority to temperature-controlled bulk delivered
packages as they can be
moved through the RDC. Temperature-controlled bulk delivered packages can be
identified
and picked from the local market sort conveyor (24) without being scanned
(similar to CDC
outbound packages and item return packages). The Delivery Shipment Creation
Program
(340) can determine that a scanned temperature-controlled bulk delivered
package is different
from a bulk delivered package by checking the Temperature Code on its Package
record 1234
and can direct a worker to segregate the two types of bulk delivered packages
into different
delivery shipments. RDC workers can organize full-trailer-loads of temperature-
controlled
delivery shipments and load them onto temperature-controlled trailers.
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In a further aspect of the invention, the retailer-created temperature-
controlled bulk
delivered packages can be shipped to a RDC which can be specialized to process
retailer-
created temperature-controlled packages for regional distribution to CDC's and
LDDH's in
the local markets served by that specialized RDC. This embodiment is
essentially the same
as the previous one, except that the entire RDC facility can be specialized to
only process
retailer-created temperature-controlled packages.
A fiu-ther aspect of the invention can include retailers sending cases of
temperature-controlled
items to a RDC, where they can be processed using the same infrastructure that
is used to
process standard-temperature cases to create temperature-controlled bulk
delivered packages
for regional distribution to CDC's and LDDH's in the. local markets served by
that RDC. ' The
cases of temperature-controlled items can be received onto a RDC inbound
receiving dock
conveyor (32) and moved into the local market sort. Cases of temperature-
controlled items
can, for example, be labeled with a different color label or marked in some
way to indicate
that they contain temperature-controlled items. RDC workers performing the
local market
sort and the CDC sort can give a higher priority to cases of temperature-
controlled items to
move them through the RDC faster. Items can be picked from cases containing
temperature-
controlled items to create temperature-controlled bulk delivered packages.
Temperature-
controlled bulk delivered packages can be added to temperature-controlled
delivery
shipments and can be shipped to CDC's or LDDH's on temperature-controlled
vehicles.
In yet still a further aspect of the invention, cases of temperature-
controlled items can
be shipped to a RDC specialized to process temperature-controlled items, for
regional
distribution to CDC's and LDDH's in the local markets served by that
specialized RDC.
Here, the entire specialized RDC facility only processes temperature-
controlled items.
In a further aspect of the invention, cases of temperature-controlled items
can be shipped to a
RDC to be processed for national or mufti-national distribution. Here, cases
of standard-
temperature items and cases of temperature-controlled items can be mixed
together as they
enter the different sorting steps throughout the RDC (RDC sort, local market
sort, CDC sort,
and package conveyor sort). The RDC Shipment Program (318) validating whether
a
scanned case should be added to a RDC shipment, can check that the Temperature
Code of a
case matches the Temperature Code of a RDC shipment as well as checking that
its RDC Id
matches the RDC Id of the RDC shipment. Temperature-controlled RDC shipments
can be
sent from one RDC to another on temperature-controlled trailers or vehicles in
accordance
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with the same process as standard-temperature RDC shipments. Although cases of
standard-
temperature items and cases of temperature-controlled items can be mixed
together, RDC
workers performing the local market sort and CDC sort can, for example,
recognize cases of
temperature-controlled items by a different color or marking on their case
label and can move
them through the RDC with a higher priority. The Package Creation Program
(330) can be
designed to create separate bulk delivered packages for items of different
Temperature Codes
and temperature-controlled bulk delivered packages can be added to separate
temperature-
controlled delivery shipments which can be organized together and sent out to
CDC's or
LDDH's in a local market. A further aspect of the invention can include the
use of
specialized RDC facilities that only handle temperature-controlled items to be
processed for
national or multi-national distribution.
It should be readily understood that the transporting of trailers filled with
cases of
items from a retailer fulfillment site to a RDC can be achieved by using, for
example, a
tractor-trailer, a locomotive, an airplane, a ship (whether local or an ocean
vessel) depending
upon where the two sites can be located and the cost and timing of each
transportation
method. The aforementioned transportation methods, or any combination thereof,
can also be
used to transport trailers filled with RDC shipments between two different
RDC's, trailers
filled with delivery shipments from a RDC to CDC's or LDDH's, trailers filled
with RDC
returns shipments from a RDC to retailer returns facilities, or trailers
filled with CDC reverse
shipments from CDC's to a RDC. Use of airplanes to transport the different
types of
shipments can be especially useful in providing an expedited delivery service
to deliver
packages to CDC's or customer specified addresses faster. Use of ocean vessels
may be
especially economical to transport the different types of shipments between
RDC's located in
different countries. In one aspect of the invention, retailer shipments, RDC
shipments,
delivery shipments, RDC returns shipments, and/or CDC reverse shipments can be
further
transported on a vehicle, which is not a trailer, but has carrying capacity
sufficient to hold
cargo. This can include, but is not limited to, 'utility vans, cargo vans,
flat beds, and pickups.
