Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02804866 2013-10-29
CARPET DYEING SYSTEMS AND METHODS
This application is a divisional of Canadian Patent Application No. 2,629,856
filed
April 24, 2008
BACKGROUND OF THE INVENTION
[0002] A typical high volume carpet manufacturing process requires dyeing
an entire roll of
carpet in one color. The roll of carpet is then warehoused by the manufacturer
until a customer
orders a length of carpet of that color. For common colors, this process works
relatively
efficiently as there is a constant demand. However, for less popular colors, a
major portion of a
roll of that color can remain warehoused for a long period of time. When
considering that some
carpet styles can have up to 60 different colors, the inventory costs become
very large. Thus, a
challenge facing carpet manufacturers is how to produce a wide variety of
colors and styles of
carpet without having to carry large inventories of less popular varieties.
[0003] Attempts have been made to reduce the transition time necessary to
change colors,
such that it is economical to produce different color carpets on a single
roll, with limited success.
In one known method, a vacuum purge system is used to evacuate a first dye
color and
simultaneously switch to a second dye color. Although known as a "quick-
change" dye
machine, changing the dye color creates an unusable section of carpet of 18"
or more in length
when the carpet is run at a typical 60 feet per minute, and carpet may be run
as fast as 160 feet
per minute depending on carpet weight. This carpet waste has discouraged
companies from
changing colors in the middle of a roll. A need in the art therefore exists
for a carpet dyeing
process that can efficiently produce at least two different colors in a single
roll.
[0004] An additional challenge facing carpet manufacturers is how to
process orders to
reduce the need to warehouse less popular styles and colors. Typically, a
manufacturer will
- 1-
CA 02804866 2013-01-31
create a high level production plan identifying time frames for producing
various styles of carpet
based on demand forecasts and average orders per month. This production plan
can be used to
order raw materials and is often referred to when providing a customer with a
promised delivery
date.
[0005] On a daily or weekly basis, a production schedule is created. This
schedule is more
detailed than the production plan and typically identifies the SKUs to be
produced and allots
time on a particular product line or piece of equipment to produce the
particular SKUs. A
"SKU" is a number identifying a product sold and the term "SKU" will be used
herein to refer to
a particular style and color of carpet. When an order is received for a
particular SKU, known
order processing systems search the manufacturer's inventory to satisfy the
order. If the order
cannot be satisfied with present inventory, an entire roll of that particular
SKU is scheduled for
production. The unused portion of the carpet roll is then stored in a
warehouse. Thus, there is a
need in the art to increase efficiency of the order process and reduce the
carpet manufacturer's
inventory costs.
BRIEF SUMMARY OF THE INVENTION
[0006] The above and other needs are met by the present invention which, in
one
embodiment, provides a method of dyeing carpet to satisfy a plurality of
customer orders. The
method includes the steps of: receiving a plurality of customer orders wherein
each order
identifies a color and a length; determining which of the plurality of
customer orders can be dyed
in sequence based on the colors identified by the respective orders without
creating an
unacceptable visual effect of blending of sequential dyes at a transition
between colors in the
sequence; assigning the plurality of customer orders to one or more greige
rolls of carpet based at
least in part on the determined dyeing sequence wherein at least one greige
roll of carpet has at
least one transition from one color to another color; and dyeing the one or
more greige rolls of
carpet.
[0007] In another embodiment, a method of dyeing a continuous greige roll
of carpet a
plurality of colors is provided. The method includes the steps of: mixing a
first dye solution for
a first color in a first mixing system; mixing a second dye solution for a
second color in a second
mixing system; feeding a greige roll of carpet through a dye application
system; actuating at least
one multi-port valve in the dye application system such that the first dye
solution is applied to a
first portion of the greige roll of carpet as it passes through the dye
application system; actuating
- 2-
CA 02804866 2013-01-31
a
the at least one multi-port valve in the dye application system such that the
second dye solution
is applied to a second portion of the greige roll of carpet as it passes
through the dye application
system; mixing a third dye solution for a third color in the first mixing
system while the second
dye solution is being applied; purging residue of the first dye solution from
the mixing system
and at least a portion of the dye application system using the third dye
solution; and actuating the
at least one multi-port valve in the dye application system such that the
third dye solution is
applied to a third portion of the greige roll of carpet as it passes through
the dye application
system.
[0008] In a further embodiment, a roll of dyed carpet having two
different dyed colors is
provided. The carpet roll includes a first length of the carpet roll dyed a
first color; a second
length of the carpet roll dyed a second color; and a demarcation strip of
undyed carpet positioned
between the first length and second length of carpet having a length less than
18 inches.
[0009] In an additional embodiment, a method for dyeing a carpet roll
a plurality of colors
according to customer orders is provided. The method includes the steps of:
receiving a first
order identifying a first color and a first length; receiving a second order
identifying a second
color and a second length; determining a sequence in which to dye the roll of
carpet the first
color and the second color and mapping the first and second order to the roll
of carpet are based
on at least one of the following criteria: (a) reducing unacceptable visual
effect of blending of
sequential dyes at a transition between colors in the sequence; (b) reducing
the amount of unused
carpet on the carpet roll; (c) the relative popularity of the colors; (d)
inventory levels of carpet
dyed the first color and the second color; dyeing the roll of carpet to
satisfy the first order
comprising a first color and a first length and the second order comprising a
second color and a
second length in the determined sequence; and cutting the dyed roll of carpet
to separate the first
order from the second order.
[0010] In a further embodiment, a tufted product is provided. The
tufted product includes a
backing having a width and a length; yarn tufted to the backing to create a
roll of carpet having a
length and a width; wherein a first length of the roll of carpet is dyed a
first color according to a
customer order specifying the first color and a first length; and wherein a
second length of the
roll of carpet is dyed a second color according another customer order
specifying the second
color and a second length.
