GB2259685A - Production of computer packages - Google Patents

Abstract

A process (1) is disclosed for production of computer packages in which several different items are required. Production of a particular type of package is broken down into batches (eg. of 400). Each batch includes several sub-batches of blank disks for duplication. Disks before duplication are stored in colour-coded containers and in different colour-coded containers after duplication. The labelling (8, 9, 19) and duplication (20, 21, 27) operations are each carried out using one sub-batch of disks at a time and quality control checks (19, 28) are carried out for each sub-batch. A batch production record is maintained and data is registered (5) to the batch record at various steps including the quality control steps of the process. <IMAGE>

Description

"A Production Process" The present invention relates to a production process, and more particularly to a production process for software "packages", using apparatus such as that described in United States patent specification No. 4,693,659 (Burke et al) and 4,471,390 (hamann).

In such production processes, there are generally very many different versions of packages to be produced. For example, one particular type of software may require the production of twenty different packages, each for a different country in which there is a different language and possibly different versions of the software. At any one time a production facility may be involved in producing software packages, not only for many different versions of the one type of software but also for different types of software, for example, spreadsheets and word processing packages. Production operations are further complicated by the fact that many packages include several different disks.

One approach to achieving good quality control and traceability in such a production process is to set up several different production lines comprising the various machines including labelling, printing and software duplicating machines. These production lines would be kept physically separate and there would be relatively few different types of packages produced on any one individual line so that faults may be easily traced back. This is, however, an extremely expensive way of ensuring quality control and traceability as there is a requirement for a high capital investment in machines and buildings and also higher operating costs.

There is thus a need for a production process for improved production of software packages which not only provides for adherence to strict quality control standards and traceability of faults, but also efficiency.

According to the invention, there is provided a process for production of a computer package comprising the steps of: retrieving a batch quantity of each item required for a single batch of packages; storing blank disks for the package in sub-batch containers within colour-coded batch containers; storing all items for a batch on a single storage device; labelling the storage device; registering retrieval of items for the batch in a batch production record and registering details of the batch in the record; generating data from the production record relating to the batch; printing a batch of labels with the generated data, the quantity printed being the batch number; loading a sub-batch of blank disks in a label applicating machine and subsequently applying labels to all disks of that sub-batch; verifying quality of the labelling operation for that sub-batch before proceeding with applying labels to a next sub-batch of disks; registering the results of the quality control check for each sub-batch in the batch production record; transmitting software to a duplicating machine, said software relating to the production batch; loading a sub-batch of labelled blank diskettes into a duplicating machine; mounting a plurality of sub-batch containers at the output of the duplicating machine, each container being for reception of a single sub-batch; after duplication of each sub-batch of disks, carrying out quality control checks to verify the duplication operation for the sub-batch; registering results of the quality control check in the batch production record;; placing all sub-batch containers for the duplicated sub-batches of disks within a colour-coded batch container on the storage device; and moving the storage device to an assembly station for assembly of the packages used.

Ideally, the sub-batch containers are of elongate construction for storage of disks in a neat fit.

Preferably, the generated data printed onto the labels includes a unique batch identification number.

In one embodiment, the step of applying a label to a disk involves the step of supporting a disk with an upper roller above a conveyor on delivery to a reception holder for labelled disks.

In another embodiment, the sub-batch containers are mounted on a sliding support beneath a duplicating machine.

The invention will be more clearly understood from the following description of some preferred embodiments thereof, given by way of example only with reference to the accompanying drawings in which: Fig. 1 is a flowchart illustrating a production process of the invention; Fig. 2 is a sketch showing a labelling operation of the process; and Fig. 3 is a sketch showing a duplication operation of the process.

Referring to the drawings, and initially to Fig. 1, there is illustrated a production process of the invention, indicated generally by the reference numeral 1. Initially, all of the items required for software packages to be produced are stored in a relatively small warehouse which operates on the just-in time principle. Generally, the items include blank disks of the 5.25 and the 3.5 inch type, manuals in different languages, cartons, labels and disk envelopes. In general, the labels are pre-printed with general information such as a company logo.

