AU2006230638B2

AU2006230638B2 - A method and system for reducing leadtime in the packaging industry

Info

Publication number: AU2006230638B2
Application number: AU2006230638A
Authority: AU
Inventors: Joseph J Cardillo; Robert J Eller
Original assignee: ExxonMobil Oil Corp
Current assignee: ExxonMobil Oil Corp
Priority date: 2000-12-05
Filing date: 2006-10-17
Publication date: 2007-11-08
Anticipated expiration: 2021-11-14
Also published as: AU2006230638A1

Description

P001 Section 29 Regulation 3.2(2)

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Application Number: Lodged: Invention Title: A method and system for reducing leadtime in the packaging industry The following statement is a full description of this invention, including the best method of performing it known to us: QA METHOD AND SYSTEM FOR REDUCING LEADTIME IN THE PACKAGING INDUSTRY 0 BACKGROUND OF THE INVENTION r- The present invention relates to a method and a system for reducing leadtime in the packaging industry. This invention is particularly beneficial to the 00 00, flexible packaging industry which services the fast moving consumer goods

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manufacturing industry producers of snacks, cookies, crackers, candies, I health and beauty aids, etc.). Currently packaging is the longest leadtime item for these companies, and a system-wide bottleneck for them. Reducing the packaging leadtime allows for waste reduction and revenue enhancement opportunities.

The method disclosed herein comprises an embodiment of a business process which may be enabled by the internet and capable of exchanging information with other business processes.

U.S. Patent No. 6,067,406 discloses a method and device wherein the output mode of an output device for rendering electronic images on an output medium may be characterized by different user-selectable settings such as: paper type, ink type, etc. Apart from the screen characteristics such as screen ruling, frequency and angle, a calibration curve can be communicated via the page description language PostScript Level 2) for each color component. Sets of calibration curves can be prepared for specific types of rendering, and be referenced by name. By this name indication and by naming conventions based upon the output mode or screening parameters, calibration changes can be introduced quickly and consistently. U.S. Patent No. 6,067,406 is incorporated herein by reference.

U.S. Patent No. 5,991,783 discloses a system and method for generating, storing and transmitting a layout page containing graphical data correlated to at least one graphical image which has previously been graphically encoded, such that the layout page may be printed either as a complete, full-color image, or as individual color separation plates. The system and method create a set of master data files, having a main master file which stores complete RGB (red, green, blue) color data for the graphical image, and a correlated set of CMYK (cyan, magenta, I I- II I I

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Ni yellow, black) master files, each containing graphical data for a single color Sseparation plate for the graphical image. The main master file contains pointers to

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each of the CMYK master files. The system and method also create a set of preview data files: a set of CMYK preview files essentially only containing a pointer to the corresponding CMYK master file, and a main preview file 0O M essentially only containing a pointer to the main master file, and pointers to each O of the CMYK preview files. U.S. Patent No. 5,991,783 is incorporated herein by Sreference.

O U.S. Patent No. 5,982,996 discloses an information distributing apparatus for operating within a computer network environment. The information distributing apparatus includes a computer having an operating system and is configured to operate within the computer network environment. The apparatus has an application configured for running on the computer via the operating system, the application configured to generate a source job in the form of an intermediate file format comprising an output instruction file. The apparatus includes a print processor in the form of an intermediate executable code for operating on the output instruction file. The apparatus also includes at least one output device having an output device driver configured to convert the output instruction file to output instructions usable by the output device for producing output. The print processor is operable on the output instruction file to select the device driver of one of the at least one output device to render the output instruction file, and feed the output instruction file to the output device driver of one of the at least one output device. A corresponding method is also disclosed.

U.S. Patent No. 5,982,996 is incorporated herein by reference.

U.S. Patent No. 5,960,164 also discloses a method and system for producing documents at a first site from database information produced at a second site remote from the first site has enhanced system flexibility and enhanced data handling throughput, which are accomplished by adopting standard programming interface or database tables to allow a computer at the second site to obtain information necessary to generate all necessary data codes and stream formatting information which will be utilized at the first site. An object association table, which associates document production jobs with specific

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r documents and appropriate descriptions, is provided at the first site so that it is O accessible-e.g. through an online communications network-at the second site. The .0 C object association table is accessed at the second site in realizing substantially only file names in the object association table, to produce database information at the second site. The database information is supplied from the second site to the 00 rn, first site where it is translated so that it may be utilized by a specific print engine at the first site, utilizing a job formatting table to build an engine specific print r stream for one or more print engines. Then the engine specific print stream, Stailored to the particular print engine utilized, electronically controls a specific r' 10 print engine at the first site to image documents having variable information from the database information supplied from the second site. U.S. Patent No. 5,960,164 is incorporated herein by reference.

Packaging is the longest leadtime ingredient for the consumer goods manufacturer. Most components that the manufacturer uses are commodities with leadtimes of hours or days. However, packaging is a custom product with leadtimes of 2-4 weeks for a repeat order and leadtimes of 8-12 weeks or more for a new design. This relatively long leadtime creates system-wide bottlenecks; inefficiencies and waste; packaging write-offs; barriers to lean manufacturing at end user sites; and 4 to 8 weeks of delay in launching new products. The long leadtime is the primary reason that successful promotions are not fully exploited.

The long leadtime for packaging is caused by complexity of the supply chain, the distance between the parties, and the process of manufacturing and delivering the packaging to the consumer goods manufacturer. A large ieadtime reduction can be achieved by using the internet to collapse apparent distance between the parties and implementing a new business process using the intemrnet.

Accordingly, it is an object of the present invention to provide a method and system for reducing leadtime in the flexible packaging industry.

All patents and publications referred to in this application are hereby incorporated herein by reference in their entirety.

SUMMARY OF THE INVENTION The present invention relates to a method and system for linking the o various members of the packaging (including labels) supply chain. The invention provides an integrated order placement, production planning, scheduling, and material requirements planning environment for the various members of the 0 packaging supply chain. Among the members in the flexible packaging supply M chain are end users, converters, and suppliers of goods and services necessary for the creation of packaging. The method and system of the present invention allow members of the supply chain to access the additional data they need to integrate their activities and reduce packaging leadtimes. In addition, the system is designed to interface with the converter's order management, inventory, and purchasing systems to acquire data for production planning g. inventory levels), order processing, and certain other functions. The system is designed to interface with digital files containing package designs and images to provide information for item creation, production planning, and scheduling.

In one aspect, the invention provides a method for management of placement and fulfilment of orders for printed packaging products, including labels for fasting-moving consumer goods including the steps of: a) storing digital data associated with a plurality of orders for printed packaging items in a digital computer system; b) processing said digital data to create scheduling metadata which comprises the degree of technical difficulty associated with printing the images on said packaging items; c) storing digital data associated with multiple scheduling options for production of said packaging items associated with a plurality of orders in a digital computer system; d) analyzing said digital data with said digital computer system; e) generating a schedule for production of said packaging items associated with a plurality of orders from among said multiple scheduling options with said digital computer system; and f) producing said printed packaging products according to said schedule.

In another aspect, the invention provides a computer system for management of placement and fulfilment of orders for printed packaging o products, including labels for fasting-moving consumer goods, including an electronic storage means for having a computer program stored thereon, wherein the computer executes the method of the first aspect of the invention.

BRIEF DESCRIPTION OF THE FIGURES M FIG. 1 is a flow diagram setting forth a system overview of the processes of the current invention.

FIG. 2 is a flow diagram setting forth an overview of the Production Planning and Order Management processes of the current invention.

FIG. 3 is a flow diagram setting forth an overview of the Sales and Operation processes of the current invention.

FIG. 3A is an exemplary monitor view of a Demand Forecast Table of the Sales and Operation processes of the current invention.

FIG. 3B is an exemplary monitor view of a Line Availability Table of the Sales and Operation processes of the current invention.

FIG. 3C is an exemplary monitor view of a Lines Rates and Efficiencies Table of the Sales and Operation processes of the current invention.

FIG. 3D is an exemplary monitor view of line loading utilizations of the Sales and Operation processes of the current invention.

FIG. 3E is an exemplary monitor view of an Inventory Adjustment Table of the Sales and Operation processes of the current invention.

FIG. 3F is an exemplary monitor view of a Capacity Group Assignment Table of the Sales and Operation processes of the current invention.

FIG. 3G is an exemplary monitor view of a Capacity Group Demand Averages Table of the Sales and Operation processes of the current invention.

FIG. 4 is flow diagram setting forth an exemplary overview of the Master Production Scheduling processes of the current invention.

FIG. 4A is an exemplary monitor view of a Master Production Scheduling Summary Table of the Master Production Scheduling processes of the current invention.

FIG. 4B is an exemplary monitor view of the Inventory Adjustment Table of the Master Production Scheduling processes of the current invention.

O FIG. 4C is an exemplary monitor view of a Capacity Group Assignment STable of the Master Production Scheduling processes of the current invention.

c FIG. 5 is a flow diagram setting forth the supporting assumption processes of the Master Production Scheduling processes of the current invention.

FIG. 5A is an exemplary monitor view of Line Availability Assumptions Table of the Master Production Scheduling processes of the current invention.

n FIG. 5B is an exemplary monitor view of the Line Rates and Efficiencies 0Table of the Master Production Scheduling processes of the current invention.

(Ni NFIG. 5C is an exemplary monitor view of the Capacity Group Setup Table of the Master Production Scheduling processes of the current invention.

FIG. 6 is a flow diagram setting forth an overview of the Order Management processes of the current invention.

FIG. 7 is a flow diagram setting forth an overview of the order placement and Available-To-Promise (ATP)/Allocation processes of the Order Management processes of the current invention.

FIG. 7A is an exemplary monitor view of an End User-Place Order process of the Order Management processes of the current invention.

FIG. 7B is an exemplary monitor view of an Automatic ATP/Allocation run of the Order Management processes of the current invention.

FIG. 7C is an exemplary monitor view of an update to converter's Legacy Order Management System of the Order Management processes of the current invention.

FIG. 8 is a flow diagram setting forth an overview of the process for creating an end user item of the Order Management processes of the current invention.

FIG. 8A is an exemplary monitor view of an Item Definition-Image process of the Order Management processes of the current invention.

FIG. 8B is an exemplary monitor view of the Acquire Image Extract End User (EU) Metadata process of the Order Management processes of the current invention.

FIG. 8C is an exemplary monitor view of the Display Image Tile process of the Order Management processes of the current invention.

FIG. 8D is an exemplary monitor view of the Package Structure -End User process of the Order Management processes of the current invention.

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oFIG. 8E is an exemplary monitor view of the Acquire Image for Display process of the Order Management processes of the current invention.

FIG. 9 is a flow diagram setting forth an overview of the process for 0 handling pending orders of the Order Management processes of the current r invention.

0FIG. 9A is an exemplary monitor view of the Process Pending Orders Nprocess of the Order Management processes of the current invention.

S 10 FIG. 9B is an exemplary monitor view of the ATP/Allocation Check process of the Order Management processes of the current invention.

FIG. 9C is an exemplary monitor view of the Display Order process of the Order Management processes of the current invention.

FIG. 9D is an exemplary monitor view of the Change Order process of the Order Management processes of the current invention.

FIG. 9E is an exemplary monitor view of the Create Order process of the Order Management processes of the current invention.

FIG. 9F is an exemplary monitor view of an update to converter's Legacy Order Management System of the Order Management processes of the current invention.

FIG. 10 is a flow diagram setting forth an overview of the processes for converter completion of a packaging item of the Order Management processes of the current invention.