-3-
CA 02804866 2013-01-31
[00111 In an additional embodiment, a carpet dying system is provided. The
system includes
a first mixing system including a first plurality of dye holding tanks in
selective fluid
communication with a first mixing tank wherein the first mixing system is
configured to combine
dye from the first plurality of dye holding tanks to create a first dye
solution; at least a second
mixing system including a second plurality of dye holding tanks in selective
communication with
a second mixing tank wherein the second mixing system is configured to combine
dye from the
second plurality of dye holding tanks to create a second dye solution; a dye
application head in
fluid communication with the first mixing system and the second mixing system
for applying dye
to the carpet; and at least one multi-port valve in fluid communication
between the first and
second mixing systems, the dye application head and a drain, the at least one
multi-port valve
being configured for selectively providing fluid communication: (1) between
the first dye
mixing system and the dye application head, and between the second dye mixing
system and a
drain such that residue of previous dye solutions in the second mixing system
is purged by the
second dye solution, or (2) between the first dye mixing system and the drain
such that residue of
previous dye solutions in the first mixing system is purged by the first dye
solution, and between
the second dye mixing system and the dye application head.
[0012] In another embodiment, a computer apparatus for mapping customer
orders for colors
of carpet to greige rolls of carpet is provided. The computer apparatus
includes: one or more
databases associating predetermined carpet colors with a plurality of
characteristics of a
respective carpet color including dye concentrations for achieving the color,
a popularity ranking
of the color amongst customers and an inventory of carpet already dyed the
color; one or more
processors in communication with the one or more databases wherein the
processors are
configured to: receive a plurality of customer orders wherein each order
identifies a
predetermined color and a length; determine which customer orders qualify for
dye-to-order
processing based at least in part on the popularity ranking of the colors
ordered, the length of
ordered carpet for respective orders and the inventory of the colors ordered;
determine which of
the qualified dye-to-order customer orders can be dyed in sequence based on
the color of the
respective customer orders without creating an unacceptable visual effect of
blending of
sequential dyes at a transition between different colors; and map the
qualified customer orders to
greige rolls having predetermined lengths based in part on the sequence
determination and on the
ordered lengths to reduce the length of unallocated portions of the greige
rolls.
- 4-
CA 02804866 2013-01-31
=
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] Having thus described the invention in general terms, reference will
now be made to
the accompanying drawings, which are not necessarily drawn to scale, and
wherein:
[0014] Fig. 1 is a schematic diagram of a carpet dyeing system in
accordance with an
embodiment of the present invention.
[0015] Fig. 2 is a schematic diagram of a carpet dye application system in
accordance with
an embodiment of the present invention.
[0016] Fig. 3 is a schematic diagram of a portion of a roll of carpet
illustrating two different
colors and a demarcation strip.
[0017] Fig. 4 is a schematic diagram illustrating an exemplary architecture
for a dye-to-order
processing system.
[0018] Fig. 5 is a flow diagram illustrating exemplary steps for processing
orders in a dye-to-
order processing system in accordance with an embodiment of the present
invention.
[0019] Fig. 6 is a schematic diagram of a piping system for mixing a dye
solution and
providing the dye solution to a dye application system.
[0020] Figs. 7 - 8 are flow diagrams illustrating steps for processing
orders in accordance to
an embodiment of the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention now will be described more fully hereinafter
with reference to
the accompanying drawings, in which some, but not all embodiments of the
inventions are
shown. Indeed, the invention may be embodied in many different forms and
should not be
construed as limited to the embodiments set forth herein; rather, these
embodiments are provided
so that this disclosure will satisfy applicable legal requirements. Like
numbers refer to like
elements throughout.
[0022] Embodiments of the present invention provide systems and methods for
"dye-to-
order" carpet manufacturing that address deficiencies in the carpet
manufacturing industry, some
of which are discussed above. In one embodiment, an improved manufacturing
system is
provided that allows manufacturers to change colors "on the fly" (e.g., within
a single roll) with
- 5-
CA 02804866 2013-01-31
minimal waste. In another embodiment, a dye-to-order processing system is
provided that maps
multiple orders to undyed carpet rolls such that usage of the undyed carpet
rolls is optimized.
[0023] Carpet Manufacturing Process
[0024] Embodiments of the present invention may be used with any type or
style of carpet.
However, to aid understanding of the present invention, the following
paragraphs will describe
embodiments of the present invention used in the context of a tufted carpet
manufacturing
process.
[0025] The manufacture of tufted carpet typically includes the steps of:
(1) tufting yarn (e.g.,
nylon, olefin, etc.) to a primary backing, (2) dyeing and drying the tufted
construction and (3)
applying a secondary backing to the primary backing. Tufting generally
involves inserting yarn
through the primary backing using reciprocating needles. Hooks positioned
above the needles
grasp the yarn from the needle for a split second after it is forced through
the primary backing
thereby creating a loop as the needles pass back through the primary backing.
These loops may
be cut to form cut "pile" carpet. At this stage, the undyed carpet is often
referred to as a "greige
good." The tufted carpet is then dyed, dried and a secondary backing is
affixed to the primary
backing.
[0026] Fig. 1 is a schematic diagram generally showing a dyeing process in
accordance with
an embodiment of the present invention. Generally described, the exemplary
dyeing system 10
includes a dye mixing system 20 and a dye application system 30. As the names
imply, the dye
mixing system 20 combines various ingredients to arrive at a desired color and
the dye
application system 30 receives the mixed dye and delivers it to the carpet 50.
