MXPA99011559A

MXPA99011559A - Cushioning conversion system and method

Info

Publication number: MXPA99011559A
Application number: MXPA/A/1999/011559A
Authority: MX
Inventors: O Ratzel Richard; E Armington Steven; J Guth Paul; C Booze Macdonald
Original assignee: Ranpak Corp
Priority date: 1997-06-11
Filing date: 1999-12-10
Publication date: 2001-05-17

Abstract

A packaging system includes a cushioning conversion machine for converting stock material into relatively low density cushioning material or dunnage and a packaging system controller. The packaging system controller provides packaging instructions related to a part or parts to be packaged and instructs the cushioning conversion machine to produce the cushioning material. In one aspect of the present invention the packaging system controller provides packaging instructions by retrieving a predetermined set of packaging instructions associated with a particular part. In another aspect of the present invention the packaging system controller provides packaging instructions by determining an optimized packaging methodology using one or more characteristics of the part or parts to be packaged. The packaging system also provides for automated inventory control and productivity monitoring.

Description

SYSTEM AND METHOD FOR CONOURCING CONVERSION DATA OF THE RELATED APPLICATION This application claims the priority of the United States Provisional Patent Application Serial No. 60 / 049,346 filed on June 11, 1997.

FIELD OF THE INVENTION The present invention relates to a cushion conversion system that converts raw material that is in sheet or sheet form into cushion material. More particularly, the present invention relates to a packaging conversion system that includes a packaging controller, wherein the system is adapted to provide the recommended packaging and / or packing information to an operator based on the parts which are going to be packed, and to additionally provide monitoring of the packaging supply inventories. However, the features of the invention have a more general application to packaging systems that use various types of stowage products and packaging supplies.

BACKGROUND OF THE INVENTION In the process of sending a text from - 1739 / 99HX one location to another, a packing material is typically placed in the shipping container to fill any gap, to provide blocking and reinforcement, and / or to cushion the piece during the shipping process. Some commonly used packaging, protective materials are cellulose or plastic foam beads, plastic bubble wrap, shredded paper or cardboard, and converted paper pads. The converted paper pads, which are made of paper and particularly Kraft paper, are biodegradable, recyclable and are composed of a renewable resource. As a result, converted paper pads have become increasingly important in light of the fact that many industries are adopting more progressive policies regarding environmental responsibility. The conversion of the paper sheet raw material into relatively low density paper pads can be achieved by a padding conversion machine, such as those described in U.S. Patent Nos. 4,026,198; 4,085,662; 4,109,040; 4,237,776; 4,557,716; 4,650,456; 4,717,613; 4,750,896 and 4,968,291. (These patents are all assigned to the assignee of the present invention and their complete descriptions are hereby incorporated by reference). -1739/99 X When controlling the conversion machine, such as by using a programmable controller, pads of a variety of lengths may be employed. This feature allows an individual machine to meet a wide variety of cushioning needs. For example, relatively short pad lengths may be employed in conjunction with small and / or non-breakable articles, whereas longer pad lengths may be employed in conjunction with larger and / or brittle articles. In addition, a set of pads (either of the same or different length and / or different configurations such as a star, a cross or a spiral / roll) can be used in conjunction with uniquely and / or delicately shaped articles, such as electronic equipment. In some cases, a manufacturer or a shipping interest can send a wide variety of pieces where each of the pieces has different packing requirements. While a cushion conversion system, such as that described above, can provide a wide variety of pads of different lengths at the request of the operator to meet different requirements, it is often a time-consuming process to determine for each piece presented the best way to pack the piece and then to give instructions to the machine -1739 / 99MX padding conversion to produce the required number of pads that have the appropriate lengths. Also, the reliability of the packaging operation is often dependent on the level of experience of the operator, in particular the packer. In the case of complex packaging systems that involve packing many different types of products with different packaging requirements, the necessary level of skill can prevent the use of inexperienced, inexpensive packers (or operators in general). Another consequence of the shipment of a wide variety of pieces that have different packing requirements is the variability of consumption of the used packaging materials, the package, the piece or pieces, such as the stowage raw material, tape, containers (boxes) , cases, etc.), etc. Up to now, the monitoring of the inventories of the packaging materials was done manually by a person who verified the inventory levels and asked for additional supplies when needed. In the case of the paper sheet raw material rolls used in the conversion converting machines previously used to produce stowage pads, an order was typically placed for the rolls of the raw materials and / or other packing materials. with a distributor. The distributor then P1739 / 99MX complied with the order of the stock or placed an order with its supplier to send the packaging materials directly to the end user. As in the case of the end user, the monitoring of the inventories of the packaging materials in the distributor's facilities is achieved manually by a person who verifies inventory levels and re-orders additional supplies when needed. These existing systems have been labor intensive and time-consuming. Therefore, there is a need for improvements in the packaging systems, and particularly, in the efficient and effective packaging of parts in containers and in the efficient and effective maintenance of the inventories of the packaging materials.