In a further aspect of the invention, the trailers or other vehicles used to
transport retailer
shipments, RDC shipments, delivery shipments, RDC returns shipments, and/or
CDC reverse
shipments, may not be equipped with trailer conveyors and can require manual
or mechanized
labor for handling cargo. For example, the cases, cargo cages, single-item
bulk delivered
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packages can be moved into and out of the trailers or other vehicles by hand
or by using
conventional cargo moving equipment, such as a fork lift.
In still a further embodiment of the invention, discounts or penalties can be
offered to
recipients and/or customers to provide an incentive to retrieve bulk delivered
packages from a
. CDC as soon as possible. A shipper's standard package retrieval policy can
include a
reasonable grace period of time that a package recipient has to retrieve their
bulk delivered
packages from a CDC before incurring a penalty. The time that a bulk delivered
package
remains in a SBU bin at a CDC after a package recipient has been notified that
a package has
been delivered can be measured against a grace period by a shipper using the
information on
the Bin Inventory table 1300. Various penalties can be calculated if one or
more bulk
delivered packages remain in a CDC after the package recipient has been
notified of delivery,
including, but not limited to the following: a flat charge to cover all bulk
delivered packages
in the CDC each time at least one bulk delivered package is left in a CDC over
the grace
period; a charge per package; a charge per package, per day; a charge per
package, depending
upon package size; a charge per package, per day, depending upon package size;
a charge per
order; and a charge per order, per day. Incentives can also be offered to
package recipients
for retrieving bulk delivered packages prior to the end of the grace period,
such as a discount
on future shipping costs. Incentives can also be calculated as a flat discount
or can be based
upon the same per package, per day, per order factors that a shipper may use
to calculate a
penalty. The net balance of penalty charges and incentive discounts can be
tracked for a
recipient or customer, by each shipper, in an account balance field. A shipper
can apply a
recipient's/customer's net account balance.into the shipping cost of that
recipient's/customer's next ePD delivery or traditional delivery order when
the recipient/
customer selects the shipper from the retailer's web site. A shipper's
standard package
retrieval policy can be communicated in a notification message to a package
recipient, as well
as specific information related to the package recipient's package retrieval
situation. For
example, a reminder notification message can inform a package recipient that
the recipient
will be charged a fee on at least one of their packages if the recipient does
not retrieve their
packages by the end of the current day. A shipper may vary the penalties and
incentives they
offer at different seasonal times or by CDC location.
In a further embodiment of the invention, portable temporary SBU's located,
for
example, on trailers in a parking lot of the CDC or another suitable location
can be used to
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increase the bin capacity of a CDC to meet seasonal peak demands. The portable
temporary
SBU's can be transported to a CDC location on a tractor-trailer. The trailers
containing the
additional SBU's can be detached from their tractors and parked near the CDC.
The sides of
the trailers can, for example, roll up or be removed to allow workers and
recipients to access
the SBU's, which can sit back to back facing out through each open side of the
trailer. The
SBU's can be connected to the CDC server and to power sources inside the CDC
by a
protected cable connection running from the CDC to the trailer. Temporary
platforms with
ramps and/or stairs can be positioned next to the trailers containing
additional SBU's to allow
customers to access the SBU's. A large tent or awning can be temporarily
constructed over
groups of the trailers containing the additional SBU's to provide shelter to
protect the SBU's
and recipients and workers accessing the SBU's from adverse weather
conditions. One or
more temporary scaled down versions of entrance stations without electronic
locking doors
can be set up near the groups of trailers containing the additional SBU's to
allow recipients to
determine in which SBU's their bulk delivered packages can be located and to
receive the
Quick Code needed to access their bulk delivered packages. Records can be
added to the Bin
Inventory 1300 and SBU Settings 1314 tables for the additional SBU's
temporarily added to
the CDC (the added records can later be deleted if the additional SBU's are
later removed
from the CDC). Alternatively, additional SBU's can be moved on tractor-
trailers and then
unloaded from the trailers and moved onto platforms or onto the ground in the
CDC parking
lot or a nearby area. In a further aspect of the invention, additional
temporary CDC locations
can be added as needed in local markets to meet seasonal demands. A suitable
commercial
location can be rented and SBU's can be moved into that conunercial location
along with the
hardware for one or more entrance stations or scaled down versions of entrance
stations
without electronic locking doors. A CDC processing server can also be moved
into the
location and can be configured for the SBU's that were moved into the
location. A temporary
CDC location can operate in the same manner as a permanent CDC location.
While exemplary systems and methods embodying the present invention are shown
by
way of example; it should be understood that the invention is not limited to
these
embodiments. Modifications can be made by those skilled in the art,
particularly in light of
the foregoing teachings. For example, each of the elements of the
aforementioned
embodiments may be utilized alone or in combination with elements of the other
embodiments.
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