[0027] In the illustrated embodiment, the dye mixing system 20 includes two
mixing sub-
systems 20A and 20B that feed a single dye application system 30, which itself
has two holding
tanks 32a-b. The subsystem system 20A includes storage tanks 21a-c that
contain ingredients
such as colored dyes or other chemicals in various concentrations that may be
mixed according
to a specific recipe to obtain a desired dye color. Each storage tank has an
associated
recirculation loop 22a-c, in which a pump (not shown) maintains a constant
flow rate. Three
way valves 23a-c are installed in the recirculation loops 22a-c such that all
or a portion of the
flow can be diverted to a mixing tank 25A as desired. Based on a recipe
containing the quantity
of dye need to obtain a desired color, a three way valve is activated to
direct a particular dye to
the mixing tank for a predetermined length of time to achieve the necessary
quantity of dye. A
- 6-
CA 02804866 2013-10-29
more detailed description of an exemplary dye mixing system that may be used
in connection
with the present invention is provided in U.S. Patent No. 6,050,282 to Whaley.
In some
embodiments, the valves 23a-c may be partially opened to allow a desired flow
rate of dye to be
diverted to the mixing tank 25A.
[0028] Similarly, dye mixing sub-system 20B includes storage tanks 21d-f,
recirculation
loops 22d-f, three-way valves 23d-f and a mixing tank 25B. These components
are arranged
substantially the same as described for dye mixing subsystem 20A above. As
will be appreciated
by those of skill in the art, a single set of storage tanks may have
recirculation loops with
multiple three-way valves capable of diverting the solution into multiple
mixing tanks as
opposed to dedicated ingredients as shown in Fig. 1.
[0029] In the illustrated example, there are only three storage tanks
holding blue, red and
yellow dyes. One skilled in the art will appreciated that the subsystems 20A-B
may include
several storage tanks holding other colors, different concentrations of the
same colors or other
chemicals that may be mixed to achieve a desired solution. For example, each
of the primary
colors may have three storage tanks for low, medium and high concentrations,
for a total of nine
storage tanks.
[0030] Once the desired dye solution is prepared in the mixing tank 25A,
the solution may be
pumped or otherwise fed to the dye application system 30 as controlled by
valve 28a. As
shown, the dye application system 30 includes two holding tanks 32a-b, two
distribution heads
34a-b and a dye head 40. The mixed dye solution from the dye mixing system 20A
may be
pumped to holding tank 32a and the solution from the dye mixing system 20B may
be pumped to
the holding tank 32b. It should be understood that the dye solution from the
two mixing tanks
may be the same or different colors. Also, a single mixing tank may feed
multiple holding tanks
within the dye application system 30.
[0031] Fig. 6 illustrates another embodiment of a piping system 80 that may
be used to direct
dye to the dye application system 30 in accordance with various embodiments of
the present
invention. As illustrated, each of the dyes (red, yellow and blue) includes a
recirculation loop
22a-c and associated pump 24a-c, which maintain a flow rate within the
associated loops. The
loops also include valves 23a-c that may be adjusted to direct all or a
portion of the flow of the
associated dyes to the mixing tank 82.
- 7-
CA 02804866 2013-01-31
[0032] In various embodiments, the valves 23a-c are proportional-integral-
derivative
controlled (herein after "PID controlled" or "PID controllers"). Each of the
PID controllers
receives feedback from flow rate sensors (not shown) positioned downstream of
the valves.
Generally, dye color recipes may specify the flow rates of particular dyes
that are necessary to
achieve a desired dye solution. The PID controllers control the degree to
which the valves 23a-c
are opened to achieve the flow rate specified in the recipe. To change from
one color to another,
the flow rates of the various dyes (red, yellow and blue) may be adjusted such
that the quantity
of dye being mixed per unit time changes and the resulting new color dye
solution is achieved.
[0033] As will be discussed in greater detail later, some embodiments
require a quick
transition between one dye solution to another in order to achieve a desired
demarcation strip
width between the two dye solution sections of carpet. In some embodiments,
the PID
controllers may use different algorithms for actuating the valves 23a-c when
changing from one
flow rate to another depending on the difference between necessary flow rates
of the particular
dyes. For example, if the new flow rate is 15 grams per gallon greater than
the current flow rate,
the algorithm may open the valve beyond that necessary to achieve the desired
flow rate such
that the flow rate is ramped up quickly. Because the flow rate will likely
overshoot the desired
flow rate, the degree to which the valve is opened is then adjusted using
feedback from the flow
sensors until the flow rate settles at the desired flow rate. In this way, the
desired flow rate may
be achieved quickly. On the other hand, if the new flow rate is only 1 gram
per gallon more or
less than the current flow rate, a different algorithm may be implemented
where the valve is
opened slightly over the degree necessary to achieve the desired flow rate and
only minor
adjustments are made based on feedback from the flow sensors until the new
flow rate is
achieved. Since the current and new flow rates are close in this example, it
does not take the
system long to ramp up (or down) to the desired flow rate, and thus
significant changes in valve
opening are not necessary.
[0034] The valves 23a-c direct dyes to the mixing tank 82, which combines
the dyes with
water or other chemicals to arrive at a desired dye solution. Prior to
entering the mixing tank 82,
the water passes through a contact water heater 90. A contact water heater
raises the temperature
of water by placing the water in direct contact with combustion air from a gas
burner as opposed
to heating a large tank of water. As will be understood by those of skill in
the art, carpet dye
solutions are often heated to optimize dyeing of the carpet. In some
embodiments, the water is
- 8-
CA 02804866 2013-01-31
heated to 140 degrees Fahrenheit. In other embodiments, contact water heaters
are positioned
between the dye recirculation loops and the mixing tank 82 such that the dye
is heated in
addition to or in place of water heater 90 heating the water. Some of the
anticipated benefits
include improved heat transfer and efficiency of the system. In addition,
change over times may
be reduced because there is less dye to purge than in prior art systems.