SUMMARY OF THE INVENTION The present invention provides a packaging system, the components thereof and the associated method, which allow, among other things: a) more efficient and / or effective packaging of a piece or pieces, b) more maintenance efficient and / or more effective inventory of packaging materials, c) more efficient and / or effective use of packaging material, d) the most efficient and / or effective use of a labor of low experience, low cost for the packing of the pieces, e) the monitoring P1739 / 99MX and / or more efficient and / or effective analysis of packaging operations, and f) more efficient and / or effective handling and / or monitoring of the piece or pieces that are packaged. Either or both of these objectives are satisfied by one or more of the various aspects and / or features of the invention that are more particularly detailed later. A packaging system and methodology is described that automatically provides the packing instructions to an operator as a function of the piece or pieces to be packed. As a consequence, a packaging system, based on an identification of a piece or pieces to be packed, produces pads of specific lengths to satisfy the packing requirements and gives instructions to the operator regarding the recommended technique for packing the piece or pieces . The present invention provides a packaging system and method that includes a packaging material generator and a packaging system controller adapted to produce packaging material according to the packing requirements of at least one piece to be packaged. The packaging system controller provides the packing instructions for optimized packing of the part or pieces. The system controller preferably includes a device or other means for P1739 / 99 X identify the part (s) (for example, via a part number or part identifier) to be packed, a memory that contains the predetermined packing instructions associated with the part or parts identified that are going to be pack and a peripheral output device to communicate the appropriate packing instructions to a system operator. Provision is made to automatically supply an operator or an automated packaging system with a predetermined amount of packaging material along with the detailed packaging instructions to provide consistency in the packaging of the known parts. Due to the provision of a predetermined amount of packaging material and detailed packaging instructions, high quality packaging can be provided without an operator having extensive packaging training. In addition, the packaging system ensures improved packing efficiency, thereby reducing packaging costs, by eliminating waste while concurrently reducing shipping damage by ensuring an adequate quantity and effective utilization of packaging material. The packaging system according to a particular embodiment of the present invention relates to the packaging of a known article or a P1739 / 99MX normal group of parts (for example, a piece kit). The packaging system identifies the part or pieces to be packaged and retrieves the predetermined packing instructions that are used to generate one or more pieces of packaging material of the appropriate length or quantity (such as pallets) and provides detailed instructions for packaged to the operator that is displayed on a display monitor. By using the packaging material supplied together with the detailed instructions received, a highly efficient, consistent packing process is carried out, regardless of the level of experience of the operator. More particularly, this packaging system includes a cushion conversion machine for converting raw material into cushion pads that serve as the packing material, a packaging controller and a packaging terminal. A known part to be packed is identified, for example, by entering the part identification number in the system via a numeric keypad, a selection menu, or a bar code reader, etc., once the piece is identified, the package controller retrieves a predetermined set of packing instructions that are associated with the identified piece to be packed. The packing instructions are then used to generate lengths P1739 / 99MX appropriate cushioning pads in the proper sequence while simultaneously providing the textual and graphic packaging instructions on the terminal packing screen that aids in the proper packaging of the part by the operator. The predetermined set, retrieved from packaging instructions may additionally include control information for the handling of the packaging material. For example, in addition to the appropriate lengths of the cushion pads to be provided in the proper sequence, one or more of the pads generated may be rolled as needed by a roll to provide the packing material in a rolled form, appropriate for the particular packaging methodologies. Alternatively or additionally, the handling information of the packaging material may include the control data for an automated manipulator, such as a pick and place control apparatus or a robotic insertion and positioning device for automatically recovering a or more of the pads produced and place them in a packing container. According to another embodiment of the present invention, a packaging system includes a system P1739 / 99MX for monitoring the consumption of packaging material and method that counts the number of packaging containers, the amount of packaging material generated, and the quantity or number of other associated packaging supplies, in order to maintain a function of inventory control by monitoring the consumption of the various packaging materials. The packaging system compares the quantity of the consumed packaging materials to one or more replenishment thresholds of orders and generates a request for replenishment of orders for the appropriate materials if the replenishment thresholds of orders are being met or exceeded. According to yet another embodiment of the present invention, a packaging system includes a system and method for monitoring productivity, wherein the characteristics of the packaging process are monitored such as the time required to complete each step in the predetermined packaging procedures . The system then uses the collected data to generate a productivity report that provides the data of the packaging machine, the operator identification data and the productivity data that reflect the time required to complete the various steps in the packaging process. The data can be further processed to provide standardized productivity data, trend analysis, -1739 / 99MX etc. In accordance with another aspect of the present invention, a packaging system and method is disclosed which includes a packaging material generator and a packaging system controller adapted to produce packaging material in accordance with packaging requirements and a piece that is going to pack. For an unknown piece that is going to be packed, the packaging system evaluates one or more characteristics of the piece and determines the packing requirements and gives instructions for an optimized packing of the piece. This packaging system preferably includes a device and another means for identifying at least one of the characteristics of the piece to be packed. The packaging system also includes a database that contains a set of rules and data for use in determining the appropriate packing instructions based on the various characteristics of the part. The packaging system, when determining the requirements and appropriate packaging techniques, communicates the instructions to the packaging material generator to automatically generate the appropriate amount of the packaging material in the proper order. In addition, the instructions are transmitted to a peripheral output device such as a screen which includes graphic instructions P1739 / 99MX and / or textual to provide instructions to the operator when packing the part. Thus, in accordance with this aspect of the invention, the packaging system is capable of receiving an unknown part to be packaged and supplying a non-trained operator with an appropriate amount of packing material and detailed packing instructions to provide a packaging methodology, optimized, thus providing a high quality packaging that prevents damage to the product without incurring undesirable waste. This packaging system is well suited for a private shipping company that sends several items for individuals. An operator introduces an article that is unknown to the packaging system (ie, a predetermined set of packaging instructions associated solely with the article does not reside within the packaging system's memory). In contrast, the packaging system acquires one or more features of the article such as its size, shape, height and fragility. The system then applies rules within the system memory to the data provided and predetermines an optimized packaging methodology for the part. The optimized packaging methodology is transmitted as control signals to a packaging material generator such as a packaging machine.