In the initial step 2 of the process, a batch of items is retrieved from the warehouse for production of a particular batch of packages. To do this, a production record for that particular batch is either manually prepared or stored in a computer. The record indicates a set quantity of packages to be produced for that batch and accordingly, exactly that quantity of each item is retrieved. It has been found that a batch quantity of 400 is suitable. Thus, in this example, 400 manuals, 400 labels, 400 cartons, 400 disk envelopes and a multiple of 400 blank disks are retrieved. This operation is registered in the production record. Subsequently, the relevant input is made to a computerised inventory system.

In step 3, the disks are separated into sub-batches such as four sub-batches of 100 disks and are stored separately in a colour-coded container. In this embodiment, the sub-batch containers are elongate so that the disks fit neatly into them and do not move during handling of the container. The colour code of the batch container for blank disks is green. In step 4 of the process, all of the disks in the colour-coded containers and the other items for the batch are stored on a single storage device such as a dolly or a pallet. This step is registered in the production record and a label or sign is placed on the storage device to indicate the batch identification number. The step of registering data in the production record is indicated by step 5, and in step 6 data for labels on a diskette is generated by a computer apparatus.

This data generally includes the batch identification number, the date, and data indicating the version of software which is to be duplicated onto the blank disks. In step 7, a printer prints a batch of labels using the data which is generated by the computer in step 6. Only the exact batch quantity, in this case 400, is printed.

After printing of the labels, the storage container is moved to a label applicator station which may be one of two types One type is where a label is applied directly to one face of a diskette, the other type involving a wrap-around operation wherein the label is adhered to both sides. Generally, only an end of the label is wrapped around onto the other side.

The label application operation is initiated in step 8 by placing a sub-batch of blank disks into a loading magazine of the machine and in step 9 each disk of that sub-batch has a label applied to it. This is illustrated in diagrammatic form in Fig. 2, in which portion of a label applicating machine 10 is shown. The batch of labels 11 is mounted on a drum 12 and a web carrier for the labels drops from a roll 11. The machine 10 is for "wrap-around" labels and includes an upper roller 12 and a lower brush 13 for adhering a label 14. The label 14 projects downwardly from the web carrier and is abutted by a blank disk 15 approaching on a conveyor belt 16.

At the delivery end of the machine 10, there is an upper roller 17 which maintains stability of a disk as it drops into a sub-batch holder 18. Thus, there is little chance that a disk which has been labelled will drop from the machine or be damaged in any way by rough handling. In Fig. 2, the dimensions of the labels 14 are exaggerated for clarity.

In step 19 of the process, a quality control check is made of the sub-batch of labels in the holder 18 to ensure not only that the correct quantity of labelled disks is present but also that the labels have been applied in the correct position of the disk within a tolerance of +/- 1.5 mm. This quality control check is visual although it is envisaged that a photo detector mounted at the delivery end of the machine 10 may be connected to a processor for monitoring of position of the labels and the quantity of labels passing for delivery into the holder 18. This procedure is carried out for each subbatch, and in this case there are four sub-batches of 100 disks each. After the quality check, the disks are returned to the original colour-coded container.

In step 20 of the process, software to be copied onto the blank disks is transmitted to a duplicating machine. This step may be carried out either on-line or may be pre-set if similar software is to be loaded to different batches. In step 21, each sub-batch of labelled disks is loaded into the magazine of a duplicating machine, 22, as illustrated in Fig.

