SYSTEM FOR AUTOMATIC REORDERING OF REPLENISHMENT STOCK

Abstract

A system for automatic reordering of replenishment stock is described herein. The system generally comprises a storage bin defining a first compartment and a second compartment in proximity to the first compartment where the storage bin is configured to store a predetermined product. A cover assembly may normally restrict access to the second compartment. When the product is exhausted from the first compartment, opening the cover assembly to access the product in the second compartment may trigger a sensor in proximity to the second compartment. This triggering causes the sensor to wirelessly transmit a signal to a processor to reorder a quantity of the product.

Claims

1. A method for triggering the reorder of stock in a two-bin kanban point of use storage system comprising: attaching a hinged cover assembly with a transmitter and sensing switch to the storage bin, the hinged cover assembly enclosing a rear portion of the bin, causing a signal to be wirelessly transmitted when the hinged cover assembly is lifted up and the sensing switch is triggered, using that wireless signal to initiate a restocking process for the product stored in the bin.

2. The method of claim 1 where the sensing switch utilizes a mechanical method of detecting opening of the hinged cover assembly.

3. The method of claim 1 where the sensing switch utilizes a proximity method for detecting the opening of the hinged cover assembly

4. The method of claim 1 where the method of transmitting the signal utilizes the Zigbee specifications.

5. The method of claim 1 where the transmitter uses a proprietary wireless technology.

6. The method of claim 1 where the hinged cover assembly utilizes existing provisions in the bin for creating a hinge.

7. The method of claim 1 where the hinged cover assembly has a built-in hinge mechanism.

8. The method of claim 1 where a restock access door is provided in the top cover of the hinged cover assembly

9. A system for triggering the reorder of stock in a two-bin kanban point of use storage system comprising: attaching a hinged cover assembly with a transmitter and sensing switch to the storage bin, the hinged cover assembly enclosing a rear portion of the bin, causing a signal to be wirelessly transmitted when the hinged cover assembly is lifted up and the sensing switch is triggered, using that wireless signal to initiate a restocking process for the product stored in the bin.

10. The system of claim 1 where the sensing switch is a mechanical micro-switch.

11. The system of claim 1 where the sensing switch is a proximity switch.

12. The system of claim 1 where the transmitter uses Zigbee technology.

13. The system of claim 1 where the transmitter uses a proprietary wireless technology.

14. The system of claim 1 where the hinged cover assembly utilizes indents in the main bin to provide the hinge function.

15. The system of claim 1 where the hinged cover assembly contains a hinge which in turn is attached to the bin.

16. The system of claim 1 where a restock access door in the top cover of the hinged cover assembly

17. A system for automated reordering of a product, comprising: a storage bin defining a first compartment and a second compartment in proximity to the first compartment, wherein the storage bin is associated with a predetermined product; a cover assembly having a first closed configuration which restricts access to the second compartment and a second open configuration; a sensor in proximity to the second compartment, wherein movement of the cover assembly from the first closed configuration to the second open configuration triggers the sensor to wirelessly transmit a signal to a processor to reorder a quantity of the predetermined product.

18. A system for automated reordering of a product, comprising: a storage bin defining a first compartment and a second compartment in proximity to the first compartment, wherein the storage bin is associated with a predetermined product; a cover assembly having a first closed configuration which restricts access to the second compartment and a second open configuration; a sensor in proximity to the second compartment, wherein movement of the cover assembly from the first closed configuration to the second open configuration triggers the sensor to wirelessly transmit a signal for reordering the product; and a processor configured to receive the signal and further programmed to reorder a quantity of the predetermined product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 shows the features of a typical commercially available storage bin, to which the invention may be attached.

[0006] FIG. 2a and FIG. 2b show a perspective and side view of one variation of the hinged cover assembly of the invention.

[0007] FIG. 3 shows a variation of the hinged cover assembly mounted in a storage bin.

[0008] FIG. 4 shows the addition of a restock access door to the hinged cover assembly.

[0009] FIG. 5 shows how multiple installed hinged cover assemblies may transmit their signals through a network to a central computer system for reordering product.

DETAILED DESCRIPTION OF THE INVENTION

[0010] FIG. 1 shows the elements of a typical commercially available bin used for kanban. In some cases a kanban system uses two separate bins so that when the front bin is empty, the user does something to initiate restock, like moving the empty bin to the back or placing it in a restock request area, and moving the back bin to the front. Or the restock technician simply removes an empty bin on a restock round, and returns with a full one. In our case the invention may utilize a single bin 1. When used for the kanban process, one of the multiple divider slots 5, 6, or 7 is used to place a divider 8 to divide the whole bin into at least two compartments, the front one 4 from which stock is taken, and the rear compartment 3 which holds the back-up stock to be used while the reordering process proceeds. It is typical (but not necessary) that these commercially available bins have round indents 9, allowing separately supplied lids to be snapped into place across the top of the bin, and rest as a top cover on ledges 10 and 11.