P1739 / 99MX padding conversion dictating the appropriate container (eg, size and type), the number of cushion pads, their length and their generation sequence. Additionally, the optimized packaging methodology is communicated to the operator in a form of graphic and textual instructions to ensure that the piece is packaged according to the optimized packaging methodology. In accordance with another embodiment of the present invention, a preview of the packaging methodology is provided to the operator that illustrates the materials to be used in the packaging process and provides both the costs incurred for packaging and shipping Of the piece. Then the operator is given the option to continue with the packaging process, where the generation of packaging material is started, appropriate, or alternatively the process is finished. According to yet another aspect of the present invention, a controller of the packaging system includes an "expert" system that automates the decision by making the process of designing the packaging methodology. The controller of the packaging system preferably includes a memory containing a plurality of expert-based rules and packaging data. Packing rules and data are used in conjunction with the data P1739 / 99MX provided by the operator with respect to the piece to be packed to produce conclusions (ie, an optimized packaging methodology). The expert system can represent knowledge of the system in the form of "yes, then" rules, where "if" certain conditions are true, "then" certain conclusions must be taken as a result. In some cases, the expert system may use several approaches to determine if certain conditions exist. The system can identify a condition within an established, internal database or use the data from the database plus additional rules to establish the existence of a certain condition. In addition, the system can ask the operator about additional information in order to fill in the spaces required in the order for the system to make additional progress in establishing the optimized packaging methodology. In a preferred embodiment of the present invention, the expert system uses inputs such as the size, shape, weight and brittleness of the piece to determine the appropriate container and an optimized packaging methodology. In addition, you can also use a shipping method as well as an operator preference for either packaging optimization or cost optimization in the determination of the packaging methodology.

P1739 / 99MX In accordance with yet another aspect of the present invention, a packaging system and method is described which includes a packaging material generator and a packaging system controller adapted to produce packaging materials in accordance with packaging requirements of a plurality of pieces that are going to be packed. For a plurality of known pieces to be packed, the packaging system evaluates a shipping order and obtains the data in relation to the pieces to be packed. The packaging system then determines the packaging techniques for optimized packing of the pieces. This packaging system preferably includes a device or other means for analyzing a shipping order to identify in this way the plurality of pieces to be packed. The packaging system includes an internal database and / or access to an external database that contains a list of the pieces that can be packed together with the data related to the pieces, such as their weight, shape, size and fragility . The packaging system also includes another database that contains the set of rules and data associated with the packaging material for use in determining appropriate packing techniques to optimize the packaging methodology. The packaging system, when determining the techniques of P1739 / 99MX packaged, communicates instructions to the packaging material generator to automatically generate the appropriate amount of packaging material in the proper order. In addition, the instructions are transmitted to a peripheral output accessory such as a screen that includes graphic and / or textual instructions to provide an explanation and instructions to the operator in the appropriate packing of the plurality of pieces. This packaging system of the present invention is well suited for a postal ordering company or warehouse distributor that retrieves multiple pieces (products) and packages the pieces together for shipment to a customer. A packer (ie the operator) or the packaging system receives a shipping order that is read by the packaging system. The packaging system, using the order number, identifies each of the pieces to be packed and retrieves the additional data associated with each piece in the order from a warehouse management database or an internal database. The packaging system of the present invention then determines an optimized packaging methodology based on the recovered data including the determination of the appropriate container (eg, box, box, etc.) to pack the order. In addition, the packaging system determines the position and orientation (and P1739 / 99MX this way the packing sequence) of the pieces to be packed inside the container and generates the appropriate amount of the packing material in the appropriate sequence to pack the parts according to the determined packaging methodology. According to another particular embodiment of the present invention, the packaging system may include a system for verifying the list of choice. In cases where pieces are chosen by an individual and packaged by another, it is often required that the packer confirm that the items chosen are consistent with the shipment order. The packaging system identifies all the pieces that must be in the shipment order and evaluates each piece, preferably with a reading device, to identify that the items recovered correspond to the items in the shipment order before the packaging system Determine an optimized packing methodology, thus saving time and money. According to yet another particular embodiment of the present invention, the packaging system controller includes an expert system that automates decision making in the packaging methodology design process. The controller of the packaging system includes an associated memory that contains a plurality of expert rules and packaging data that relate to the packaging material.