[0035] To aid the mixing function, a second mixing tank 84 may be placed
downstream of
the mixing tank 82. The flow may be assisted by a pump (not shown) between the
two mixing
tanks.
[0036] After exiting the second mixing tank 84, the dye solution may then
flow through a
damper 86, which is configured to reduce the transfer of pressure spikes
through the system. In
one embodiment, the damper 86 includes a diaphragm which is supported by air
pressure in
order to absorb pressure spikes in the system. In some embodiments, the dye
head 40 switches
quickly from one solution to another, and this can create pressure spikes in
the both the piping
systems supplying the old and the new dye solutions. The damper 86 mitigates
the effect of the
pressure shocks on the upstream systems and thus allows quicker changeover
from one dye
solution to another.
[0037] After passing through the damper 86, the dye solution may flow
through a third
mixing tank 88 to further ensure a substantially homogenous dye solution. Dye
exiting the third
mixing tank 88 may feed directly to the distribution head 34a or to a holding
tank 32a of the dye
application system 30 shown in Fig. 1. As will be discussed in greater detail
later, various
embodiments of the present invention utilize the new dye solution to purge the
old dye solution
from the piping system 80. The multiple mixing tanks reduce the length of
piping needed to
arrive at an acceptably homogeneous dye solution. Because of the reduced
piping length, less
dye is wasted when purging the system.
[0038] The distribution heads 34a-b receive the dye solution from the
holding tanks 32a-b,
respectively and are configured to transfer the dye to the dye head 40. Each
distribution head
34a-b includes multiple feed lines 35a-b connected to input ports on the dye
head 40 that are
spaced uniformly across the dye head width such that the fed dye is
distributed across the entire
width of the carpet 50. Although illustrated above the carpet for ease of
understanding, the dye
head 40 can also be positioned under the carpet web, as is known in the
industry.
-9-
CA 02804866 2013-01-31
[0039] Fig. 2 provides a cross section view of the exemplary dye head 40
showing one of a
plurality of feed lines 35a-b from each distribution head 34a-b entering the
dye head 40. As
shown, the dye head 40 includes dye input ports 41a-b that receive dye from
distribution heads
34a-b, respectively. The dye head 40 also includes a slot 42 that directs dye
to the carpet 50 and
an outlet port 43 leading to a valve 46 and a drain 45. A valve 44 controls
which input port 41a-
b is in fluid communication with the slot 42. In the position shown, dye from
input 41a is
directed to the slot 42 and dye from the input port 41b is directed to the
drain 45. When a color
change is desired, the valve 44 is rotated clockwise 90 degrees such that
input ports 41a and 41b
are in fluid communication with output port 43 and the slot 42 respectively.
When desired, the
valve 44 may be rotated counterclockwise 90 degrees to again produce carpet
with dye from
holding tank 32a.
[0040] In some embodiments, the valve 44 is replaced with two three-way
valves. One of
the three-way valves controls whether input port 41a is in fluid communication
with the slot 42
or with the drain 45. Likewise, the other three-way valve controls whether the
input port 41b is
in fluid communication with the slot 42 or with the drain 45. In various
embodiments, an
additional valve may be positioned between the two three-way valves and the
slot 42 to further
control which of the two three-way valves is in fluid communication with the
slot 42.
[0041] Dyeing Process
[0042] With reference to Figs. 1, 2, and 6 the following paragraphs
describe an exemplary
process for making two color changes. The process begins by mixing the
necessary ingredients
for a first dye color in dye mixing subsystem 20A. This involves adding
measured quantities of
various dyes and other chemicals according to a recipe into mixing tank 25A.
In one
embodiment, a plurality of storage tanks 21a-c contains various dyes and
chemicals in known
quantities. Each tank has a dedicated recirculation loop 22a-c and a three-way
valve 23a-c that
when actuated, directs the flow from the recirculation loop 22a-c to the
mixing tank 25A.
According to a recipe, three-way valves for select recirculation loops are
opened for
predetermined times to add the necessary dye or chemical to the mixing tank
25A. In other
embodiments, the valves 23a-c located in the various recirculation loops are
adjusted to allow a
desired flow rate to the mixing tanks according to a recipe.
[0043] After the dye is mixed, it is pumped into holding tank 32a in the
dye application
system 30. This dye is then fed from the holding tank 32a through the
distribution head 34a and
- 10-
CA 02804866 2013-01-31
dye head 40 onto the carpet 50. In other embodiments, the dye flows directly
from the final
mixing tank (e.g., mixing tank 88) into the distribution head 34a.
100441 Meanwhile, a second color is mixed in the dye mixing subsystem 20B
as generally
described above with reference to the mixing subsystem 20A. This second color
is fed into
holding tank 32b. Once the desired length of the first color carpet is dyed,
the valve 44 in the
dye head 40 is rotated such that the second color is fed through the slot 42
onto the carpet. Any
of the first color dye remaining in the slot may be flushed out by the second
dye color. The slot
may also be flushed with water.