FIG. 10A is an exemplary monitor view of the Acquire Image Extract Converter (CV) Metadata process of the Order Management processes of the current invention.

FIG. 10B is an exemplary monitor view of the Package Structure Converter Data process of the Order Management processes of the current invention.

FIG. 10OC is an exemplary monitor view of the Enter/Change Item process of the Order Management processes of the current invention.

FIG. 10D is an exemplary monitor view of the Bill of Materials process of the Order Management processes of the current invention.

4d O FIG. 10E is an exemplary monitor view of the Ink Bill of Materials process Sof the Order Management processes of the current invention.

o FIG. 11 is a flow diagram setting forth an overview of the Schedule Orders processes of the current invention.

FIG. 11A is a flow diagram setting forth an overview of the process for 0 scheduling presses of the Schedule Order processes of the current invention.

Mq FIG. 11B is an exemplary monitor view of the Select Schedule process of the Schedule Order processes of the current invention.

(Ni FIG. 11C is an exemplary monitor view of the View Scheduled and Unscheduled Orders process of the Schedule Order processes of the current invention. See also paragraph [00185] of the specification.

FIG. 11D is an exemplary monitor view of the Schedule Press process of the Schedule Order processes of the current invention.

FIG. 11E is a flow diagram setting forth an overview of the process for scheduling laminators of the Schedule Order processes of the current invention.

FIG. 11F is a flow diagram setting forth an overview of the process for scheduling slitters of the Schedule Order processes of the current invention.

FIG. 11G is a flow diagram setting forth an overview of the Inventory/Purchasing Interface processes of the Schedule Order processes of the current invention.

FIG. 11H is an exemplary monitor view of the Get Inventory Data from Legacy Order Management System process of the Schedule Order processes of the current invention.

FIG. 111 is an exemplary monitor view of the Get Purchasing Data from Legacy Order Management System process of the Schedule Order processes of the current invention.

FIG. 11J is a flow diagram setting forth an overview of the Update Order and Schedule Status process of the Schedule Order processes of the current invention.

FIG. 11K is an exemplary monitor view of Schedule Versions process of the Schedule Order processes of the current invention.

FIG. 11L is an exemplary monitor view of the Update Production process of the Schedule Order processes of the current invention.

O FIG. 12 is a flow diagram setting forth an overview of the Material SRequirements Planning processes of the current invention.

O FIG. 12A is a flow diagram setting forth an overview of the Inventory/Purchasing Interface process of the Material Requirements Planning processes of the current invention.

FIG. 12B is an exemplary monitor view of Inventory/Purchasing Interface oo r process of the Material Requirements Planning processes of the current invention.

N FIG. 12C is a flow diagram setting forth an overview of the Run Material Requirements Planning, Prepare Purchase Requirements process of the Material Requirements Planning processes of the current invention.

FIG. 12D is an exemplary monitor view of the Procure Raw Materials process of the Material Requirements Planning processes of the current invention.

FIG. 12E is an exemplary monitor view of the Get Orders process of the Material Requirements Planning processes of the current invention.

FIG. 12F is an exemplary monitor view of the Explode BOMs process of the Material Requirements Planning processes of the current invention.

FIG. 12G is an exemplary monitor view of the Consolidate Requirements process of the Material Requirements Planning processes of the current invention.

DETAILED DESCRIPTION OF INVENTION General Overview The present invention provides a method for reducing leadtime and waste in the packaging supply chain together with an integrated computerized platform for order placement, production planning, scheduling, and ensuring that the materials required to produce the ordered packages are available to support the schedule. The phrase "packaging" means containers for storing, shipping, and selling goods and products as well as labels for use in connection with such containers. In order to operate efficiently and economically, the method of the present invention comprises a computer system. Accordingly, the present invention comprises both the method and an enabling computer system.

4f In this application, Packaging Design means the graphic design (image)

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displayed on a package. Packaging Product Design means the combination of o the Packaging Design with the structure of the package, which includes at least some of the materials used to make the package. Packaging Item means the 00

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O combination of the Packaging Product Design (the design of a single package) combined with at least one of following categories of information: production O configuration (multiple packages produced together), a specific bill of materials, and routing (the sequence of machines used to produce the item). A skeleton of 5 the item may be created by the end user (end user item), and completed by the 00 0c converter (converter item). Order means the combination of a packaging item Iwith a specified delivery date and a specified quantity.

SCompared to current methods for operating the packaging supply chain, the present invention comprises the following innovations which allow the invention to accomplish its objective of reducing leadtime and waste: Complete Information The first requirement for improving the performance of the packaging supply chain is to eliminate the errors caused by planning with incomplete information. Today, much information, especially information about the image, is generally unavailable to planners. The present invention has the capacity to make both the image itself, and critical scheduling information extracted from the image (scheduling metadata) available to planners at all levels in the supply chain.

Sales and Production Items From the viewpoint of the supply chain, there are two equally important views of every packaging item. First, the item is a sales unit, a single package to be filled and sold. Simultaneously, the package is a production unit, for example, a sheet of cardboard with four cardboard boxes printed on it. Up to now, planning systems have emphasized the production unit, with the result planning across multiple suppliers (with often different sizes of equipment) is nearly impossible. The present invention solves this problem by introducing two items an end user item corresponding to the sales unit, and a -converter item (for each converter) corresponding to that converter's production unit.

Networked Environment A typical packaging supply chain consists of six to ten widely separated companies, and chains with up to 50 members are not uncommon. By utilizing computer networks, and particularly by exploiting the ease and availability of the internet, the members of the supply chain can shrink the apparent distance between companies and greatly reduce distance related

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c delays. The potential of a networked environment to speed up the supply chain 0 depends on the quality of the information being communicated over the network 0 (otherwise, the only effect of networking the supply chain is to speed up the rate at which mistakes are made). The present invention solves the problem of data quality by providing complete information and meaningful item definitions. It oO c, then goes on to introduce a suite of business processes that fully exploit the Spotential of a networked environment to slash leadtimes.

SReliable Leadtimes An effective networked environment is an important Sleadtime reduction component. However, speed without reliability will not result in a breakthrough (if a process is sometimes fast and sometimes slow with no apparent reason for the difference, a prudent business will plan as if the process will be slow all of the time). The present invention introduces a set of integrated business methods and systems tools which maximize the likelihood that promised leadtimes will be met, thus allowing the supply chain to take advantage of the reduced leadtimes in all phases of its operation.

Schedule Optimization Short, reliable leadtimes allow companies in the packaging supply chain to wait longer before committing to packaging decisions.

The result of waiting longer is that there is less opportunity for circumstances to change or, equivalently, more schedule stability. In this environment, a powerful, easy to use scheduling tool coupled with the availability of complete information can greatly decrease waste in the supply chain. Accordingly, the present invention provides such a tool, together with the business methods required to enable its effective use.

Networking The Packaging Environment While there are many members involved in the packaging industry supply chain, the principal members of the supply chain are the end user, the converter, and suppliers of goods and services necessary for the production of packages. The end user uses the packages to store ship, promote, and/or sell its products.

Generally, it is the end user that places orders for the creation and delivery of packaging. Generally, the converter is responsible for production of finished I- II I

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Spackaging ready to be filled or finished labels ready to be applied. The converter coordinates the printing of a package design selected by the end user onto a O suitable substrate. The converter often actually performs the service of printing rthe package design and further processing the printed substrate to produce finished packaging materials for the end user. The third general category of 00 members in the packaging supply chain are the suppliers of goods and services Irequired by the converter to produce packaging. These suppliers supply materials N, such as plastic film from which the packages are made and services such as cylinder engraving.

S 10 The present invention provides a method and computer system for networking and integrating the packaging supply chain. The method and computer system of the present invention are particularly suitable for use in connection with the internet. The internet comprises a vast number of computers and computer networks that are interconnected through communication links. The interconnected computers exchange information using various services, such as electronic mail, Gopher, and the World Wide Web The www service allows a server computer system web server or web site) to send graphical web pages of information to a remote computer system. The remote computer system can then display the web pages. Each resource computer or web page) of the www is uniquely identifiable by a Uniform Resource Locator To view a specific web page, a computer system specifies the URL for that web page in a request a HyperText Transfer Protocol ("HTTP") request). The request is forwarded to the web server that supports that web page.

When that web server receives the request, it sends that web page to the remote computer system. When the remote computer system receives that web page, it typically displays the Web page using a browser. A browser is a special-purpose application program that effects the requesting of web pages and the displaying of web pages. Web pages can be defined using Hyper Text Markup Language ("HTML") or Extended Markup Language HTML provides a standard set of tags that define how a web page is to be displayed. When a user indicates to the browser to display a web page, the browser sends a request to the server computer system to transfer to the client computer system an HTML document I 1- 1111 II I

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that defines the web page. When the requested HTML document is received by C.) othe client computer system, the browser displays the web page as defined by the

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HTML document. The HTML document contains various tags that control the displaying of text, graphics, controls, and other features. The HTML document 00 5 may contain URLs of other web pages available on that server computer system or Mc, other server computer systems.

SThe system of the present invention allows the various members of the packaging supply chain to access the system though a system homepage appropriate to the member's position in the supply chain displayed on the monitor 10 of the member's computer connected to the system of the present invention thorough the internet. Each member can log into the system through this homepage using a secure ID. The system of the present invention may also connect each member to the system through a communications link such as dedicated wide area network, a frame relay network, a local area network, or any other commercial networking technology. Each member having connection to the system of the present invention is capable of transmitting to and receiving data from the system useful to the member to fulfill its role in the packaging supply chain.

The Method Of The Present Invention The starting point for the method is a design which has been developed to the point of being a digital contract proof a Portable Data Format file commonly referred to as a "PDF" file or other suitable file format) and an end user requirement for packaging carrying this design. From this starting point, the invention enables one or more of the following methods: distributed item creation, order placement, capacity planning and order acknowledgement, material requirements planning, procurement of raw materials and services, scheduling, order status tracking, and access control.

Distributed item creation comprises a method for accessing images, algorithms to calculate item data percent ink coverage), and a collaborative item creation process using this data which comprises end user creation of the -I I-

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Sitem skeleton (image and basic package structure) and converter addition of item o details (bill of materials, plate/cylinder identification numbers, routings, etc.) 0 Capacity planning and order acknowledgement is a method for capacity planning (sales operations planning, master production scheduling), capacity checking (slotting orders to production lines for available to promise and 00 Mc, allocation checks), and material availability checking.

Procurement of raw materials and services comprises a method for C providing suppliers with immediate notification of urgent material/service requirements directly out of the material requirements planning process; and 10 mechanisms for transferring requirements to purchasing systems, ordering materials/services from suppliers, and tracking the status of materials and services on order.

Scheduling comprises a method for scheduling converting operations (press, laminator, metallizers, coaters, slitters, etc.) using complete information; accessing image files and algorithms for extracting scheduling information from these files process print degree of difficulty, degree of bounce associated with the color separated design, etc.); intuitive (drag and drop) scheduling methods for increased productivity; maintaining multiple "what if' scenarios; and scheduling methods that are designed for compatibility with the ATP/allocation process methods to insure schedules can be developed to fulfill the commitments made in the ATP/allocation process).

Access control and security management methods comprise having a defined owner for each data element with the owner having the ability to grant access to other users a converter can grant an end user access to the converters order status information); and security management that prevents access to information not owned or authorized for access by the inquiring party.