P1739 / 99MX Packing rules and data are used in conjunction with the data associated with the parts to be packed to produce conclusions (ie, an optimized packaging methodology). The expert system can represent the knowledge of the system in the form of rules of the action-reaction type. Alternatively, the expert system may employ a cubing concept, wherein each piece to be packed occupies (when packed) a cubic volume in the container. The expert system then analyzes the various cubes that correspond to the pieces to be packed and determines an optimized cube arrangement (ie, pieces) within the specified container, thereby reducing a quantity of the necessary filling of voids, extra cases, etc. The foregoing and other features of the invention are fully described below and particularly pointed out in the claims, the following description and the accompanying drawings which set forth in detail the illustrative embodiments of the invention. These modalities, however, are a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and characteristics of the invention will become apparent from the following detailed description of the invention P1739 / 99MX when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a block diagram illustrating a packaging system according to the present invention; Figure 2 is an illustration of a packaging system according to the present invention that includes a cushion conversion machine and a packaging system controller; Figure 3 is a block diagram illustrating a portion of the controller of the packaging system according to the present invention; Figure 4 is a flow diagram illustrating an operational flow diagram of the packaging system according to the present invention; Figure 5 is a flow diagram illustrating a preview characteristic of the packing routine that allows a packer to verify if the proper packing routine has been recovered for the identified piece to be packed; Figure 6a is a peripheral output screen and the user interface illustrating a predetermined set of retrieved packing instructions for an identified part to be packed; Figure 6b is a peripheral screen of P1739 / 99MX output and user interface that highlights a method for identifying or entering the parts to be packaged according to one aspect of the present invention; Figure 6c is a peripheral output screen that illustrates in greater detail a particular step of a predetermined set of retrieved packing instructions for packaging the identified part; Figure 7 is a flow diagram illustrating an operational flow diagram for generating the packaging material and providing instructions to an operator for the packaging of one or more pieces; Figure 8 is a flowchart illustrating the operation of the packaging system including a packaging material handling apparatus for either rolling up the generated packaging material and / or initiating a choice and placement control routine for packaging automated Figure 9a is a partial top view of the cushion conversion system of Figure 2 employing a winder accessory mechanism to take a length of the packaged material and roll it up according to the recovered packing instructions; Figure 9b is a partial, enlarged side view of the cushion conversion system of P1739 / 99MX Figure 2 employing the furling attachment of Figure 9a, wherein the furling accessory can be operated to be rotating in and out of the outlet flow path of the cushioning conversion machine; Figure 10a is a side view of a cushion conversion machine employing a cushion handling system such as a choice and placement apparatus in accordance with the present invention; Figure 10b is a top view of the cushion conversion machine and the cushion pad handling system of Figure 10a, wherein the generated cushion pads are placed on a conveyor belt for transporting the generated pads to an apparatus for choice and placement; Figure 10c is a top view, isolated from the choice and positioning apparatus of Figure 10b according to the present invention; Figure 11 is a flow diagram illustrating a method for providing inventory control, inventory monitoring and automated order refill for packaging materials in accordance with the predetermined consumption thresholds; Figure 12a is a flow chart illustrating in greater detail an example method for providing the inventory control method of the P1739 / 99MX Figure 11; Figure 12b is a flow chart illustrating in greater detail an exemplary method for providing the inventory control method of Figure 11; Figure 13 is a flow chart illustrating a method for monitoring the packaging productivity of the operator and for providing a productivity report in accordance with the present invention; Figure 14 is a flow chart illustrating in greater detail an example method for monitoring productivity and generating the productivity report of Figure 13; Figures 15a-15d are flow charts illustrating in detail the operation of the packaging system of Figure 2 according to one embodiment of the present invention; Figure 16a is a block diagram illustrating a packaging system according to an alternative embodiment of the present invention; Figure 16b is an idealized side view of the packaging system according to the present invention; Figure 17 is a flow diagram illustrating an operational flow diagram of the packaging system according to an alternative embodiment of the present invention; -173- / 99MX Figure 18 is a flow chart illustrating the step of identifying the piece to be packed by providing one or more features that characterize the piece to be packed; Figures 19a-19c illustrate various methods for determining the fragility of the piece to be packaged using selection menus, a selection of general categories, automated techniques such as pattern recognition, expert systems and neural networks; Figure 20 is a block diagram illustrating an expert system associated with the controller of the packaging system in accordance with the present invention; Figure 21 is a block diagram illustrating several pieces of data residing within the database of the expert system according to the present invention; Figure 22 is a decision diagram illustrating an exemplary method for determining the packaging control methodology using an expert system in accordance with the present invention; Figures 23a-23n are graphs illustrating the dynamic cushion conversion curves used in the determination of the cushioning functional requirements or the expert system according to the present invention; Figure 24 is a graph that illustrates a P1739 / 99MX dynamic cushion conversion curve in greater detail, where the use of the curve when determining either a particular configuration of the cushioning product is capable of satisfying the functional cushioning requirements determined by the expert system; Figure 25 is a graph illustrating the dependence of the lateral friction coefficient of the static load for a type of packaging material; Figures 26a-26b are graphs illustrating the impact of vibration on the packaged product according to the present invention, in particular, typical vibration frequencies for different types of transport; Figure 27 is an operational flow diagram of the packaging system for packaging a plurality of known pieces according to another aspect of the present invention; Figure 28 is a block diagram illustrating the packaging system according to the present invention; Figure 29 is a flow diagram illustrating a method for identifying parts to be packaged and for determining the packaging instructions for the identified parts; Figure 30 is a flow chart illustrating a step of reading an order number for a shipment of items; P1739 / 99HX Figures 31a-31d are block diagrams illustrating example cubing configurations in accordance with the present invention; Figure 32 is a flow diagram illustrating the functions controlled by the particular packaging instructions according to the present invention; and Figure 33 illustrates data collection to generate productivity statistics.