100451 Next, a third dye solution is mixed in dye mixing subsystem 20A as
generally
described above with reference to the first dye color. It should be understood
that the third dye
color mixing process may be initiated shortly after emptying the first color
from the mixing tank
25A into the holding tank 32a. Once the third dye color is mixed, it may be
fed into the holding
tank 32a and a portion of the third dye color may be allowed to flow into the
distribution head
34a and dye head 40 thereby flushing out residue of the previous dye color
(i.e. the first dye
color) and priming the third dye color. The flushing process of the residue
from the first dye
color can take place while the second dye color continues to be applied to the
carpet 50. Due to
the position of the valve 44, the residue is flushed to the drain 45. In one
embodiment, the
flushing process is allowed to continue for a predetermined period of time or
quantity of fluid.
In an alternative embodiment, the flushing process continues until the new dye
color (i.e. the
third dye solution in this example) is detected at the drain. At this point,
valve 46 leading to the
drain is closed to stop the flushing process and the valve 44 may be rotated
to apply the third dye
color when desired. Because the second dye color can be continuously applied
during the
flushing of the first dye color and the priming of the third dye color, the
transition from the
second dye color to the third color can be substantially instantaneous.
100461 Fig. 3 is a schematic diagram of an exemplary length of carpet dyed
in accordance
with an embodiment of the present invention. As shown, the length of carpet
includes two dyed
sections 51 and 52 with an undyed demarcation strip 53 therebetween. Carpet
section 51 is dyed
to Color A and section 52 is dyed to Color B with the undyed demarcation strip
53 having a
width "d". The minimum "d" value for a given process is a function of how
quickly the dyeing
process can be switch from Color A to Color B. Using the dyeing system 10
described above,
the width "d" can be held to 1.5 inches or less at a standard processing speed
of 60 feet per
- 11-
CA 02804866 2013-01-31
minute. The width "d" may be increased as desired by delaying the application
of the next color.
This may be accomplished by slowing the action of the valve 44 or installing
an additional valve
between the distribution head and the carpet. For example, some embodiments
may have
demarcation strips held to less than 18 inches, 12 inches or six inches.
[0047] In some embodiments, the demarcation strip 53 may be used to
identify the transition
from one color to the next when the colors themselves are difficult to
distinguish. In other
embodiments, the carpet sections may be sequenced or the section lengths
adjusted to position
the demarcation strip at a seam between carpet rolls. Seams and undyed strips
are typically cut
from the finished carpet and discarded. In one embodiment, the demarcation
strip helps
identifying the seam and/or a change in dye color for an operator or automated
cutting system,
which may use a sensor to detect the undyed demarcation strip.
[0048] The dyeing system 10 described above is capable of substantially
eliminating the
undyed strip so that one dye section ends and a new section begins at the same
linear position.
Thus, a roll of carpet may be manufactured having various different dye
section colors.
Furthermore, this process may be used to create a carpet having a striped
pattern. For example,
carpet may be produced with a repeating pattern consisting of a predetermined
length of Color A
(e.g., a two foot section) followed by a predetermined section of Color B
(e.g., a three foot
section). This quick changeover helps economically justify smaller production
runs of any
given color, because the wastage between productions runs can be greatly
reduced.
[0049] Dye-to-Order Processing System
[0050] In a further aspect of the invention, an order processing system is
provided for
optimizing the use of greige goods to fulfill known and/or expected orders.
Fig. 4 is a schematic
diagram of one embodiment of the order processing system 60. The system 60
includes a
mainframe computer 61, and a data repository 72.
[0051] The mainframe computer 61, which may be an iSeries AS/400, includes
an order
entry module 62, a dye-to-order ("DTO") module 63 and a transfer module 64.
The order entry
module 62 initially receives data from a customer such as their identity
(e.g., name, and address),
a requested delivery date and a SKU. The order entry module may use the
received information
to retrieve other data related to the order such as a style code, a color
code, a size code, a backing
code, other customer information. The order entry module may also assign an
order number and
calculate a customer promise date. In one embodiment, the order entry module
queries the data
- 12-
CA 02804866 2013-01-31
repository 72 using the SKU number to retrieve the additional data. If there
is no inventory
available or an existing production plan for the SKU, this information is
transferred to the DTO
module 63 for processing.
[0052] The DTO module 63 determines whether the order can be produced using
existing
greige rolls or whether new greige rolls will need to be produced. The DTO
module then assigns
existing orders to greige rolls to optimize yield of the greige rolls and
enters the information into
a dye production schedule.
[0053] The transfer module 64 tracks the location of greige rolls and
directs the transfer of
greige rolls to warehouse locations or manufacturing facilities to satisfy the
dye production
schedule created by the DTO module 63. This module may update physical
inventory data in the
data repository 72 as necessary.
[0054] The data repository 72 includes one or more databases for storing
information
associated with the production process and the products manufactured.
Information stored in the
data repository related to the production process may include equipment
limitations such as feed
rates, width limitations and the number of color changes allowed per standard
carpet length.
[0055] Data associated with the products manufactured may include SKU
profiles which
may contain details about a given product such as a style code, a color code,
a color recipe, a dye
code and/or raw material details such as types of yarns, backings, and
coatings. The data
repository 72 may also include sales ranking data for each SKU. In one
embodiment, a
manufacturer assigns each SKU to one of several categories (e.g., a sales
ranking) based on its
historical sales volume. Over time, a particular SKU's sales ranking (or
category) may change
due to a change in sales volume for that particular SKU.
[0056] The data repository 72 may also include physical inventory data
identifying quantities
and locations of various raw materials and work-in-process such as the
quantity and location of
greige goods. Inventory data associated with finished goods may also be stored
in the data
repository 72.
[0057] Users may access the mainframe computer 61 via "dummy" terminals 76
or via a
computer 77 over a network 78. Those skilled in the art of data networking
will realize that
many other alternatives and architectures are possible and can be used to
practice the principles
of the present invention. For example, the order processing system may be run
on one or more
- 13-
CA 02804866 2013-01-31
,
=
networked computers or on a distributed architecture utilizing servers
communicating with
multiple computers over a network.