The Computer System Of The Present Invention The computer system for integrating the flexible packaging supply chain comprises a computer system accessible for networked interactive communications, which may include on-line communications using the intemet, I I I I Iwith users which comprises a first memory area for storing functionality and data o for end user members of the supply chain; a second memory area for storing functionality and data for converter members of the supply chain; and a third memory area for storing functionality and data for other members of the supply O0 5 chain (including but not limited to film suppliers, cylinder suppliers, ink suppliers, M, adhesive suppliers, etc.).

0 SIn one embodiment of the system, the computer system is programmed to IND perform the steps of providing an end user with networked access to an end user homepage, with the homepage linking to the first memory area, and providing the end user with the ability to create an item, place orders for the item, receive confirmation of promise date, and track order status; providing a converter with networked access to a converter homepage, with the homepage linking to the second memory area; and providing the converter with the ability to receive orders, add item details, plan production, check "available to promise" against these plans, schedule orders for production, plan material requirements, initiate orders for material, track production, and insure production meets promised delivery dates; and providing other users with networked access to other user homepage(s), with the homepage(s) linking to a third memory area, and providing the ability to send and receive information concerning orders, forecasts, schedules, etc. as required to synchronize and integrate the supply chain.

In another embodiment of the system, the computer system is further programmed to support distributed item creation in a collaborative planning environment comprising: tools for collaborative item creation (facilities for creating and storing elements of item information- for example structure, material descriptions, multilevel bills of materials structure, ink, routings, etc.); (2) tools to access images and extract metadata (information extracted from the digital image which is essential to prepare production plans and schedules e.g. difficulty of print; specific colors used to print image; percent coverage by color; etc.) and a collaborative item creation process using these tools: end user creation of the item skeleton (image and basic package structure); converter addition of item details (bills of materials, plate/cylinder identification numbers, routings, etc.).

o In another embodiment of the system, the computer system is further programmed to support electronic placement of orders by the end user and o electronic confirmation of the original date and quantity (or proposal of a new r'date and quantity) by the converter.

In another embodiment of the system of the present invention, the 00 computer system is further programmed to support capacity planning and order IND acknowledgement in a collaborative planning environment comprising: (1) capacity planning tools (sales operations planning, master production IN scheduling), capacity checking tools (available to promise, allocation), and S 10 material availability checking tools; a capacity planning management process enabled by these tools; an acknowledgement process enabled by these tools; mechanisms for capturing inventory and order status; mechanisms for slotting orders to production lines; and mechanisms for dynamically reallocating material among jobs.

In one embodiment of the system, the computer system is further programmed to support material requirements planning in a collaborative planning environment.

In another embodiment of the system, the computer system is further programmed to support procurement of materials and services in a collaborative planning environment comprising: tools for providing suppliers with immediate notification of urgent material/service requirements directly out of the material requirements planning process; and mechanisms for transferring requirements to purchase systems, ordering materials/services from suppliers, and tracking the status of materials and services on order.

In another embodiment of the system, the computer system is further programmed to support line scheduling enhanced by the availability of image information in a collaborative-planning environment comprising: scheduling tools for converting operations (printing, laminating, metallizing, coating, slitting, etc.); access to image files and algorithms utilizing scheduling information extracted from these files process print degree of difficulty, degree of bounce associated with the color separated design, etc.); intuitive (drag and drop) scheduling based on complete information; ability to maintain multiple "what

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if' scenarios; a scheduling process enabled by these tools; and scheduling process and tools are designed foi compatibility with ATP/allocation processes these processes and tools ensure that schedules can be developed to fulfill the commitments made in ATP/allocation).

In another embodiment of the system, the computer system comprises 00 Mc, order status tracking (an internet site providing the capability to track the status of packaging orders).

i In another embodiment of the system, the computer system comprises access control and security management comprising: defined owner for each data CI 10 element with the owner having the ability to grant access to other users a converter can grant an end user access to the converters order status information); and security management that prevents access to information not owned or authorized for access by the inquiring party.

In another embodiment of the system, the computer system comprises output compatibility (a system designed to interface with all known digital output technologies monitors, cylinder/plate engravers, ink jet printers, toner fusion printers, thermal printers, etc.).

Imae Metadata Production planning and scheduling systems depend on complete information about the jobs being scheduled in order to prepare high quality plans and schedules. In the case of packaging, much of this information is related to the demands that the graphics on the package will place on the printing operation.

Today, in virtually all cases, this information is not readily available to the production planner or scheduler. As a result, production plans and schedules are -often-flawed, sometimes-to the point-of being completely unusable. The missing information is data about the image (graphic design).

Generically, data about an image is called "metadata". In order for packaging production planning and scheduling systems to operate with peak efficiency and effectiveness, a new class of metadata must be created: metadata for item creation, production planning, and scheduling. The present invention satisfies this -I

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O requirement by defining specific metadata elements, providing algorithms to extract these elements from an image, and incorporating the use of these elements O into its enabling computer system. This section describes the individual elements rof metadata identified and the algorithms for extracting each element. The more metadata elements created and utilized, the more effective the method and system 0 of the present invention will be. However, it is understood that one or any Icombination of the individual metadata elements may be useful in the present invention.

1. Printing Colors Description. Once a digital contract proof (PDF file or 1 0 other suitable format) has been approved, the next step is to color separate this file. The result of this step is to create one color separated file (monochrome TIFF or other suitable format) for each color to be printed on the press. This algorithm retrieves the colors used to print the job and stores them (together with the RGB values required to display them on a monitor) in the metadata file.

Printing Colors Algorithm. For each color separated file, retrieve and store the color name Kinder Orange) or color number Pantone color number) of the ink to be-used in the associated press station in the metadata file.

Look up and store the corresponding RGB value (three byte representation of the color as displayed on a monitor) in the metadata file. If the sequence in which these colors will be printed on the press is known, store this information in press station sequence Station 1 Color Name or Color Number, Station 1 RGB Value, Station 2 Color Name or Color Number, Station 2 RGB Value, etc.).

2. Ink Coverage Description. The amount of ink used to print an image can be calculated from the ink's coating weight and the percent of the image which will be covered by the ink. This algorithm calculates the percent ink coverage for -each color and stores-the result in the metadata file.

-Ink Coverage Algorithm. For each color separated file, calculate percent coverage as follows: Image Coverage Sum of the grayscale values for each byte in the image Total Coverage Number of bytes in the image Max grayscale value Percent Coverage (Image Coverage Total Coverage) 100

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and store the resulting percentages in the metadata file in the same order as the O color names.

If dot gain emulation software is available, the accuracy of this estimate can be improved by preprocessing the image to emulate dot gain on the target press before calculating Percent Coverage using the algorithm shown above.

00oO Mc, 3. Process Difficulty Description. Packages contain a variety of image 0types. Simple line art (solid color images) can be printed by even the oldest, most N, poorly maintained presses. High quality photorealistic images, on the other hand, Sare printed using 4-color process and require high quality, well maintained I 10 machines to render an acceptable image. Vignettes (images that fade continuously from highly saturated color to white) are the most difficult images to print using conventional printing techniques since a continuous reduction in dot size is the most demanding test of press capability. This algorithm examines an image file to determine the degree of process difficulty associated with the printing the image.

Process Difficulty Algorithm. Analyze the CMYK image file (PDF or other suitable format) as follows: If 100% of image has only black bytes (line art) or consists of vector art at constant grayscale, then process difficulty equals If 100% of image has only one byte (line art) or two bytes (duotone) "on", but some of the image has two bytes on, then process difficulty equals If some of the image has three bytes (3-color process) or four bytes (4color process) then process difficulty equals If 5% or more of the image is a monotone decreasing grayscale from some positive value to zero (vignette), then process difficulty equals Finally, store the maximum resulting process difficulty level 2, 3, or 4) in the metadata file.

4. Bounce Description. When a color separated image is rendered as a flexographic or letterpress plate, the plate will consist of raised areas where there is printing and blank areas where no printing exists. During the printing process, the raised areas support the plate against the impression cylinder. If a blank area extends across the entire width of the plate, the plate will droop toward the cylinder, and will tend to bounce when the next raised area comes into contact I- II I I- I I- O with cylinder as the plate continues its revolution. Presses differ considerably in Stheir ability to maintain print quality when printing such an image. This algorithm

O

O examines the image for the existence of blank areas across the entire image. The resulting measure can than be correlated with the capabilities of individual presses to insure that jobs are scheduled on lines that are capable of maintaining print 00 quality when printing the image.

ISO Bounce Algorithm. For each color separated file, calculate void area as Cc follows: IORetrieve the Minimum Void Width (Vm) corresponding to the target press.

(In the absence of a press specific Vm, use the default Vm value).

Beginning at the start of the file, extract a full width subset of the file Vm units high. Sum of the grayscale values for each byte in the subset.

If the sum of the grayscale values 0 (or is a press specific threshold value), then write the position of the first byte in the subset to the metadata file.

Index down one line, and repeat the process until the full width subset contains the last byte of the file. When the last byte first appears in the subset, process this subset and stop.

The metadata file now contains the start position of each segment of the file that has the potential to cause a bounce problem. Further process this file to combine overlapping void areas into a set of discrete voided bars. The height of the largest void bar is then compared to an empirically derived table which links maximum void height to image quality when printed on the target press.

If the image is printed more than one across the plate, the preceding algorithm is applied to the fully stepped and repeated image. Alternatively, the positions of the voided areas can be passed to an optimization algorithm which offsets the images in..such a way asto minimize for the-stepped and repeated image. The -resultant H,,n can-then be-taken-from the-optimizing algorithm. Store-H-, in the metadata file.

Image Dimension Description. Packages are often printed in multiples of the finished package four boxes printed on a single sheet of cardboard stock, which is subsequently cut and folded to make four individual I I

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I boxes). In order to choose the most efficient press for printing a package (or O label), the dimensions of the image are required.

O

Image Dimensions Algorithm. Retrieve image width and image length r'- (cutoff) from the image file. Store these values in the metadata file. If the converter has slotted the item to a particular press, retrieve the number of images 00 M across and down (around) the plate or cylinder. Store these values in the metadata Cfile.

C-

Invention Process Overview Figure 1 provides an overview of the processes involved in the method of the present invention. Referring to this figure, the Production Planning Process (Process 1.0) of the present invention is capable of operating on two time horizons, long range and near term planning. Sales Operations Planning combines forecasts of demand and production capacity to provide a long range view of production line loading, highlighting supply and demand imbalances. This long range view may be 12 months or more. Master Production Scheduling fine tunes the near term S&OP view over short time periods such as on a week by week basis over the next 6-8 weeks. As part of the MPS process, the total capacity of the system is divided in capacity buckets (e.g.

available capacity by line, by week), which MPS in turn maintains. The capacity remaining in these buckets is the basis for checking orders to insure production capacity available to produce the ordered packages. This process in depicted in Process 2.0 of Figure 1.

The Order Management Process (Process 2.0) of the present invention is a shared activity managed jointly by the end user and the converter. The Order Management process begins with item creation by the end user linking digital data associated with a package image with a structural specification for the package to create a packaging stock keeping unit or other unique designation for a package design). Once the item has been created, the end user can place an order by combining the item with quantity and date requirements. Upon receiving an order from the end user, the converter adds converter specific data to the item (e.g.

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O printing cylinder numbers, ink specifications, etc.) if required, and checks for the availability of materials and line time to produce the order. If the order is a repeat O order for an existing item, the entire process can be performed by the present t"invention automatically. Once accepted by the converter, the end user receives an acknowledgment of the converter's promised delivery date.

00 The Schedule Order Process (Process 3.0) of the present invention stores IND orders acknowledged by the system for subsequent scheduling using decision ,support tools. These tools allow the converter to prepare finite schedules IND (individual jobs sequenced for production on a particular line) for presses, 1 0 laminators, slitters, and other items of converting equipment.