3. The duplicating machine 22 comprises a vertical magazine 23 for labelled blank disks and a delivery chute 24. After loading of the sub-batch of labelled disks in the magazine 23, in step 27, sub-batch containers 26 are placed on a sliding support 25. When a quantity of duplicated disks is delivered to the output holder of the chute 24, they are manually transferred to the relevant sub-batch container 26. Each container 26 is suitable for holding one sub-batch of 100 duplicated disks and is of elongate construction to ensure that the disks are not damaged while being handled. Because the support 25 is slidable beneath the machines 22, it can support the desired number of containers in a convenient manner.

As each sub-batch of disks has been duplicated, a quality control check is carried out in step 28 to ensure that the correct quantity is present in the relevant container 26 and random checks are made on the quality of the duplication to ensure that there are no faults in operation of the duplicating machine 22. The result of the quality control check is registered in the production record and subsequently in step 29 all of the loaded containers 26 are placed back on the original storage device when all of the sub-batches have been duplicated.

After carrying out all of the duplication operations, the storage device is moved to an assembly station at which all of the items for a single computer package are assembled together to produce the computer package. This is indicated by the step 30. This generally involves inserting a duplicated and labelled disk in an outer envelope, and placing them in an assembled carton together with the relevant manual. The carton is subsequently sealed by, for example, shrink-wrapping.

Because of the manner in which a production record is maintained for a particular batch, final checking is eliminated in most cases and efficiency of the assembly operation is ensured. If mistakes have occurred such as, for example, a sub-batch of non-duplicated disks being placed on the storage container before assembling, this mistake would be readily apparent to personnel because of use of colour-coded containers. Further, the record of that batch during the production process may be easily verified before assembling.

It will also be appreciated that because of the manner in which batches and sub-batches are produced in the production process and because of the quality control checks on the subbatches, any faults which occur during the production process are immediately identified and rectified. This avoids re-work which would significantly decrease efficiency in the production process. Thus, not only does the production process of the invention ensure quality control, but efficiency is also maintained.

It will also be appreciated that because of the manner in which various quality control checks are registered in the record throughout the production process, traceability of a computer package is easily carried out in the event that a faulty package is dispatched. The batch identification number is unique to that particular batch of only 400 items.

The invention is not limited to the embodiments hereinbefore described, but may be varied in construction and detail.

Claims (7)

1. A process for production of a computer package comprising the steps of: retrieving a batch quantity of each item required for a single batch of packages; storing blank disks for the package in sub-batch containers within colour-coded batch containers; storing all items for a batch on a single storage device; labelling the storage device; registering retrieval of items for the batch in a batch production record and registering details of the batch in the record; generating data from the production record relating to the batch; printing a batch of labels with the generated data, the quantity printed being the batch number; loading a sub-batch of blank disks in a label applicating machine and subsequently applying labels to all disks of that sub-batch; verifying quality of the labelling operation for that sub-batch before proceeding with applying labels to a next sub-batch of disks; registering the results of the quality control check for each sub-batch in the batch production record; transmitting software to a duplicating machine, said software relating to the production batch; loading a sub-batch of labelled blank diskettes into a duplicating machine; mounting a plurality of sub-batch containers at the output of the duplicating machine, each container being for reception of a single sub-batch; after duplication of each sub-batch of disks, carrying out quality control checks to verify the duplication operation for the sub-batch; registering results of the quality control check in the batch production record; placing all sub-batch containers for the duplicated sub-batches of disks within a colour-coded batch container on the storage device; and moving the storage device to an assembly station for assembly of the packages used.

2. A process as claimed in claim 1, wherein said sun-batch containers are of elongate construction for storage of disks in a neat fit.

3. A process as claimed in claims 1 or 2, wherein the generated data printed onto the labels includes a unique batch identification number.

4. A process as claimed in any preceding claim, wherein the step of applying a label to a disk involves the step of supporting a disk with an upper roller above a conveyor on delivery to a reception holder for labelled disks.

5. A process as claimed in any proceeding claim, wherein the sub-batch containers are mounted on a sliding support beneath a duplicating machine.

6. A process substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

7. A computer package whenever produced by a process as claimed in any preceding claim.