[0058] Fig. 5 is a process flow diagram illustrating steps for a DTO
processing in accordance
with an embodiment of the present invention. The process begins at Step 100
with the receipt of
an order. The order may include an SKU number, the length of the carpet
ordered and a
promised delivery date. This promised date is generally determined based on
the production
plan and transportation lead-times.
[0059] At Step 105, the order details are analyzed to determine if it
qualifies for the DTO
process. In one embodiment, the DTO process is triggered when one or more
parameters of the
order satisfy predetermined thresholds such as a minimum or maximum order
length. Provisions
may also be provided for manually flagging orders for the DTO process. For
example, an order
may be flagged for DTO processing if it is a special one time order of a
particular style or color.
Alternatively, dye-to-order processing may be triggered if the received order
cannot be filled
from current inventory or a plan does not already exist for producing the
ordered carpet.
[0060] An additional parameter for triggering DTO processing may be the
popularity of the
SKU ordered. The relative popularity of an SKU may be designated by the SKU's
sales ranking,
which is based on historical sales data. For example, each SKU offered by a
manufacturer may
be assigned one of the following rankings: A, B, C, E, F and G. Rankings A, B
and C may be
relatively high volume SKUs and rankings E, F and G may be relatively low
volume SKUs. In
one embodiment, the low volume SKU rankings (e.g., E, F and G) trigger DTO
processing.
Alternatively, specific rankings may trigger DTO processing such as an F and G
ranking. It
should be understood that any type of sales ranking scheme may be used in
connection with the
present invention and that any combination of high and/or low volume SKU
rankings may
trigger DTO processing as desired.
[0061] It should be understood that any combination of parameters discussed
above for
triggering DTO processing may be used in connection with the present
invention. In an
alternative embodiment, the system may include a switch allowing a user to
specify that all or
none of the orders are to utilize the DTO process.
[0062] Assuming DTO is triggered at Step 105, the process continues to Step
110 where a
DTO plan is created. The DTO plan assigns the ordered SKUs to standard greige
rolls (e.g.,
undyed carpet rolls). Various factors may be considered when creating the DTO
plan, which is
- 14-
CA 02804866 2013-01-31
the optimum assignment of ordered SKUs to greige rolls. Generally, the orders
of a particular
style of carpet and therefore a particular style of greige good are grouped
together and then
assigned to standard greige rolls (e.g., 150 foot length of undyed carpet).
[0063] One factor in assigning SKUs to particular rolls may be the ordered
length for the
particular SKUs as compared with a standard greige roll. A waste factor may be
added to each
order before starting the optimization process. In one embodiment, a heuristic
process is used to
determine how to combine the orders to optimize utilization of greige rolls.
In other words,
various combinations of orders are mapped to a standard greige roll in order
to identify the
combination having the best utilization of the roll. As will be appreciated by
those skilled in the
art, other optimization algorithms may be used to assign SKUs to greige rolls.
[0064] As part of the optimization process, standard lengths of high volume
colors may be
added to finish partial rolls. For example, a 30 foot section of an "A" sales
ranked SKU may be
included in the combination of DTO orders when optimizing the allocation of a
greige roll. The
selection of the "A" SKU may be based on a variety of factors such as the
relative inventory
levels of the different "A" ranked SKUs. The "A" SKU may be placed at the end
of the roll such
that any length variation in the roll will be absorbed by a popular style of
carpet. It is not
uncommon for carpet rolls to stretch during processing such that the finished
roll is 10 to 15 feet
longer than it was during the initial processing. By placing the "A" SKU at
the end of the roll,
any additional length would be in a popular color, which would have a better
chance of being
sold than extra lengths of an unpopular color.
[0065] An additional factor that may be considered in assigning SKUs to
greige rolls is the
sequence of colors dyed for a given greige roll. When dyeing a section of
carpet in a new color,
the beginning portion of the dye section of the carpet is the portion where
shade variations are
most likely to occur. These shade variations may be due to residual dye from
the previous dye
section flowing through the dye head, which may cause a slight blending of the
old and new dye
colors. However, if a previous dye color and a new dye color are similar and
related, it is less
likely that the beginning portion of the new dye section of carpet will be out
of shade (e.g., color)
tolerance. For example, there will be decreased scrap losses if a red dye
section of carpet is
followed by a pink dye section as compared to a sequence where a red dye
section is followed by
a white dye section. Although the same dye blending may occur, the effect is
less obvious to a
consumer and more likely to be within acceptable tolerance levels for the red-
pink example.
- 15-
CA 02804866 2013-01-31
A
[0066] In one embodiment, the processing system sequences colors to
minimize the visual
effect of any blending of sequential dyes in the dyeing system. This may be
accomplished using
a master sequence of all SKUs that is consulted by the processing system.
Alternatively, the
SKUs may be sequenced based on concentrations of the dyes (e.g., blue, red and
yellow) where
SKUs having similar concentrations are placed in sequence.
[0067] In a further embodiment, the processing system may avoid placing
incompatible
colors in sequence. This may be performed by comparing the concentrations of
the various dyes
used to arrive at specific colors and not allowing SKUs to be in sequence if
the concentrations of
the dyes (e.g., blue, red and yellow) differ between the two colors by more
than a predetermined
threshold. Different thresholds may exist for different styles of carpet. The
dyeing sequence
may also be determined by the relative dye concentrations. For example, it may
be preferred to
dye a relatively light color before a darker color due to residue from the
previous dye. It has also
been discovered that the compatibility of various dye colors may be one-way in
nature. For
example, it may be acceptable to go from a red to an orange but not from
orange to red. In
various embodiments, the system considers whether the specific sequence of dye
changes is
acceptable.