DETAILED DESCRIPTION OF THE INVENTION The present invention will now be described with reference to the drawings in which reference numerals are used throughout to refer to similar elements. In one embodiment of the present invention, an automated packaging system and method is disclosed which includes a packaging material generator such as a cushion conversion machine and a packaging system controller. An operator, who wishes to efficiently pack a known, identified piece, interacts with the packaging system to produce an appropriate amount of packing material in an appropriate sequence to pack the piece into an identified container. In addition, the packaging system and method provide detailed packing instructions to the operator either in a textual and / or pictorial format providing this P1739 / 99MX mode efficiency and packing consistency that results in reduced damage to the part and reduced packaging costs. According to a preferred embodiment of the present invention, a known part to be packed is identified, for example, by reading or entering its part identification number. Once the piece to be packaged is identified, the packaging system retrieves a predetermined set of packing instructions that correspond uniquely to the identified piece. The packaging instructions preferentially indicate the recommended packaging container, generate the necessary packing material and provide step-by-step instructions to assist the operator in packing the piece. Preferably, each instruction step is provided to the operator via a computer display terminal in conjunction with a length (or amount) of the packaged material generated by the packaging material generator. The packaging system reduces packaging costs by dictating the appropriate controller and the appropriate quantities of packaging material. As a result, unnecessary and excess packing spaces are eliminated. In addition, detailed packaging instructions reduce the need for highly experienced operators since the container, the quantities of the packaging material, the sequence with P1739 / 99HX which the packaging material is generated and the way in which the packaging material will be used for efficient packaging is dictated and explained by the packaging system. In accordance with another aspect of the present invention, an inventory monitoring system is provided in which the materials consumed in the packaging of the pieces are monitored. For example, for a particular piece to be packed, a predetermined container and a predetermined amount of packaging materials will be used. While the packaging materials are being consumed during the packaging of a piece, the inventory monitoring system, for example, decreases an internal list of inventory and compares the updated list to one or more refill thresholds of orders. If one or more items in the updated inventory list (that is, a consumption list) satisfy a replenishment order criterion (for example, falls below a minimum threshold), the inventory monitoring system automatically generates a request of replenishment of orders to ensure that packaging inventories are not unduly exhausted. In addition to the monitoring of containers and packaging material, the inventory monitoring system can also monitor other packaging supplies such as the product literature associated with the identified part, P1739 / 99MX warranty cards, packing tape, etc. In accordance with another aspect of the present invention, a packaging system may include a productivity monitoring system. The productivity monitoring system can be operated at the time of packing each piece for an identified operator and monitor the time required to complete each step within the pre-set packing routine. The productivity monitoring system then creates a productivity report in which operator productivity is provided in an easy-to-evaluate format. The productivity report preferably includes an average type required to perform one or more packaging steps, but may also include standardized productivity data and trend information, as may be desired, that can be stored in a database. Referring now to the drawings in detail, and initially to Figures 1-4, a packaging system and method according to the present invention is shown. In Figure 1, the packaging system 10 includes a generator 12 of packaging material to generate packing material to be used in the packaging of the identified piece. According to the present invention, the term "pieces" is widely used to include an individual piece, a piece of equipment that includes a known arrangement P1739 / 99MX of parts, and several items that require shipping, regardless of the nature of the part, whether it's an item, product, component, part, etc. The packaging material generator 12 includes a controller 14 for controlling the various operational components (not shown) within the generator 12 as will be discussed in greater detail infra. A controller 16 of the packaging system is coupled to the packaging material generator 12 and the packaging material generator 12 is communicated via the controller 1. The packaging system controller 16 is also coupled to an output peripheral device 18 and an input peripheral device 20, respectively, and can be operated to retrieve a predetermined set of packaging instructions in response to the identification of a part that is will pack, which is preferably identified via a peripheral input device 20. The predetermined packing instructions are preferably recovered from a memory (not shown) associated with the controller 16 of the packaging system or a communication network and are selectively sent to the controller 14 and the peripheral output device 18. The packaging instructions sent to the controller 14 refer preferably to the generation of particular lengths (or quantities) of the material P1739 / 99MX packing in a particular sequence. In addition, as will be described in more detail infra, the packaging instructions may additionally include the control signals of the handling of the packaging material after generation, to manipulate the packaging material, generated for particular packaging options such as wrapping or the implementation of a choice and placement functionality. The packaging instructions that are sent to the peripheral output device 18 (eg, a computer display monitor) are explanatory instructions, preferably detailed, that assist the operator in efficiently packing the identified part. The explanatory instructions include, for example, explanatory text that accompanies the graphic images of the piece to be packed, the packaging material, the container, etc. Preferably, the instructions provided via the peripheral output device 18 clearly illustrate the manner in which the packaging material engages the parts to be packaged and how the packaging material engages the packaging container to secure properly and efficient the piece inside the container. These instructions may additionally include video-type instructions that include audio data, as may be desired. The P1739 / 99MX packing instructions can also include pre- and / or post-package information such as instructions for selecting and choosing a particular container, inserting a liner, tape instructions, shipping instructions, etc. Returning now to Figure 2, the packaging system 10 of Figure 1 according to a preferred embodiment of the present invention is illustrated. The packaging system 10 includes a cushion conversion machine 12 as the packaging material generator and a personal computer 16 constitutes the controller of the packaging system of Figure 1. The personal computer 16 couples to a peripheral input device 20 ( not shown) such as a keyboard, a bar code reader, a mouse, etc., to enter the data or orders. The personal computer 16 is also coupled to a display monitor 18 which corresponds to the peripheral output device 18 of Figure 1 and can also be connected to a computer network. The input peripheral device 20 and the display monitor 18 are used for interaction with