The Material Requirements Planning Process (Process 4.0) of the present invention calculates requirements for printing cylinders, substrates, inks, and adhesives based upon acknowledged orders. As orders are scheduled, the timing of material requirements is further refined. Time phased requirements are compared to quantities available in stock and quantities on order to generate net requirements for purchasing.

Figure 2 shows how the Production Planning and Order Management Processes described above work together to maximize profitability for the business operating the assets and simultaneously maximize reliability for the customer receiving the product.

Production planning in the present invention begins with an analysis of business options over an upcoming time period such as the next 12 months as depicted in this figure. The first step in this process is the monthly S&OP cycle.

By modeling manufacturing operations using forecast demand and forecast capacity, the S&OP process loads production lines presses, laminators, etc.) and highlights--imbalances between--supply and demand for resolution. This process-has-two-outcomes: long range-decisions that affect the operation of the business in the 3-12 month timeframe timing of major capital outages, planning for the ramp-up of new businesses, planning for discontinuation of existing business, etc.), and short range decisions affecting operations in the 1- 2 month timeframe maintenance outages, inventory builds and draws, and execution of long range decisions whose implementation date has reached the 1-2 I-

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month time horizon). These short range S&OP decisions are a primary input to o the second production planning process, Master Production Scheduling (MPS).

MPS fine tunes these near term S&OP decisions for execution on a week by week basis over the next 6-8 weeks. In order to accomplish this goal, MPS evaluates 00 5 near term S&OP decisions in the context of actual demand and actual capacity rn available. The results are used to time the execution of events an outage), c and to control the flow of orders (through the Available To Promise (ATP) IfN functionality discussed hereinafter). S&OP and MPS both depend on computer Smodels to forecast the impact of alternative courses of action. These models, in 10 turn, depend on a number of parameters which are input and maintained through a series of tables production line characteristics, the forecasts described below, and other data required to support the models).

To use the S&OP process, a user prepared demand forecast is entered as digital data in an electronic storage area of the system in accordance with the present invention. The forecast can be prepared in any way that fits the business ranging from a simple sales estimate, to a statistical forecast adjusted for market intelligence.

Similarly, a user prepared production forecast is entered as digital data in an electronic storage area of the system in accordance with the present invention.

A production forecast typically includes information such as output rates by product and line, material efficiencies by product and line, and available production hours by line.

Once the demand and production forecasts have been loaded the S&OP model is run to support the long and short range decisions described above.

One embodiment of the present invention also provides an interface between the MPS functionality and the ATP check. The MPS functionality maintains capacity buckets -available capacity by line and week). As each order is taken, an ATP check determines if the targeted bucket can accept the order without exceeding its available capacity.

The process described above will be described in more detail hereinafter.

NO

O Invention Functionalities Detail (-i C.) o In this section, we provide a detailed description of the method and O t computer system of the present invention. In general, the method is represented by a process diagram identified as a number Figure A computer system to enable this method is then described in figures beginning with the method 00 Mc number and suffixed with a letter Figures 3A 3G).

Figure 3 depicts the S&OP process in accordance with the present .,invention. While Figure 3 and the accompanying description refer to S&OP in the context of a month, it is understood that the S&OP process in accordance with the C, present invention may be applied to any time interval selected by the user.

Similarly, it is within the scope of the present invention to practice the S&OP process, and the other processes of the present invention, without practicing all of the process steps depicted.

At the beginning of each monthly cycle or other chosen time interval cycle, the user loads digital demand data into the S&OP model by updating the Demand Forecast Table as depicted in process step 1.1.1 of Figure 3. Figure 3A provides a transaction summary of this S&OP step, including an exemplary monitor view of this functionality accompanied by computer programming specifications for achieving this functionality. The user of the system may update the production line availability data to reflect periods when lines will not be available for production due to holidays, outages, or other sources of scheduled downtime as depicted in process step 1.1.2 of Figure 3. Figure 3B provides a transaction summary of this S&OP step, including a monitor view of this functionality accompanied computer programming specifications for achieving this functionality.--. The user completes the capacity forecast by loading output rates and material efficiencies for each product line combination which will be considered in loading the system as depicted in process step 1.1.3 of Figure 3.

Figure 3C provides a transaction summary of this S&OP step, including an exemplary monitor view of this functionality accompanied by computer programming specifications for achieving this functionality.

10240/2US Sto enable this method is then described in figures beginning with the method number and suffixed with a letter Figures 3A 3G).

10065] Figure 3 depicts the S&OP process in accordance with the present 00 invention. While Figure 3 and the accompanying description refer to S&OP in the Ncontext of a month, it is understood that the S&OP process in accordance with the Spresent invention may be applied to any time interval selected by the user.

NSimilarly, it is within the scope of the present invention to practice the S&OP process, and the other processes of the present invention, without practicing all of the process steps depicted.

[0066] At the beginning of each monthly cycle or other chosen time interval cycle, the user loads digital demand data into the S&OP model by updating the Demand Forecast Table as depicted in process step 1.1.1 of Figure 3. Figure 3A shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Lookup all records on Table 1.1.1 using converterno from login Setup display to include 12 months of data starting with the current month Create any records that do not exist and fill with zero's Lookup converter demand length unit of measure on the converterdb using converterno 10240/2US -21- SUser Workflow Resultant Processing STypical Place cursor on the first capacity group (row) of the month 00(column) for which you want to enter data I- Enter demand length for the capacity group C <Enter> or <Tab> to the next field and enter value Continue down the column or across row entering length and C-i ofjobs for each capacity group Exceptional Point and click to select individual cell Change value in cell Notes The user may elect to enter data by row or by column, screen operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be horizontally and vertically scrollable The user may elect to enter data by row or by column, screen operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be horizontally and vertically scrollable [0067] The user of the system may update the production line availability data to reflect periods when lines will not be available for production due to holidays, outages, or other sources of scheduled downtime as depicted in process step 1.1.2 of Figure 3. Figure 3B shows a monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Lookup all records on Table 1.1.2 using converter_no from login Setup display to include 12 months of data starting with the current month 10240/2US A2 -22- Lookup gross hours and holiday hours in the month_db using month 0 and year Create any records that do not exist and fill Maintenance hours, Exp 00 M hours, Other Hrs, with zero's Calculate Net Hrs Gross Hrs Maint Hrs Exp Hrs Other Hrs 1 Holiday Hrs SUser Workflow Resultant Processing C Typical Place cursor on the Maint Hrs for the first production line (row) of the month (column) for which you want to enter data Enter Maint Hrs <enter> Cursor moves to the next field in this column (Exp Hrs) Enter Exp Hrs <enter> Cursor moves to the next field in this column (Other Hrs) Enter Other Hrs <enter> Calculate Net Hrs Gross Hrs Maint Hrs Exp Hrs Other Hrs Holiday Hrs Continue down column to next line Exceptional Point and click to select individual cell Change value in cell Notes The user may elect to enter data by row or by column, screen operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be horizontally and vertically scrollable 10068] The user completes the capacity forecast by loading output rates and material efficiencies for each product line combination which will be considered in loading the system as depicted in process step 1.1.3 of Figure 3. Figure 3C 10240/2US c-23- T shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing c0 0 Default month and year to current month and year Lookup all records on Table 1.1.3 using converter_no from login and C current month and year

INO

User Workflow Resultant Processing Typical Enter month, enter year Place cursor on cell you want to change Enter new data Notes The user may elect to enter data by row or by column, screen operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be horizontally and vertically scrollable "LS" Line Speed, "ME" Material Efficiency, "CO" Changeover Downtime (Average Per Job) [0069] As depicted in process step 1.1.4 of Figure 3, with demand and capacity updated, the user runs the S&OP model. Initially, the model assigns demand to production units based on the final loading used in the previous S&OP cycle. The user reviews the resulting line utilizations and attempts to resolve imbalances by making adjustments in line loading. Imbalances which cannot be resolved by moving demand between lines require changes in assumptions by changing data in the tables holding these assumptions). Figure 3D shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Lookup Average Material Efficiency(ME), Line Speed (LS) and 10240/2US A= -24-

F

T Changover Time (CO) for each class of demand in Table 1.1.7 using 0 Converter_no, Month, Year, Class of Demand SLookup and display percent demand in table 1.1.4 using 00 00 Converterno, Month, Year, Capacity Group Lookup demand and of jobs in table 1.1.1 using Converter no, C Month and Year

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S* Lookup inventory draw and build from Table 1.1.5 using C converterno, month, year Use inventory build or draw to adjust demand from Table 1.1.1 lookup. Adjusted demand demand (table 1.1.1) demand build (table 1.1.5) demand draw (table 1.1.5) Display adjusted demand and of jobs. Demand Demand (table 1.1.1) Demand build (table 1.1.5) Demand draw (table 1.1.5) Lookup and display Avail Hrs in Table 1.1.6 using Month, Year and Capacity Group Calc and display Hrs (D*1000*P/(ME*LS*60) (#Jobs*P*CO) (D=Demand, P=Percent) Calc and display Used Hrs Sum of Hrs In Each Capacity Group Calc and display Utilization Demand Capacity User Workflow Resultant Processing Typical Copy forward percentages from last month Adjust percent demand to balance capacity Commit Changes Notes Screen should be horizontally and vertically scrollable Action button to copy last months %'s Screen should have easy links back to Availability Detail, and Capacity Group Data 10240/2US Screen should have a commit button O [0070] One data input area in which assumptions can be changed is the Inventory Adjustment Table depicted in process step 1.1.5 of Figure 3. This 00 00, process allows the user to move capacity from periods where the system is Iunderutilized to periods where the system is oversold by building inventory in the C, former periods and consuming it in the later. Figure 3E shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Set month and year to current month and year unless access from 1.1.4. If access from 1.1.4 set month and year to month and year used at the time of the call from 1.1.4 Lookup all records on Table 1.1.7 using converter_no from login and current month and year for all capacity groups Lookup all records on Table 1.1.5 using converter_no from login and current month and year User Workflow Resultant Processing 0 Typical Enter month, enter year Place cursor on cell you want to change Enter new data System calculates length Length (time 60) Average LS for this capacity group Notes: None [0072] Another data input step in which assumptions can be changed is the Capacity Group Assignment Table depicted as process step 1.1.6 of Figure 3. The S&OP model loads demand onto capacity groups virtual lines composed of hours from physical lines having similar manufacturing capabilities). This process allows the user to shift hours from under loaded capacity groups to 10240/2US -26- Coverloaded ones in order to resolve supply imbalances. Figure 3F shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: 0 0 Initial Processing I* Default and display month and year to current month and year For converter-no from login and current month and year, lookup: S- Table 1.1.2 (available hours for each line) CN Table 1.1.3 (LS, ME, CO by line by capacity group) Table 1.1.6 (all existing entries) Table 1.1.7 (Total Hrs by class of demand) Display all Table 1.1.6 records Display Total Hrs for each class of demand (from Table 1.1.7) User Workflow Resultant Processing Typical Enter month, enter year Place cursor on the cell you want to change Enter new data System will calculate: Hrs entered available hours for that line Check column sum of for that line Total Hrs (Table 1.1.7) Row sum of hours for each capacity group When all changes have been entered, click "DONE" The system checks to insure all lines are 100% allocated. If not, hard error The system generates a table of LS, ME, CO all of the average values for table 1.1.7 LS Average AllI lines (line Hrs for CGD/Total Hrs for CGD) Line LS for CGD 10240/2US d -27- ME Average XAll lines O (line Hrs for CGD/Total Hrs for CGD) Line ME for CGD CO Average ZAII lines 00 M (line Hrs for CGD/Total Hrs for CGD) Line CO for CGD Save Table 1.1.7 value C Exceptional S- Point and click to the cell to be changed c Change value in cell Notes The user may elect to enter data by row or by column, screen operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be horizontally and vertically scrollable [0073] When capacity groups are utilized, production rates and efficiencies for each capacity group must be created by averaging the rates and efficiencies of the lines comprising the capacity groups. S&OP process step 1.1.7, depicted in Figure 3G, shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Default month and year to current month and year Lookup all records on Table 1.1.7 using converter_no from login and current month and year User Workflow Resultant Processing Typical Enter month, enter year Lookup and display all records for the Month and Year Notes Display Only [0074] An embodiment of the system in accordance with the present invention allows the user to resolve supply imbalances by changing the line availability 10240/2US -28assumptions originally loaded in process step 1.1.2. For example, the user could decide to delay a planned maintenance outage or to schedule work on a holiday.