[0068] Limitations may also be imposed on the number of color changes
for a given greige
roll. For example, some equipment may only be able to accommodate a limited
number of color
changes for a standard roll. Accordingly, embodiments of the present invention
may consider
limitations of the proposed processing equipment when assigning SKUs to a
greige roll. In an
alternative embodiment, the processing equipment may be assigned based on the
number of color
changes needed to optimize the greige roll.
[0069] In one embodiment, a DTO plan is created at Step 110 when orders
are received. In
some embodiments, the DTO plan is re-optimized at predetermined times to
determine if better
combinations of colors exists or better utilization of greige rolls can be
achieved. In one
embodiment, this re-optimization occurs just prior to converting all or a
portion of the DTO plan
into a dye production schedule at Step 120.
[0070] After determining a DTO plan at Step 110, the physical greige
rolls to be dyed
according to the DTO plan are located or produced at Step 115. In one
embodiment the DTO
system queries inventory records and reserves the physical greige rolls for
the associated SKUs
in the DTO plan. The physical greige roll may be located in a separate
facility. If a physical
- 16-
CA 02804866 2013-01-31
=
roll cannot be found in inventory, one may be scheduled to be produced. Also,
as new orders
arrive and re-optimizing of the orders occurs, physical rolls may be added
back to inventory if
they are not longer needed due to the optimization process.
[0071] At Step 120, all or a portion of the DTO plan is entered into the
dye production
schedule. The dye production schedule provides a detailed plan specifying
equipment and
production times for dyeing individual greige rolls. If necessary, the dye
production schedule
takes into account the time necessary to produce or deliver greige rolls as
necessary.
[0072] A DTO plan may be kept open (i.e., not entered into the dye
production schedule) for
a predetermined time frame or until certain parameters are met. For example, a
DTO plan may
be entered into the dye production schedule based on the customer promise
date. Using
predetermined manufacturing and transportation lead-times, a deadline date may
be established
for initiating the dyeing process in order to satisfy the customer promise
date. The portion of a
DTO plan associated with a particular SKU may be kept open until that SKU
reaches this
deadline date. In this embodiment, the order would be placed in the dye
production schedule on
or before the deadline date. Other SKUs assigned to the same greige roll would
also be added to
the production dye schedule at that time. The system may also allow a user to
alter the dye
production schedule as desired.
[0073] A relatively common occurrence in the carpet manufacturing industry
is the
cancellation or alteration of an order. For example, a customer may cancel an
order, or change
its parameters such as the length, style or color ordered. In an embodiment of
the present
invention, a user may access the DTO processing system and remove or alter
pending orders.
The system may then re-shuffle or re-optimize the current orders as generally
described above.
[0074] After dyeing, the carpet is further processed. In various
embodiments, a resulting roll
of carpet may include multiple different SKUs. In the prior art, each carpet
roll was typically a
single SKU and therefore individual orders could be cut from the finished
rolls in any sequence.
However, with the introduction of multiple SKUs on a single roll, the cutting
sequence takes on
greater importance because an improper cutting sequence could lead to the
wrong SKU for a
particular order or multiple SKUs on a cut order. Various embodiments of the
processing
systems 60 track the orders assigned to particular rolls and the dyeing
sequence such that the
orders can be cut from the finished carpet roll in the proper sequence.
- 17-
CA 02804866 2013-01-31
[0075]
In various embodiments, the processing system tracks the dyed sections of
carpet
and notes the dye lot from which each section was dyed. Because color
variations may occur
between dye lots of the same prescribed color, the system may avoid sending
carpet sections
having nominally the same color but having different dye lots to the same
customer. However, if
one dye lot is used at the tail end of one roll and at the beginning of a
subsequent roll, the system
may allow the two dye sections to be shipped to the same job site since they
were produced using
the same dye lot. However, if there is an intervening dye lot between two dye
lots of nominally
the same color, the system may avoid sending those two sections to the same
job site.
[0076]
During the dyeing or subsequent processing, an error may occur that results in
the
finished carpet not satisfying an associated order. For example, the color may
not meet quality
standards or the length of carpet produced does not satisfy the quantity
ordered due to a cutting
error. In one embodiment, the DTO system allows a user to enter a replacement
order and
initiate the optimization routine (DTO processing) to schedule the dyeing of a
greige roll as soon
as possible to satisfy the customer's order.
[0077]
Figs. 7-8 describe another method for processing orders in accordance with an
embodiment of the present invention. More particularly, Fig. 7 illustrates a
process for
establishing a promised completion date for a customer's order. Fig. 8
illustrates a process
generating an actual production schedule for the various orders received.
[0078]
Turning to Fig. 7, the process begins at Step 200 with the entry of an order
into the
system. The order may include a SKU and a length. A check is then made at Step
205 to
determine if the order can be satisfied with product currently in inventory.
If inventory is
available, the associated inventory allocated to the order at Step 210.
[0079]
In some instances, a customer order may include multiple SKUs. At Step 215, a
check is made to determine if additional SKUs exist for the particular order.
If so, the process
returns to Step 200 where an additional SKU may be entered into the system. If
no additional
SKUs exist, the order is complete and the process ends at Step 220.
[0080]
Assuming that no inventory exists for the entered SKU at Step 205, the process
continues to Step 225 where the system searches its database for an existing
production plan for
the ordered SKU. If one exists, the order is "pegged" to the specific order at
Step 230. In other
words, a portion of the production plan is allocated to the specific order.