[0011] FIG. 2a and FIG. 2b show a perspective and side view respectively, of the hinged cover assembly 19 of the invention. This hinged cover assembly is designed to attach to the bin of FIG. 1, so at each end of the back of the top element of the top part of the cover 20, are boss projections 23, which snap into and fit into the round indents 9 of FIG. 1 to form a hinge. For different commercially available bins 1, a different attachment might be provided. For example, the hinge can be part of the hinged cover assembly itself, with a mechanism for attaching that hinge to the fixed back wall of the storage bin 1 by, e.g., clips or screws. The hinged cover assembly may be rotatable along the back edge of the top surface 20. A lifting tab 24 may be included to facilitate lifting the hinged cover assembly. The second part of the cover 12, may be attached perpendicularly to the top member 20. On the inner surface of the vertical part 21 of the cover is attached a transmitter sub-assembly 25, with an associated sensor switch 26.

[0012] The placement of the transmitter assembly and switch is such that when the cover 12 is closed the switch 26 is off, and when the cover is lifted the switch 26 is on and the transmitter assembly is energized and communicates to a central system to re-order the product. The transmitter assembly may be battery operated and can use a variety of wireless communications methods such as Wi-Fi, Zigbee, etc., or a custom device at an appropriate wireless band match to a remote receive. The transmitter is low power consumption so that the battery will last the expected lifetime of the mechanical parts, which will be in excess of five years. To that end the transmitter may be designed to send a pulse signal, and immediately switch off, only to be re-energized the next time the switch is activated, from a closed position.

[0013] FIG. 3 shows the cover assembly installed in the bin of FIG. 1. The intention for use is that the user takes product from the front compartment 4 until there is none (or a few) left. Knowing that there is back-up product in the rear compartment 3, the user then lifts the hinged cover assembly 19, in the direction 30, using the tab 24, and slides the product forward from the back compartment 3 to the front compartment 4. The act of accessing that back compartment by lifting the lid engages switch 27, which causes the transmitter assembly 25 to send a re-order signal to the restock system.

[0014] FIG. 4 shows a useful modification to the top surface 20 of the hinged cover assembly that facilitates the restock process. While it is easy for the user to open the hinged cover assembly 19 open wide and move the material from the back compartment 3 to the front compartment 4, often by just tilting the bin up, it may be difficult for the restock person to place a large quantity of parts in that back compartment by the same process of lifting the hinged cover assembly 19. First it is likely the parts will cover the whole bottom surface of the bin, preventing the lid from closing, or making it difficult to close and requiring the restock person to try and push parts backwards and forwards within the bin to make a clear space for the bottom edge of the vertical part of the hinged cover assembly 19 to close properly. Worse it is likely that the new parts will get co-mingled with the older parts, and in many situations, it is desirable to keep a first-in, first-out (FIFO) policy on parts especially those with expiration dates. To facilitate re-stocking a restock access door 40 may be placed in the top cover 20, secured with a latch 41. This latch 41 does not need to be locked. While it is true that, when there are no parts left in the front compartment, a user could access parts through the restock access door 40, it is much easier for them to simply lift the hinged cover assembly 19. It may be hard to reach into the restock access door 40 and find parts in the bottom of the backup compartment 3, with limited visibility. Furthermore, in many cases, where parts and bins are small, it may be particularly hard to even get a hand through the restock access door 40. Consequently for the user, lifting the hinged cover assembly remains the easiest way to get parts out. For the restock person trying to get parts in, the restock access door 40 provides an easy way, while maintaining separation of old from new product.

[0015] While a hinged cover assembly is described, other variations of the cover assembly as well as opening mechanisms may be utilized in any number of combinations. For example, rather than a hinged cover, a sliding or removable cover may be used. In other variations, no cover may be used but sensors may be positioned to detect for the presence of products within the rear compartment 3. The same or additional sensors may also be used to detect whether the rear compartment 3 has been accessed, e.g., by a user, as an indicator of whether additional product should be automatically re-ordered.

[0016] FIG. 5 shows how multiple storage bins 1, equipped with hinged cover assemblies 19, each with a transmitter 25, communicate wirelessly 51 with a wireless receiver hub 52, which in turn is either physically connected, or connected via Wi-Fi or other wireless protocol, to the facility network 54, and so to a computing device 55, where the requirements for restocking items can be shown and/or printed out so that the necessary items can be pulled from stock and taken to the bins.

[0017] The applications of the disclosed invention discussed above are not limited to any particular industries, but may include any number of industries and applications. Modification of the above-described methods and devices for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the arts are intended to be within the scope of this disclosure. Moreover, various combinations of aspects between examples are also contemplated and are considered to be within the scope of this disclosure as well.