The user may also resolve supply imbalances by adjusting the production rates 00and efficiencies originally loaded in process stepl.l.3. For example, the user ayF Ncould decide to accelerate the implementation of a previously planned Sproductivity program.

N[0075] Another way that a user can resolve imbalances in accordance with an Sembodiment of the present invention to change the demand forecast originally loaded in process step 1.1.1. For example, the user might delay the ramp up of a new application or other piece of new business.

10076] Figure 4 depicts the steps which are part of the MPS process in accordance with the present invention. While Figure 4 and the accompanying description refer to MPS in the context of a week, it is understood that the MPS process in accordance with the present invention may be applied to any time interval selected by the user. Similarly, it is within the scope of the present invention to practice the MPS process, and the other processes of the present invention, without practicing all of the process steps depicted.

[0077] Referring to Figure 4, as depicted in process step 1.2.1, at the beginning of each MPS cycle, the present invention provides an MPS summary (monitor display) depicting available and remaining capacity by capacity group.

Figure 4A shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Lookup all records on Table 1.2.1 using converter number from login Display all records User Workflow Resultant Processing Typical User may click on Production Bucket (at top of column, ie// 18) and control should transfer to transaction PLANI1.2.9, 10240/2US -29- .Display Bucket Detail.

Notes SDisplay Only 00 00 [0078] The computer is further programmed to allow planned inventory draws Ior builds to be changed as depicted in process step 1.2.2. Figure 4B shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: ~Initial Processing Lookup all records on Table 1.2.2 using converter number from login Calculate "todays" bucket see algorithm Bucket Calc Set display such that initial production bucket is "todays" bucket Display all records User Workflow Resultant Processing Typical Use horizontal scrolling to get to the bucket to display Enter an inventory build or draw (in hours for that bucket) for a specific capacity group. Move to comment field and add a comment on the build or draw.

Notes None 10079] Process step 1.2.3 in Figure 4 depicts a second table where the present invention allows assumptions to be changed. This data is referred to as the Capacity Group Assignment Table. The MPS model is programmed to load demand into capacity groups virtual lines composed of hours from physical lines having similar manufacturing capabilities). Process 1.2.3 allows the user to shift hours from underloaded capacity groups to overloaded ones in order to resolve supply imbalances. For example, if the 10S (10 Station printing line) capacity group is under loaded, some of the 10S capacity could be used to produce 8S (8 Station printing line) demand since a line with 10 stations can substitute for 10240/2US a line with 8 stations. Figure 4C shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: 00 00 Initial Processing I Lookup and display all records on Table 1.2.3 using converter-no, Cyear, and bucket User Workflow Resultant Processing Typical User will select a cell and change the percentage.

Prior to exiting the screen, all check sum's must be 100% or error.

Notes 0 None 10080] In an embodiment of the present invention, the computer is also programmed to allow orders to be moved from one production bucket to another bucket. Typically when this is done, orders are "pulled in" and produced early.

Orders can only be "pushed out" and produced later if the user request date can still be met or if the user agrees to a new request date. This process capability is represented by process step 1.2.6 in Figure 4. In order to support this functionality, the computer may also be programmed to display all of the orders in a bucket with their runtime requirements to assist in choosing which orders can be "pulled in" or "pushed out". This functionality is depicted in process step 1.2.9 of Figure 4. (Orders identified in processes 1.2.6 and 1.2.9 are moved using process 2.1.1 shown in Figure 7A.) [00811 In one embodiment, the computer is also programmed to allow customers time reservations to be changed when actual demand differs from these customer reservations, and the customer agrees with this change. This process is represented by process step 1.2.7 of Figure 4 and is executed using process 1.2.4 depicted in Figure 10240/2US 1 -31- 10082] MPS depends on a number of supporting assumptions concerning the planned availability, operability, and capability of each production line. These assumptions change over time and need to be updated periodically. Figure 00 depicts how the present invention accomplishes these updates. Process step 1.2.4 NOrepresents an update of the system's production line availability assumptions.

Figure 5A shows an exemplary monitor view of this functionality, which is IOachieved according to the following computer programming specifications: Initial Processing Lookup all records on Table 1.2.4 using converter number from login Display all records User Workflow Resultant Processing Typical User will click on a cell and change value System should recalculate totals and update the screen Notes None [0083] As represented by process step 1.2.5 of Figure 5, the user can adjust the production rates and efficiencies based on recent manufacturing performance.

Figure 5B shows an exemplary monitor view of this functionality, which is achieved according to the following computer programming specifications: Initial Processing Lookup and display all records on Table 1.2.5, using converter-no, process step, year, and bucket.

User Workflow Resultant Processing Typical User may change process step, bucket, or year.

Notes Average data should be display only.

10240/2US S-32- [00841 The user may also adjust the slotting algorithm and change the way in which orders will be slotted to the capacity groups. Process step 6.1.8 of Figure shows this process. Figure 5C shows an exemplary monitor view of this 0 functionality, which is achieved according to the following computer Sprogramming specifications: SInitial Processing Lookup and display all data on the capacity group DB using Sconverter-no, and process step.

User Workflow Resultant Processing Typical User will add a new capacity group (row) to the matrix System should check that the priority numbers are unique Notes None [00851 The impact of these updates on orders already in the system can be ascertained by rerunning the available to promise (ATP) process for selected orders using the revised assumptions. This capability is depicted in process step 1.2.8 of Figure 5. Orders selected for reprocessing at this step are re-ATP'd using process 2.1.1 shown in Figure 7A.

[0086] The system in accordance with the present invention is programmed with an order management system to capture order data required for production planning (Process scheduling (Process and material requirements (Process Figure 6 provides a graphical overview of the order management functionality which may be programmed into the system of the present invention.

100871 As shown in Figure 6, Order Management begins with the availability of a digital contract proof. As mentioned previously, the digital contract proof may be in PDF format or other suitable file format. The contract proof and associated artwork is stored as digital data and is provided by the end user (or an entity acting on behalf of the end user) as part of the item creation process. This file is acquired and analyzed by the present invention (Process In addition to 10240/2US -33- Sproviding a low resolution copy of the image (for verification purposes), this process also extracts scheduling metadata from the image. Scheduling metadata is data about certain characteristics of the image that can be used to more accurately 00plan production and schedule the job. For example, scheduling metadata allows pF IDthe scheduler to anticipate the degree of difficulty associated with printing the ils I image using various technologies so the job can be assigned to a press which is Itechnically capable of running the job. Algorithms for extracting scheduling metadata and are described in the foregoing detailed description of the invention.

10088] Once the image has been acquired, the user links it to a package structure to create an End User Item (Process With the item complete, the end user creates a purchase order in the end user's legacy purchasing system. At this point, an order for this item is entered using the present invention, and transmitted over the internet to the electronic storage area of the present invention (Process The system in accordance with the present invention may be programmed to automatically process the order (Process 2.4) or place the order in a "pending" status for manual processing, depending on the converter's setup and selected preferences.

10089] If the converter selects automatic order processing (Process 2.4) and a converter item corresponding to the end user item already exists, ATP and allocation are automatically checked by the system as soon as the order is entered.

This step involves the following four checks: 1. Is there production capacity available to meet the requested delivery date (ATP)? 2. Does the user have sufficient allocated capacity available (Allocation)? 3. Will required production materials be available at the time of production? 4. Will printing cylinders be available at the time of production? [0090] If the order passes these checks, it is accepted and transmitted to the legacy Order Management System (Process If the order fails any of the 10240/2US -34- Schecks or if the converter item does not exist, it is put into a pending order queue that must be manually processed by the converter (Process 100911 If the converter selects manual order processing, all orders entered by 00the end user are placed into a pending order queue (this queue also holds failed IND orders from the automatic process). To manually process this queue (Process the converter selects an order or group of orders and runs an ATP allocation Icheck. If an order passes this check, the converter may accept the order and Stransmit data to the legacy Order Management System (Process If an order fails due to ATP or allocation, the converter works with the end user to adjust the order quantity or the requested delivery date so that it will pass ATP and allocation. If an order fails due to the lack of production materials or printing cylinder availability, the converter may elect to expedite delivery of the production material or reallocate printing capacity to fulfill the order in the time period requested. If the converter item does not already exist, it can be created using Process 2.6.

(0092] The order management functionality described in Figure 6 is implemented as a series of methods in the present invention. Figures 7 through provide detailed descriptions of the individual methods which are required to implement the order management function.

100931 Figure 7 is a graphical depiction of the order placement and ATP/allocation process (Process 2.1 and Process 2.4) in accordance with the present invention. The order placement and ATP/Allocation processes are generally described as follows: Place Order (Process The end user places an order. This is done by specifying the item number, quantity required, date required and converter to produce a given order. If the item does not already exist, the end user can create it.

Auto ATP Allocation Check (Process If the specified converter's automatic ATP/Allocation check is turned on then ATP/Allocation will be run automatically. If the order passes, it will be accepted and transmitted 10240/2US T to the converter's Order Management System. Otherwise, the order is placed in a pending order queue.

[00941 Figures 7A 7C provide detailed descriptions of an embodiment of the 00 order placement step and ATP allocation processes in accordance with the present \Oinvention. Figure 7A shows an exemplary monitor view of Process 2.1 which is achieved according to the following computer programming specifications: IInitial Processing None User Workflow Resultant Processing STypical Enter purchase order number from legacy Purchasing system Enter Item No Lookup on Item DB using Item item description, end user target converter yield, cutoff, width Set sold to customer number to end user Lookup on converter DB using target converter converter name, address, and auto processing field Lookup on end user DB using sold to customer name, customer address, default ship to customer number Set ship to to default ship to customer number Lookup on end user DB using ship to customer name and address Enter the date required Enter quantity Enter quantity unit of measure Calculate alternative units of measure Imps to Mass ((cutoff width imps) (yield))/ uoml Imps to Length impressions up) cutoff) uom2 aMass to Imps uom3 (mass Yield) (cutoff width) 10240/2US -36- Mass to Length uom4 (mass Yield) (width across) Length to Imps uom2 (Length cutoff) across Length to Mass (Length across width) Yield uom4 0 0 Note: uom# factors are needed because commercial unit of Smeasure conventions in metric and english units of measure are Sinconsistent.