This may occur when
the order is for a popular SKU that is run on a periodic basis independent of
specific orders.
- 18-
CA 02804866 2013-01-31
Once the order is pegged to the production plan, the process continues to Step
215 where
additional SKUs for the customer order may be entered.
[0081]
If no production plan exists that can satisfy the specific order, a
determination is
made at Step 235 as to whether the order qualifies as a "Make to Order"
product. This
determination may be made based on the popularity of the particular SKU. For
example, a
highly popular SKU may not qualify because these types of SKUs are
manufactured often and
the risk of this type of SKU being stored in inventory for an extended period
of time is relatively
low. An unpopular SKU (e.g., low popularity ranking) may qualify for "Make to
Order"
processing because these types of SKUs are rarely manufactured, and the cost
of storing these
types of SKUs in inventory can be expensive. Assuming the SKU does not qualify
for "Make to
Order" processing, the order is temporarily left unassigned until a standard
production plan can
be created for the SKU at Step 240. The process then continues to Step 215.
[0082]
If the SKU qualifies for "Make to Order" processing at Step 235, the process
continues to Step 245 where a check of inventory of greige goods or pre-dye
goods is made. If
no greige goods or pre-dye goods for the particular SKU exist in inventory,
the process continues
to step 240 where the order is left unassigned. A production plan will need to
be created for the
necessary greige or pre-dye goods.
[0083]
If the greige goods or pre-dye goods exist, a determination is made at Step
250 as to
whether existing goods need to be dyed. Greige goods are work-in-process rolls
of carpet than
have not yet been dyed and coated. On the other hand, "pre-dye" goods are
rolls of carpet which
have been dyed but have not yet been coated. As will be understood by those
skilled in the art,
various types of coatings may be applied to carpet such as various stain
resistant coatings. If at
Step 245 it is determined that dyeing is not necessary, a coat plan is created
at Step 255 and
constraint resource planning (i.e. "CRP") is performed at Step 260.
The constraint resource
planning step involves identifying the appropriate equipment to produce the
SKU based on a
number of factors such as the capabilities of the equipment (e.g., width
constraints, styles of
carpet that may be run) and verifying the selected equipment's availability.
[0084]
If the existing goods require dyeing (i.e. are greige goods), the process
continues to
Step 265 where a determination is made as to whether the SKU qualifies for Dye-
to-Order
processing. This determination may be made based on the popularity ranking of
the SKU
coupled with the length ordered. If the SKU qualifies for Dye-to-Order
processing, a dye plan is
- 19-
CA 02804866 2013-10-29
created for the exact footage ordered plus a waste factor at Step 270. The
waste factor may be a
percentage of the total length or a predetermined additional length.
Otherwise, at Step 275 a
standard dye plan is created, which may be based on dyeing a standard length
(such as a number
of rolls) of greige goods instead of the actual footage ordered.
[0085] Continuing to Step 280, constraint resource planning is performed to
select the
necessary equipment to dye and coat the existing greige goods. At Step 285, a
promise date is
estimated as to when the coating process will be complete.
[0086] Turning to Fig. 8, the process for scheduling specific orders begins
at Step 290 where
a determination is made as to whether the work-in-process goods slated to
create the finished
product are pre-dyed. If not, the process continues to Step 295 where a
determination is made
as to whether the product is a Dye-to-Order SKU. Assuming the SKU qualifies
for Dye-to-Order
processing, a dyeing schedule is created at Step 300. The greige goods are
then dyed at Step
315 according to the created schedule. If the SKU does not qualify for Dye-to-
Order processing,
the SKU is entered into a general dye plan (Step 310) and is eventually dyed
at Step 315.
[0087] After dyeing, quality checks are performed at Step 320. If the color
of the dyed
product is not approved, the product is evaluated to determine if it can be
reworked at Step 325.
If the product is reworkable, the rework operation occurs at Step 330 and the
reworked product
is evaluated again at Step 320. Otherwise, a determination is made as to
whether the dyed
product can be used to fill backorders at Step 335. If not, the product
continues to Step 355
where a coating schedule is generated. If the dyed product can at least
partially fulfill a back
order, the process continues to Step 340 where the dyed product is associated
with the back
order. The process continues to Step 345 where a request to fulfill the
remaining portion of the
back order is made and then the process returns back to Step 245 to initiate a
new order to satisfy
the remaining backorder. Meanwhile, the actual product continues to Step 355
where a coating
schedule is generated. The dyed goods are then coated at Step 365 according to
the schedule,
cut (Step 370), and the finished product placed into inventory (Step 375).
Pegged orders are
also placed into new production inventory at Step 380. From here, the finished
product is
available for shipping to the customer to fulfill the order.
[0088] Assuming the work-in-progress was determined to be pre-dyed at Step
290, the
process continues to Step 360 where a coating schedule is generated. The goods
are then coated
at Step 365 according to the schedule, cut (Step 370), and the finished
product placed into
-20-
CA 02804866 2013-01-31
inventory (Step 375). Pegged orders are also placed into new production
inventory at Step 380.
From here, the finished product is available for shipping to the customer to
fulfill the order.
[0089]
[0090]
It should be understood that other many modifications and other embodiments of
the
invention set forth herein will come to mind to one skilled in the art to
which the invention
pertains having the benefit of the teachings presented in the foregoing
descriptions, and the
associated drawings. For example, the DTO system may be implemented for non-
tufted carpet.
Therefore, it is to be understood that the invention is not to be limited to
the specific
embodiments disclosed and that modifications and other embodiments are
intended to be
included within the scope of the appended claims. Although specific terms are
employed herein,
they are used in a generic and descriptive sense only and not for purposes of
limitation.
-21-