the operator with the cushion conversion machine 12. The cushion conversion machine 12 preferably includes a frame 24 on which the various components of a conversion assembly 25 and a machine controller 14 (which is P1739 / 99MX schematically illustrates) to control the cushion conversion machine 12 including the assembly components 25 for conversion. The frame 24 has mounted thereto or included therein a raw material supply assembly 26 that includes a weft separation assembly and a raw material support bar (not shown) that supports a roll of raw material (e.g. , paper) for the conversion by the conversion assembly 25 into a cushioning material (not shown). The conversion assembly 25 illustrated is comprised of plural conversion assemblies including a forming assembly 30, a feed / connection assembly 32 driven by a feed motor 34, and a sawing or cutting assembly driven for example by a motor cutting 38 selectively coupled with cutting assembly 36 by a clutch 40. A post-cut restriction assembly or outlet 42 is also provided to guide the cushioning material from the cutting assembly. During the conversion process, the forming assembly 30 causes the side edges of the raw material (not shown) to rotate inward to form a continuous strip having two lateral pillow-like portions and a central band between them as the raw material progresses through the training montage. The assembly of P1739 / 99MX power / connection 32, which includes a pair of toothed gear (gear) members in the cushioning conversion machine, illustrated, performs a feeding function, for example, by pulling, when extracting the continuous strip through the separation of the two cooperating and opposite gears of the feed / connection assembly 32 when extracting the raw material through the forming assembly 30 during a range which are determined by the time interval that the feed motor 34 rotates the opposing gears. The feed / connection assembly 32 additionally performs a "connecting" function as the two opposing gears wedge the central strip of the continuous strip as it passes through these to form a coined strip. As the wedged strip travels downstream through the feed / connection assembly 32, the cutting assembly 36 cuts the strip into sections of a desired length. These cut sections exit from the post-cut restriction assembly 42 and are then available for use in packing the part. The controller 14 of the machine is preferably a programmable controller based on the microprocessor such as that described in the co-owned US Patent Applications, Serial No. 08 / 482,015 and 08 / 279,149 filed on June 7, 1995. and the 22 P1739 / 99MX of July 1994, both entitled "Cushioning Conversion Machine ", which are incorporated herein by reference, The machine controller 14 controls the operation of the various components of the cushion conversion machine 12 (e.g., power / connection assembly 32, and more specifically the feed motor 34, and the cutting assembly 36, or more specifically the feed motor 34, and a cutting assembly 36, or more specifically, the cutting motor, etc.) to form one or more pads of particular lengths according to a number of control signal inputs.These control signal inputs may include inputs from the sensors of the machine, such as can be used to detect pincers or accurately measure the formation of the length of the pad, for example, and inputs from the personal computer 16 (i.e., the controller of the packaging system) via a control line 44. Specifically, when desired When an appropriate length of pad is formed, the controller 14 of the machine causes power to be supplied to the feed motor 34 for a duration that is sufficient for the conversion assembly 25 to produce the desired length of the pad. Then the power to the feed motor 34 is disabled and the controller 14 of the machine causes the clutch 40 of the cutting motor P1739 / 99MX engage the cutting motor 38 with the cutting assembly 36 to saw or cut the pad to the desired length. Referring now to Figure 3, a detailed block diagram of the controller 16 of the packaging system according to a preferred embodiment of the present invention is shown. The controller 16 of the packaging system preferably includes a central processing unit (CPU) 50 which is coupled to a bus 52. The CPU or processor 50 may be any of a plurality of processors, such as a Pentium ™, a Power PC ™, Sparc ™ , or any other similar and compatible processor. The CPU 50 functions to perform the various operations described herein as well as carry out other operations related to the controller 16 of the packaging system. The manner in which the CPU 50 can be programmed to perform the functions in relation to the present invention will be readily apparent to those skilled in the art based on the description provided herein. The bus 52 includes a plurality of signal lines 54 for transporting addresses, data and control between the CPU 50 and a number of components of the system bus. The other components of the system bus include a memory 58 (including a random access memory (RAM) 60 and a read only memory (ROM) 62) and P1739 / 99MX a plurality of ports for connection to a variety of input / output devices (1/0) which collectively comprise the peripheral output device 18 and the input device 20, respectively. The memory 58 serves as the data storage which can store the appropriate operation code to be executed by the CPU 50 to carry out the functions described herein. The RAM 60, the hard disk drive 78 or another type of storage medium provides storage of the program instructions, the working memory for the CPU 50 and the predetermined packing instructions associated with the particular pieces to be packed. Preferably, the packaging instructions correspond to the pieces to be packaged through a search table, however, other storage and retrieval techniques such as an algorithmic search machine are contemplated as they fall within the scope of the invention. present invention. For example, the predetermined packing instructions can be stored on the hard disk drive 78 or other data storage means (eg, a CD ROM) and can be accessed by the CPU 50 according to the program instructions of RAM 60. ROM 62 has program instructions for P1739 / 99MX computation as it is known for the basic input / output system (BIOS) to perform the interconnection operations with the 1/0 devices. Also stored in ROM 62 is a computer program routine that operates to load a startup program. The start program will typically run when the controller 16 of the packaging system is actuated or when the initialization of the controller 16 of the packaging system is needed. 1/0 devices include basic devices such as data storage devices (eg, floppy disks, tape drives, CD ROMs, hard drives, etc.). Typically, the I / O devices communicate with the CPU 50 when generating interrupts. The CPU 50 distinguishes interrupts between the I / O devices through individual interrupt codes assigned to them. The responses of the CPU 50 to the interruptions of the I / O devices differ, among other things, in the devices that generate the interrupts. The interrupt vectors can also be provided to direct the CPU 50 to different interrupt handling routines. The interruption vectors are generated during the initialization (i.e., startup) of the controller 16 of the packaging system by the P1739 / 99MX BIOS execution. Because the CPU 50 responses to device interrupts may need to be changed from time to time, the interrupt vectors may need to be modified from time to time in order to direct the CPU 50 to different interrupt handling routines . To allow the modification of the interruption vectors, they are stored in the RAM 60 during the operation of the controller 16 of the packaging system. A disk control subsystem 70 bi-directionally couples one or more disk drives 72 (for example, floppy disk drives, drives CD ROM, etc.) to bus 52 of the system. The disk unit 72 works in conjunction with a removable storage medium such as a floppy disk or CD ROM. A