S- Press Submit Order Key S- If AutoATP "ON" Then: Slot order to capacity group (See Algorithms) Calculate production bucket (See Algorithms) Lookup on Capacity group DB using capacity group: average changeover time, average line speed, average material efficiency Slot order to laminator (if applicable) (See Algorithms) Lookup on Equipment DB using laminator line average changeover time, average line speed, average material efficiency Calculate estimated quantity quantity (capacity group me laminator me standard slitter me) Calculate estimated production hours Press: #Across INTeger(Max width Capacity Group Image Width) Length Imps Orders #Across Length Length Cutoff) (1000) AdjLength Length Material Eff of Cap Group Press Hrs (Length Average Line Speed Capacity Group) Average Change Over Time for CG Laminator: Laminator Hrs (Length Material Eff of Laminator 10240/2US -37- Average Line Speed Laminator) Average Change Over Time for Laminator Send Order No, Press Hrs, Lam Hrs, Item No, Press 0 Bucket, Lam Bucket, Capacity Group to AutoATP Check 2.4.1.

SELSE (AutoATP "OFF") Change Order Status To "PendingConv" C End Exceptional Change Target converter number Lookup on converter DB using converter and get converter name and address Change ship to customer number Lookup on customer DB using ship to and get customer name and address Change ship to address Change and reATP order Retrieve existing order, display current values, and allow user to reATP the order with or without changes to date and/or quantity.

Notes There should be drop down buttons on the following fields so that the user can do a lookup: Item No, Sold To Customer Ship To Customer Target Converter, Quantity Unit of Measure 100951 Figure 7B shows an exemplary monitor view of Process 2.4.1, which is achieved according to the following computer programming specifications: Initial Processing Send: Order number Press bucket 10240/2US -38- S- Laminator bucket O Required press hours Required laminator hours 00 M End user number \0 0- Item number CI Return: ATP Status

C

Allocation Status Film Status Cylinder Status User Workflow Resultant Processing None Notes See Alg AutoATP for detailed calculations [0096] Figure 7C shows an exemplary monitor view of Process 2.7.1, which is achieved according to the following computer programming specifications: Initial Processing Send: CV Item EU Item End User End User PO Quantity requested Quantity unit of measure Date requested Return: Order User Workflow Resultant Processing None 10240/2US -39- SNotes SNone [00971 Figure 8 is a graphical depiction of the process for creating an end user 00 00, item (Process Figure 8 also shows how the process for acquiring the package Idesign (image) and extracting end user metadata (Process 2.3.1) links to the item creation process. The process for creating an end user item and the linking of the processes for acquiring the package design and extracting end user metadata are generally described as follows: Create Item (Process Create Item, Image Data. The end user creates an item in system. The user enters an item number and an image number. The system interfaces with the Image Acquisition and Metadata Extraction Module to retrieve image status, width, cutoff, and a low resolution image display.

Acquire Image Extract EU Metadata (Process Acquire Image Extract EU Metadata. The system requests a specific image from any suitable digital workflow. Once the image is retrieved, the system processes the image file to extract image status, width, cutoff, and a low resolution image display. If there is no approved contract proof in response to the system's request, the create item process is stopped.

Display Image Tile (Process The low resolution image display will be segmented into "tiles." The user can click on a tile and the system will request and display a low resolution image of that tile.

Acquire Image For Display (Process Acquire Image For Display.

The system makes a specific image and tile request to the Image Acquisition and Display module. The module returns a low resolution tile image display. If this is not the correct image, the user will can jump back to Create Item (Process 2.2.1) and can enter a different image number.

Create Item (Process Create Item, Packaging Structure. The user can enter the package structure.

10240/2US S[0098] Figures 8A 8E provide detailed descriptions of the process steps represented in Figure 8 according to an embodiment of the present invention.

Figure 8A shows an exemplary monitor view of Process 2.2.1, which is achieved 00 according to the following computer programming specifications: SInitial Processing Ci Lookup all records on Table 2.2.1 using enduser_no from login Default Customer to customer name from login User Workflow Resultant Processing Typical Enter Item Enter Image Interface with the Image Acquisition and Metadata extraction module. Send image number. Receive image status, width, cutoff, and a low resolution image for display.

User clicks on the "Set Up Pkg Structure" button and is transferred to transaction 2.2.3.

Exceptional User clicks on the "More Image Detail" button and is transferred to transaction 2.2.2.

Notes None [0099] Figure 8B shows an exemplary monitor view of Process 2.3.1, which is achieved according to the following computer programming specifications: Initial Processing Send: Image number Return: Image Status Image width 10240/2US -41- S- Image cutoff O Low Resolution Image Display file Calculations 00 C None Required SUser Workflow Resultant Processing C1 None 0Notes

C

None [00100] Figure 8C shows an exemplary monitor view of Process 2.2.2, which is achieved according to the following computer programming specifications: Initial Processing Display image with tile grid lines User Workflow Resultant Processing Typical User clicks on one of the "tiles" The system requests the specified tile from the Image Acquisition and Display Module by sending the image number and the tile number. The module returns a low resolution, full screen image of the tile (Process 2.3.2).

User clicks on "Return to Create" button Exceptional Notes None 1001011 Figure 8D shows an exemplary monitor view of Process 2.2.3, which is achieved according to the following computer programming specifications: Initial Processing Lookup allowable items for layer on Table "Layers" User Workflow Resultant Processing Typical 10240/2US -42c~ Pick layer off list Enter all other fields Exceptional 00 Mn Point and click to select individual cell Change value in cell C Notes 0 The user may elect to enter data by row or by column, screen 0 C operation should allow both using standard navigation: <enter> moves down a cell, <tab> moves over a cell Screen should be vertically scrollable 1001021 Figure 8E shows an exemplary monitor view of Process 2.3.2, which is achieved according to the following computer programming specifications: Initial Processing Send: Image number Tile number Return: Full Screen Low Resolution Image Display of tile Calculations None Required User Workflow Resultant Processing None Notes None 1001031 Figure 9 is a detailed graphical depiction of the order management process for handling pending orders (Process 2.5) and interfacing to the existing OMS system (Process 2.7) in accordance with the present invention. The order management process for handling pending orders and the process for interfacting to existing OMS systems are generally described as follows: 10240/2US c- -43- Process Pending Orders (Process The first step in processing orders is viewing the list of pending orders. The pending orders may be the result of failed automatic processing, or the result of disabled auto processing.

00 00The user may wish to select an order(s) and "View" the order(s) in detail.

IThe next step is to determine if the item definition is complete. This can CI be determined by looking in column #4 of the Pending Orders que. If this column is blank, then the converter must fill in additional data to complete CI the item definition by going to Process 2.6.

ATP Allocation Check (Process Both ATP and allocation are checked. If either item fails to pass the check, the system will provide an explanation via a recommended change to the data such that it will pass.

For example, if the original order were for 476,000 impressions on July h a failure would trigger ePack to display what items could be produced and when (380,000 impressions on July 10"' or 476,000 impressions on July 1 5 th).

Change Create Order (Process If ATP or allocation fails, the converter will have to change the quantity or request date on the order.

Change Create Order (Process If there is a significant change to quantity or request date, the end user may require an additional order be entered to ensure they do not run out of material. The converter will enter the new order.

Interface To Legacy OMS (Process Once an order passes ATP and allocation, it is accepted and passed to the Legacy OMS system.

100104] Figures 9A 9F provide detailed descriptions of the process steps represented in Figure 9 according to an embodiment of the present invention.

Figure 9A shows an exemplary monitor view of Process 2.5.1, which is achieved according to the following computer programming specifications: Initial Processing SLookup on the "Orders" database, using converter number, all orders with a "Pending" status 10240/2US 1 -44- |i User Workflow Resultant Processing Typical The user will check off a group of orders S- The user will click on the "Process Orders" button S- List of checked orders and corresponding data will be sent to ec, STransaction 2.5.2 (Check ATP/Allocation) Exception C The user will check off a group of orders The user will click on the "Display Orders" button List of checked orders and corresponding data will be sent to Transaction 2.5.3 (Display Order) The user will check off a group of orders that do not have CV Item numbers listed in column #4 The user will click on the "Setup Item" button List of checked orders and corresponding data will be sent to Transaction 2.6.1 (Create Item, CV data) Notes No data can be changed on this screen The user may only check off orders and push the setup item or process orders buttons 100105] Figure 9B shows an exemplary monitor view of Process 2.5.2, which is achieved according to the following computer programming specifications: Initial Processing Lookup on order DB using order date requested, quantity requested, uom requested, enduser number Send order data to ATP/Allocation check Display ATP Allocation results User Workflow Resultant Processing Typical 10240/2US C- User will look at the results of ATP Allocation, if cylinder or film is red, the user will "click" on the film or cylinder button to get more detail. Display Film Detail Sch 3.1.4, Display 00 Cylinder Detail Sch 3.1.3 N- If ATP is "NO" find alternate proposals, see algorithms ATP Allocation Check.

User will look at the "proposed" solutions and accept one of Sthem.

Exception If any one of the indicators is No (red) the user will click on one of the "display detail" buttons and go to the detail screens.

Display Film Detail Sch 3.1.4 Display Cylinder Detail Sch 3.1.3 Display ATP Detail Display Alloc Detail Notes This screen is only displayed if the order fails for 1 or more of the checks: cylinders, film, ATP, allocation.

1001061 Figure 9C shows an exemplary monitor view of Process 2.5.3, which is achieved according to the following computer programming specifications: Initial Processing Lookup on Order DB using order all order data Display order User Workflow Resultant Processing Typical User will look at order details Exception User may click on buttons to look at package structure or bill of material or image details 10240/2US r- -46- CNotes This is a read only screen [00107] Figure 9D shows an exemplary monitor view of Process 2.5.4, which is 0 0 achieved according to the following computer programming specifications: I Initial Processing Lookup on Order DB using order all order data I* Display order (N User Workflow Resultant Processing Typical User will change order quantity or request date Exception Notes None [00108] Figure 9E shows an exemplary monitor view of Process 2.5.5, which is achieved according to the following computer programming specifications: Initial Processing Lookup on Order DB using order all order data Display order User Workflow Resultant Processing Typical User will fill in a new order number and an order number to copy from User will push copy button System will copy order and display copy on screen User will change date requested and quantity Exception Notes None [00109] Figure 9F shows an exemplary monitor view of Process 2.7.1, which is achieved according to the following computer programming specifications: 10240/2US 1- 0 0 47- SInitial Processing Send: CV Item 00 EU Item End User N End User PO Quantity requested c- Quantity unit of measure Date requested Return: Order User Workflow Resultant Processing None Notes None [00110] Figure 10 is a detailed graphical depiction of the process steps for a converter to complete a package item (Process including the process for acquiring the image and extracting metadata to support this process (Process The process for converter completion of a packaging item, including acquisition of the image and extraction of meta data are generally described as follows: Acquire Image Extract CV Metadata (Process Get Item from Order DB using order Get Image from Item DB using Item Interface with the Image Acquisition and Metadata Extraction Module using Image and get all converting data.

Create Item (Process The converter adds structure data to the item. Some of the data elements for this transaction have already been entered by the end user.

Create Item (Process The converter adds cylinder data to the item.

10240/2US 48- Create Item (Process The converter adds film data to the item O bill of material.

Create Item (Process The converter adds ink data to the item 00 M^ bill of material.

-0 [00111] Figures 10A 10E provide detailed descriptions of the process steps C represented in Figure 10 according to an embodiment of the present invention.