hard disk drive control subsystem 76 bi-directionally couples a fixed disk or hard drive unit 78, rotatable to the bus 72 of the system. The hard disk drive control subsystem 76 and the hard disk drive 78 provide mass storage for the instruction data of the CPU, by way of example. The disk unit 72 and the disk control subsystem 70 can be used to download one or more pieces of data to the RAM 60 or hard drive 78 of the system. For each piece or collection of pieces, for example, you can provide the data that relate to the appropriate container that P1739 / 99MX will be used for packaging, part identification number, control requirements for the generation of packaging material (both quantity and sequence) and packaging instructions to the user (including text, graphics, photos) digital and / or video data). Therefore, as packing requirements change or additional pieces are required to be packed, the controller 16 of the packaging system can be updated dynamically. A terminal control subsystem 86 is also coupled to the bus 52 and the output is provided to the peripheral output device 18, typically a CRT monitor, and receives the inputs from a manual input device 20 such as a keyboard. Manual input can also be provided by a signaling device such as a mouse or other type of peripheral input devices such as a bar code reader. In addition, the input device 20 may include a microphone for receiving voice instructions and may be processed by the CPU 50 according to speech recognition techniques as is well known to those skilled in the art. Additionally, the peripheral input device 20 may include a touch-activated screen such as a capacitive touch-sensitive screen. Any type of data entry device is considered as falling P1739 / 99MX within the scope of the present invention. A network adapter 90 is provided for coupling the packaging controller 16 to a network. This network adapter 90 is coupled to the system bus 52 and allows the provision of the communication link to other systems either local or remote to the packaging system 10. In addition, other types of physical equipment can also be connected to the bus 52. computer. For example, a modem 91 may be provided to transmit, in accordance with the instructions provided by the CPU 50, various pieces of information such as requests for replenishment of orders to the inventory distributors to update the inventories in the case that they are satisfied. the replenishment thresholds of orders. Returning now to Figures 3 and 4, a method 100 is provided in which the packaging system of Figure 1 provides packaging material and packaging instructions to a user. The method 100 preferably begins with the entry of an identification number of a known part to be packed in step 102. The identification step 102 can be carried out in a number of ways. For example, the part can have a part identification number which can be manually entered into the controller 16 of the packaging system via the peripheral device 20 of P1739 / 99MX input such as typing the part number into the system using a numeric keypad or keyboard. Alternatively, a selection menu illustrated in the peripheral output device 18 (for example, the computer screen) can be accessed using a mouse as the peripheral input device 20. The selection menu can include in the list of all the known pieces that have associated sets of predetermined packing instructions in the packaging system 10. When selecting the part number in the selection menu using the mouse, the piece that is going to pack. In yet another alternative method for introducing the piece to be packaged, step 102 may include reading the piece identification number from the piece (or its associated packing request paperwork) using a pattern recognition device such like a bar code reader or a video monitor with optical character recognition. In yet another alternative method, the peripheral input device 20 may include a microphone for receiving audio signals and the part may be introduced by reading up the part number in the microphone of the packaging system 10. In this case, the microphone receives the acoustic sounds and transmits the data to the CPU 50 that identifies the piece using speech recognition techniques. By P1739 / 99MX example, the microphone can receive the acoustic sounds and convert the sounds into * analog signals and then transmit the data to the CPU 50 which converts the audio data into digital data using, for example, an A / D converter. Finally, although a few methods for identifying the part 102 are described above, it should be understood that there are other methods for identifying the part and that each is contemplated as falling within the scope of the present invention. Once the part is introduced, the CPU 50, according to the instructions programmed within the RAM 60, retrieves a packaging control methodology that includes a predetermined set of packing instructions that are associated with the part identified as the step 104. The data used is retrieved from an associated memory such as the hard disk drive 78 or a data rewriting means in the disk unit 72 or the network unit. For example, the instructions may be stored in the hard disk unit 78 or in the CD ROM in the disk unit 72. Upon identifying the piece to be packaged, the CPU 50 retrieves the packaging instructions associated with the part in step 104. In a preferred method of the present invention, the CPU 50 uses a look-up table or an algorithmic search engine. to retrieve the default packing instructions. In this P1739 / 99 X method, each part number is attached to an address space that contains the packaging instructions associated with the part number. The CPU 50, using the addresses corresponding to the space and address, retrieves the instructions and excludes those instructions that correspond to the control instructions of the packaging material generator and that are directed to the instructions of the operator's packing. According to the present invention, the term "operator" is used to mean broadly anyone who interacts with the packaging system and may include, for example, a packer, a customer, a user, a supervisor, etc. The CPU 50 sends the instructions directed to the control of the packaging material generator to the controller 14 of the generator 12 of the packaging material to initiate generation of the appropriate amount of the packaging material in the appropriate sequence. For example, in the preferred embodiment of the present invention, the packaging material generator 12 is a cushioning conversion machine. In this case, the control instructions to the controller 14 will dictate how many cushion pads are produced to properly pack the piece, the proper length for each piece and the order or sequence in which the pads will be produced. For the P1739 / 99MX thus, the retrieved packing instructions from the CPU 50 will provide control of the packing material generator in step 108 of Figure 4. The CPU 50 also sends the instructions directed to the operator to the peripheral device 18 of output (preferably, a computer screen) to provide step-by-step explanatory instructions in step 110 to ensure that the packaged material generated by the generator 12 is used appropriately in the packaging of the part and that the piece is packaged in the appropriate container. Preferably, the instructions consist of text and graphics data that are used by the CPU 50 to drive the peripheral device 18 and thereby provide pictorial outputs with accompanying textual instructions. In addition, the instructions are preferably provided in a sequence corresponding to the order in which the packaging material is generated. Although the preferred embodiment of the present invention provides packaging instructions in step 110 using graphics and text, the packaging instructions may additionally include video and / or audio data for the packaging instructions. Any form of packaging instructions is contemplated as falling within the scope of the present invention.