SFigure 10A shows an exemplary monitory view of Process 2.3.3, which is C achieved according to the following computer programming specifications: Initial Processing Send: Image number Return: Image description Customer number Customer name Across Around Bounce level of difficulty Color for each cylinder ink coverage for each cylinder (color) Calculations None Required User Workflow Resultant Processing None Notes None [00112] Figure 10B shows an exemplary monitor view of Process 2.6.4, which is achieved according to the following computer programming specifications: Initial Processing 10240/2US -49- Lookup and display data elements from Table 2.2.3(Item Definition, 0 Package Structure) using item_no User Workflow Resultant Processing 00 00 Typical 0 Enter routing C Enter coating weight (if applicable)

\D

S* Enter coating units (if applicable) C Enter Print film and side Notes None [00113] Figure 10C shows an exemplary monitor view of Process 2.6.1, which is achieved according to the following computer programming specifications: Initial Processing Calculate width across across width Calculate width around #around cutoff User Workflow Resultant Processing Typical Enter ink system for each cylinder Enter cylinder for each cylinder On first cylinder, lookup cylinder width on the cylinder DB using converter_no and cylinder number Fill in cylinder width field For all subsequent cylinders, lookup cylinder width on the cylinderDB using convert_no and cylinder number and check it against the cylinder width field. If there IS NOT a match, error.

Enter Print Enter process level of difficulty Click on Package Structure button 10240/2US I Notes None [00114] Figure 10D shows an exemplary monitor view of Process 2.6.2, which 0 0 is achieved according to the following computer programming specifications: SInitial Processing None User Workflow Resultant Processing C' Typical Enter basis quantity Enter basis unit of measure If basis unit of measure is not impressions, calculate basis impressions (required for ink calculations) Kg to Imps Kg Yield/(1000^2)/cutoff mm/width mm Sqm to Imps Sqm cutoff mm width mm 1000^2 For all materials Enter material number Lookup on Material DB using material material description Enter material, width, gauge, quantity required to produce basis quantity For all coatings Enter material number Lookup on Material DB using material material description Enter material, coating weight, coating units, quantity required to produce basis quantity Click on Ink Bill of Materials button Notes None 10240/2US -51- 1001151 Figure 10OE shows an exemplary monitor view of Process 2.6.3, which is achieved according to the following computer programming specifications: Initial Processing 00 00 None IUser Workflow Resultant Processing C€3 Typical For all materials C- Enter material number Enter coating weight Enter solids Calculate Quantity (BasisImpressions cutoff width /1000/1000) coating weight coverage solids/l00O Notes 9 None 1001161 To fill an accepted order, its production must be scheduled. The purpose of the scheduling process is to sequence orders in a way that optimizes the effectiveness of manufacturing assets while still meeting customer delivery requirements. Figure 11 provides a detailed graphical overview of the scheduling process in accordance with the present invention.

[001171 Scheduling begins with a set of new or changed orders that have passed ATP/Allocation in the order management process. These orders have been accepted based on capacity and resource availability in a specific production bucket (day or week) to meet the promised date. The scheduling process defines the specific line and time an order will run, thus converting a capacity commitment into executable instructions for production.

1001181 When an order is scheduled (Process 3.1 for presses, Process 3.2 for laminators and Process 3.3 for slitters), inventory and purchasing data is retrieved from existing system(s) (Process This data is used to project inventory levels and determine the availability of the packaging film and cylinders (plates) at the specific date and time an order is scheduled to run in manufacturing. This check 10240/2US -52- Sof packaging film and cylinders (plates) improves schedule conformance by preventing raw material shortages. With this information in hand, the order is added to an existing schedule (at the beginning, at the end or in the middle of the 00 schedule).

\O

IND1001191 The scheduling process automatically recalculates the entire schedule Cc whenever an order is added or removed from the schedule. This recalculation

,O

Iinvolves detailed changeover and line speed calculations to accurately quantify Sstart and end times. This instantaneous recalculation is a powerful decision tool for schedulers. Presses, laminators and slitters are scheduled in a similar way, using different formulas for changeover and line speed calculations.

[001201 The completed schedule is sent to manufacturing for execution. A list of projected late or incomplete orders are sent to customer service so that appropriate action(s) can be taken. As the schedule is run, manufacturing updates are added to the system of the present invention (Process 3.5) to support projections of order status and schedule conformance. This data is used to adjust the start time for the next period (manufacturing may be running ahead or behind schedule).

[00121] Figures 1 lA I IL provide detailed descriptions of the scheduling process steps represented in Figure 11 according to an embodiment of the present invention. Figure 11A generally describes the scheduling process for presses (Process 3.1) as follows: Select a Schedule (Process Gives the user the ability to select the schedule they would like to work on. A user may have several "versions" of a schedule.

View Scheduled Unscheduled Orders (Process Gives the user split screen capability (of the schedule they have selected) to view a line schedule on one side and a specified group of unscheduled orders on the other side of the screen.

Schedule Press (Process Gives the user the ability to schedule a press by selecting the job to schedule and dragging it onto the schedule 10240/2US -53in the desired position. The schedule is automatically adjusted.

Scheduling statistics and job indicator lights are provided to help the user assess the impact of the change.

00 Cylinder Availability (Process When ajob is scheduled there is San instantaneous check on available print cylinders. If any of the Scylinders are not going to be ready then this transaction will show the user the status and projected compete dates on the cylinders.

N Film Availability (Process When a job is scheduled there is an instantaneous check on film availability. If film is not going to be ready then this transaction will show the user a view of film inventory.

The user can do a query on film sizes that are close to the desired size and may elect to "use" some of film for this job.

1001221 Figure 1 1B shows an exemplary monitor view of Process 3.0.1, which is achieved according to the following computer programming specifications: Initial Processing Default process step to printing Lookup and display existing schedule version data on the scheduleversion db using converter-no and process step User Workflow Resultant Processing Typical Change process step Lookup and display existing schedule version data on the schedule-version db using converter-no and process step Click and highlight desired version Click on the Get Schedule button To build version PVX (Print version A) scheduled orders for line L for the next screen Join Order DB and ScheduleDB (only records where schedule DB records exist) 10240/2US -54- Select all orders with printstatus (OrderDB) "unscheduled" Select all orders with schedule line (ScheduleDB) "L" (default to lowest line number to build first tab on next screen) 00 M Select all orders with version (ScheduleDB)= "X" Sort orders on sequence C¢3 Get PVX start date and time from the schedule-timeDB using Sprocess-step "Print", Version and Line-no "L" Starting with first order (in sorted sequence) and continuing through the list, calculate start time, run time, and changeover time Build "Schedule PVX" pane for the default line, this will be the first display pane on the next screen.

Build the other scheduled line panes in the background.

To build version PVX (Print version X) unscheduled orders for the next screen Join order DB and schedule DB (using all order records) Select all orders with Print-Status "Unscheduled" Select all orders with Version NOT= (these should be all of the unscheduled orders for version X) Sort the unscheduled orders based on capacity group, on customer on item description.

Default capacity group to the first alphabetical group and select those orders. Build the unscheduled PVX pane for that capacity group. This will be starting display pane for the unscheduled orders on the next screen.

Build the other unscheduled capacity group panes in the background.

SExceptional Delete schedule button The user highlights a schedule and 10240/2US Spresses the delete schedule button. Note: You are not allowed to delete the active schedule. If you want to get rid of the active schedule, you must pull it up (get schedule) and 0 unschedule the orders.

I Get the ScheduleDB and get all of the records with schedule verion (the version to delete).

Delete these records CI Update production button The user presses the update schedule button.

Join the ScheduleDB and the OrdersDB Select all records with Scheduleversion "A" Build the display for transaction UP 1.0.1 Merge with Actual Schedule button The user highlights a schedule and presses the merge with actual schedule button.

Join the OrderDB and ScheduleDB (only records where ScheduleDB records exists).

Select all records with version or version "X" Sort on Line number on version on sequence number (this should segment by line, putting all active schedule jobs first, then VX jobs).

For each line number, renumber sequence from 1 to N.

Notes None [00123] Figure 11C shows an exemplary monitor view of Process 3.1.1, which is achieved according to the following computer programming specifications: Initial Processing See transaction SCH 3.0.1 for details on how to build the "tab panes" for this screen.

Get start date and start time from the schedule-timeDB process-step "Print", Version and Line-no "L" 10240/2US -56- SUser Workflow Resultant Processing Typical Go to scheduled portion of the screen and click on the tab for 00 Mc, the line to be scheduled Go to the unscheduled portion of the screen and click on the C tab for the group of orders to be used as candidates for scheduling (this may be a capacity group, the pool, or all i orders) Scroll through both sections of the screen and find order to be scheduled and the location for it.

Click on the order to be scheduled Transfer control to transaction Sch 3.1.2 passing line number for scheduled orders and line number and order number for unscheduled orders.

Exceptional Adj Start t button The user will change the displayed start date and start time and click on the Adj Start t button.

Save the new start date and start time in the schedule time DB using process step, schedule V# and line-no.

Starting with first order (in sorted sequence) and continuing through the list, calculate new start times.

New start time start time from last job run time from last job changeover time to this job.

Sort button The user will click on the sort button.

SBring up a sort menu with all of the order characteristics.

Allow the user to pick "sort on" criteria and hit OK.

Resort the unscheduled orders based on the sort criteria.

Find button User will click on the find button 0 Bring up a find dialog box so the user can key in an order 10240/2US r-

O

-57- Snumber. Search the unscheduled list and adjust the display to show the "find" order in the middle of the unscheduled window.

00 0 Notes Initial processing for this screen should be done on transaction SCH S3.0.1. For performance reasons, it may make sense to build the Sdefault tabs in transaction SCH 3.0.1 and then build the subsequent C- tabs in the background.

[00124] Figure 1 1D shows an exemplary monitor view of Process 3.1.2, which is achieved according to the following computer programming specifications: Initial Processing Use the datasets created in SCH3.1.1.

Build the job bars using DB information from the orders DB.

Indicator lights Top light Ontime light green if xworks date ship date 2, yellow if xworks ship date xworks-date 2 red if xworkds ship date xworkds-date 0 Next light Film light green if film exists yellow if film arrives on production day red if no film Next light Cylinder green if cylinders exists yellow if cylinders arrives on production day red if no cylinders by production day Next light Next Step light green if xworks date for next step this step yellow if xworks date for next step this step 10240/2US -58- 4 red if xworks step for next step this step User Workflow Resultant Processing STypical 00 M User will scroll through the scheduled orders and look for a good position to schedule the order they are interested in I User will go to the unscheduled portion of the screen and click on the order they want to schedule.

I User will drag the order to the position on the scheduled portion of the screen that they want to schedule the order Execute Alg Schedule Order User will review the department metrics and schedule indicator lights SExceptional Undo button The user clicks on the "undo" button.

Remove (undo) the last order scheduled Recalculate the changeover times Recalculate the start times Recalculate the department metrics Sort button The user will click on the sort button.

Bring up a sort menu with all of the order characteristics.

Allow the user to pick "sort on" criteria and hit OK.

Resort the unscheduled orders based on the sort criteria.

Save As button The user will click on the Save As button.

Bring up a file save dialog box and allow the user to save the schedule as VI, V2, V3, V4, V5. If one of those already exists, ask the user if they want to overwrite it.

Take all of the scheduled orders and go to the scheduleDB and change the Version column to the Save as X version. For example, the user may have originally 10240/2US -59done a "get schedule" on version V1, made some changes and decided to save as V2.

Notes 00 00 None 1001251 Figure 11E generally describes the scheduling process for laminators C€3 N (Process 3.2) as follows: SSelect a Schedule (Process Gives the user the ability to select the N schedule they would like to work on. A user may have several "versions" of a schedule.

Schedule Laminator (Process Gives the user the ability to schedule a laminator by selecting the job to schedule and dragging it onto the schedule in the desired position. The schedule is automatically adjusted.

Film Availability (Process When a job is scheduled there is an instantaneous check on film availability. If film is not going to be ready then this transaction will show the user a view of film inventory. The user can do a query on film sizes that are close to the desired size and may elect to "use" some of film for this job.

1001261 Figure 1 IF generally describes the scheduling process for slitters (Process 3.3) as follows: SSelect a Schedule (Process Gives the user the ability to select the schedule they would like to work on. A user may have several "versions" of a schedule.

10240/2US View Scheduled Unscheduled Orders (Process Gives the user split screen capability to select a line schedule on one side and a specified group of unscheduled orders on the other side of the screen.

00 00 Schedule Slitter (Process Gives the user the ability to schedule a slitter by selecting the job to schedule and dragging it onto the schedule in N the desired position. The schedule is automatically adjusted. Scheduling statistics and job indicator lights are provided to help the user assess the impact of the change.

1001271 Figure 1 IG generally describes the Inventory/Purchasing Interface processes (Processes 3.4.1 and 3.4.2) as follows: Get Inventory Data From Legacy System (Process As orders are scheduled, inventory data on the required film and cylinders is retrieved from the legacy system. This data is used for raw material availability checking.

Get Purchasing Data From Legacy System (Process As orders are scheduled, purchasing data on the required film and cylinders is retrieved from the legacy system. This data is used for raw material availability checking.

1001281 Figure 1 IH shows an exemplary monitor view of Process 3.4.1, which is achieved according to the following computer programming specifications: Initial Processing Receive order number and item number from SCH 3.1.2 Get Bill of Material (BOM) items from BOM DB using Item number For each BOM item with class "Film", send request to inventory legacy system Store returned inventory values For each BOM item with class "Cylinder", send request to inventory legacy system 10240/2US S-61- Store returned inventory values User Workflow Resultant Processing STypical 00 Mc, Notes SNone [00129] Figure 11I shows an exemplary monitor view of process 3.4.2, which is achieved according to the following computer programming specifications: SInitial Processing Receive order number and item number from SCH 3.1.2 Get BOM items from Born DB using Item number For each BOM item with class "Film", send request to purchasing legacy system Store returned purchasing values For each BOM item with class "Cylinder", send request to purchasing legacy system Store returned purchasing values User Workflow Resultant Processing Typical Notes 0 None 100130] Figure 1 IJ generally describes the Update Order and Schedule Status process (Process 3.5) as follows: Schedule Versions (Process The update production screen is accessed from the schedule versions screen. You may only update the active schedule from this screen. From the screen, push the "Update Production" button.

Update Production (Process UP1.0.1) From this screen, the user can update the schedule and readjust the start time of the active job.

1001311 Figure 11K shows an exemplary monitor view of Process 3.5.1, which is achieved according to the following computer programming specifications: 10240/2US 11 -62- SInitial Processing Default process step to printing 0 Lookup and display existing schedule version data on the schedule- 00 version db using converter-no and process step.

IUser Workflow Resultant Processing Typical User will click on the "Update Production" button System will lookup the Active schedule on the schedule DB and transfer control to UP1.0.1 Update Production.

Notes None [00132] Figure 11L shows an exemplary monitor view of Process UP 1.0.1, which is achieved according to the following computer programming specifications: Initial Processing Display input screen with first six fields filled in from the active schedule.

User Workflow Resultant Processing Typical User will fill in the Status, Prod Q, Cy, Film, and Reason columns for all pertinent orders. See glossary section for a list of acceptable codes.

User will mark the active job in the status column with an "A" and put the actual start date and start time below in the Active Job section of the screen.

The system will resort and recalculate the start times for all of the active jobs left on the schedule.

Exceptional User will highlight a row (order) and click on the "Split Order" 10240/2US ci -63- Sbutton.

The system will split the order into two orders with a suffix of- A and-B.

00 0 The user will fill in the pertinent data columns for the split job.

N Notes None

\O

1001331 In order to produce packaging items and to schedule their production, CI it is necessary to make sure that materials necessary for the production of the packaging items are available when needed. This process is referred to as materials requirements planning. Figure 12 provides a detailed graphical overview of the Material Requirements Planning Process in accordance with an embodiment of the present invention. The purpose of material requirements planning is to generate a requirements list so that raw materials can be ordered and ready in time for manufacturing. The material requirements planning process begins with loading inventory and purchase order data into the system of the present invention (Processes 4.1 and This inventory and purchase order data is used to calculate stock levels of raw materials on a day-by-day basis. The comparison of this data to manufacturing requirements generates a net daily material requirement (Process This net daily requirement is then "rolled up" into purchase requisitions which are transmitted back to the Legacy system to create purchase orders (Process 4.4).

100134] Figures 12A 12G provide detailed descriptions of the MRP steps represented in Figure 12 according to an embodiment of the present invention.

Figure 12A generally describes the Inventory/Purchasing Interface of Processes 4.1 and 4.2 as follows: SUpdate Inventory Purchasing From Legacy System (Processes 4.1.1 At the beginning of the MRP process it is critical to have an inventory load and PO load from the Legacy systems. Prior to the loading inventory and PO's will be cleared such that the Legacy load is a complete reload of data. This approach eliminates the problem of 10240/2US -64- Skeeping 2 systems in synch. The legacy system is the master system and the present invention simply accepts the inventory and PO loads it is given.

00 00 The load is initiated via transactions 4.1.1 and 4.1.2, which request Ndata from the Legacy system.

Inventory Request (4.1.1)

INO

Legacy returns For all raw materials: Material material description, material quantity and material unit of measure Purchasing Reauest (4.1.2) Legacy returns For all raw materials: PO#, material material description, material quantity, material unit of measure, and the expected delivery date The material numbers in the bills of material should be identical to the material numbers being used in the legacy system.

[001351 Figure 12B shows an exemplary monitor view of Process 4.1.1. and 4.1.2, which are achieved according to the following computer programming specifications: Initial Processing Lookup date and time of previous download on Download DB User Workflow Resultant Processing Typical User will click on Update Inventory User will click on Update Purchasing Notes None 1001361 Figure 12D shows an exemplary monitor view of Process 4.3.1, which is achieved according to the following computer programming specifications: 10240/2US CInitial Processing Lookup the current week number on CalenderDB Default "From" to the current week and "To" to current week 3 0 0 User Workflow Resultant Processing Typical C- User will edit the from and to weeks or dates 0- User will check off the materials that they would like to run 'N MRP for User will click on the "Run MPR" button If user has filled in weeks, calculate the "from" and "to" dates using "from" and "to" weeks Get all orders on the Orders DB that have date-xworks-print or date-xworks-lam between these two dates For all of these orders, get all material in the BOM by doing a lookup on BOM DB using Item Select only those materials where MaterialClass one of the selected classes from the MRP screen For each material, calculate a required order quantity If BOM item UOM BOM basis UOM then convert BOM basis UOM Imps to kg IMPs (width cutoff)/1000/1000 yield Kg to Imps KG yield 1000 1000 (width cutoff) Required Order Quantity (Gross Order Quantity BOM Basis quantity) item bom quantity Sort all bom items, for all selected orders on item number and on date required, subtotal on required order quantity (by date) For each item calculate an on hand quantity Inventory sum of all item quantities from earlier dates 10240/2US -66- S- For each item calculate an on order quantity sum of all O item po's from earlier dates, up to the "to" date Notes 00 c None 0[00137] Figure 12E shows an exemplary monitor view of Process 4.3.2, which N is achieved according to the following computer programming specifications: SInitial Processing Receive "from" and "to" weeks from MRP transaction Calculate from and to dates Get all orders on the Orders DB that have Xworks dates between these two dates User Workflow Resultant Processing Typical Notes None [00138] Figure 12F shows an exemplary monitor view of Process 4.3.3, which is achieved according to the following computer programming specifications: Initial Processing For each of the orders in 4.3.2 Get list of bom items by doing a lookup on BOM db using Item For each item calculate a required quantity Required Quantity (Gross Order Quantity/Bom Basis Q)*Item BOM Quantity User Workflow Resultant Processing Typical Notes None 10240/2US -67- [00139] Figure 12G shows an exemplary monitor view of Process 4.3.4, which is achieved according to the following computer programming specifications: Initial Processing Sort BOM items on item number and on date User Workflow Resultant Processing Typical Notes None [001401 The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and variations will be apparent to those skilled in the art, and are considered within the spirit and scope of the claimed invention.

Claims

2. The method of claim 1, wherein said scheduling metadata about said images is analyzed by said digital computer system to confirm availability of production resources technically capable of printing said images on said packaging items.
3. The method of claim 1, wherein said digital data associated with said plurality of orders comprises packaging designs, packaging product designs, packaging items, and orders, said orders comprise a specified quantity of packaging items for delivery on specified dates.
4. The method of any one of the preceding claims, wherein said digital data further comprises the production resources necessary to produce said packaging items. O 5. The method of any one of the preceding claims, wherein said digital data is analyzed by said digital computer system for ATP/Allocation. c, 0
6. The method of any one of the preceding claims wherein said ATP/Allocation comprises confirmation of availability of production capacity resources and production materials to fulfill said packaging order. oo
7. The method of any one of the preceding claims, wherein said orders are C accepted for scheduling by said digital computer system following confirmation of ATP/Allocation.
8. The method of claim 7, wherein said accepted orders comprise confirmation of capacity and resource availability in a specific production capacity bucket to meet a specified date.
9. The method of any one of the preceding claims, wherein said digital computer system analyzes said digital data to support scheduling of said accepted orders in a sequence to optimize the effectiveness of manufacturing assets and meet end user specified dates for delivery of said packaging items. The method of any one of the preceding claims, wherein said schedule comprises scheduling of successive steps in the manufacturing process for said packaging items.
11. The method of claim 10, wherein said schedule comprises converter operations schedules including press schedules, laminator schedules, slitter schedules, coater schedules, metallizer schedules and schedules for other converter operations.
12. The method of any one of the preceding claims, wherein said schedule includes utilization of specific production line resources and time resources for production of said packaging items associated with said plurality of orders. S13. The method of any one of the preceding claims, wherein said schedule is generated by said digital computer system using decision support tools that c provide immediate feedback on the impact of adding an order to a schedule, moving an order in a schedule, or deleting an order from a schedule.
14. The method of claim 13, wherein said decision support tools generate a 00 Mfinite schedule for orders sequenced for production on a particular converter Soperations line. IND The method of claim 14, wherein said decision support tools comprise N changeover and line speed calculations for said converter operations to quantify production start times and end times for said plurality of orders.
16. The method of claim 15, wherein said decision support tools utilize different formulas for changeover and line speed calculations for said converter operations schedules including press schedules, laminator schedules, slitter schedules, coater schedules, metallizer schedules and schedules for other converter operations.
17. The method of claim 13, wherein the means of adding, moving, or deleting an order from said schedule is drag and drop functionality.
18. The method of any one of the preceding claims, wherein said digital computer system maintains multiple alternative schedules for producing said packaging items associated with said plurality of accepted orders.
19. The method of claim 14, wherein said schedule for successive converter operations in the manufacturing process are linked to one another, and immediate feedback on the impact of adding, moving, or deleting an order includes the impact that adding, moving or deleting an order will have on the schedule for subsequent steps in the production process. A computer system for the management of placement and fulfillment of orders for printed packaging products, including labels, for fast moving consumer 71 goods, comprising an electronic storage means for having a computer program stored thereon, wherein the computer program executes the method of any one of the preceding claims. WATERMARK PATENT TRADE MARK ATTORNEYS P22791AU01