P1739 / 99MX Therefore, if the identified part to be packed requires that three pieces of cushion pads be generated in the lengths of 12", 18" and 15", respectively, the packing instructions that are retrieved by the CPU 50 will result in a generation of a 12"cushion pad while a graphic instruction with an accompanying text explanation of how to use the 12" pad to properly pack the piece will be provided on screen 18. Once the operator take the 12"pad, the cushion conversion machine 12 detects the condition (preferably by using a sensor) and then automatically generates the next pad (the 18" pad) according to the predetermined packaging instructions, while The graphic illustration is provided in the accompanying text on screen 18 to illustrate how to properly use the generated pad. Since the second pad is taken by the operator, the last pad is produced by the padding conversion machine 12 with its associated instructions on the screen to illustrate how to finish the packing process. Accordingly, the present invention ensures that the appropriate packaging container and the appropriate amount of packaging material are used in the P1739 / 99MX packaged from an identified piece. In addition, the packaging system 10 provides the appropriate amount of packaging material in the proper sequence and provides guidance in the packaging of a piece within the appropriate container to ensure that the piece is packaged independently of the level of experience of the operator. Additionally, the present invention results in the elimination of waste packaging material, allows a packing consistency and reduces packaging damage. In the previous example, the cushion conversion machine was used as the packing material generator 12. Although a cushion conversion machine is used in the preferred embodiment of the present invention, the packaging system 10 can also be used in conjunction with other types of packaging material generators or dispensers, such as generators and / or pellet dispensers. Styrofoam, bubble wrap dispensers and / or generators, air cushion machines, vacuum fill generators (for example, material shredders), etc. Any type of generator and / or distributor of packaging material is contemplated as falling within the scope of the present invention. In addition, in the previous example, the packing instructions of step 110 were limited to identify the appropriate container Packaging P1739 / 99MX and how to use the packaging material generated to pack the identified piece. However, the packaging instructions may include additional instructions such as the specification of what type of packing tape or sealant to use in closing the container, how to seal the container using the tape, if documentation is to be included within the container and what type of mail label is going to be used. In addition, the packaging instructions may include pre-package instructions such as instructions that relate to the selection and direction of the appropriate container, etc. In addition to the features of Figure 4, the method 100 may also include a preview feature, as illustrated in Figure 5. Once the known piece to be packaged is identified (step 102) and the CPU 50 retrieves the packaging control methodology (i.e., the packaging instructions, step 104), the CPU 50 sends the package preview data to the peripheral output device 18 which allows the operator to see the identified part and all the steps included in the packaging process in step 112. The preview feature allows the operator to verify whether the appropriate part has been identified, or not, in step 114. For example, if after looking at the preview again the package displayed in step 112, the operator P1739 / 99MX determines that the wrong part has been identified (that is, the part identification number was incorrectly entered, etc.), the operator can return to the beginning of method 100 and repeat the step of identifying the part that is going to pack in step 102 (i.e., re-enter the part identification number) before the generation of any packing material, thereby avoiding potential waste. However, if the operator verifies by using the preview screen that the identified part is the correct part in step 114, method 100 continues and CPU 50 sends the predetermined instructions to controller 14 and screen 18 (step 108 and 110) for the packaging of the identified piece. The method 100 of Figure 5 is illustrated in greater detail in accordance with an exemplary embodiment of the preview display feature shown in Figures 6a-6c and in the flow chart of Figure 7. Figure 6a is a example display screen in the peripheral device 18 output. Figure 6a preferably includes a window type display interface 120 having a part identification window 122. A box 124 of part title and a window 126 of box number or box to display the appropriate packing container corresponding to the identified piece. The interface 120 P1739 / 99MX additionally includes a window 128 that allows a user to indicate how many identified pieces are to be packed and a preview window 130 that illustrates a preview of the packaging process associated with the identified part. The preview window 130 includes, for each step in the packaging process, a step identifier 132a, an identifier 132b of quantity of packaging material, a window 132c indicating the number of pads required to complete the identified step, and a box 132d of packaging illustration. Finally, the interface 120 includes a preview acceptance window 134 that allows a user, after reviewing the preview window 130, to verify that the packaging instructions ("accept") are correct or to exit the process ("exit "). However, once the piece to be packaged is introduced, the CPU 50 retrieves the packaging instructions and inserts the various pieces of data on the screen as shown in Figure 6a such as the identification of the packaging container and the window 126 of the case or box number and the name of the piece in frame 124 of the part title. Preferably, the number of pieces to be packaged is entered manually in frame 128, however, the present invention can automatically receive that data when P1739 / 99MX reads the part identification number or alternatively, an order, work or batch number. In addition, the preview of the packaging methodology for the identified part is displayed by the CPU 50 to the window 130 for verification by the user. One way to identify the piece to be packed is by simply entering the part identification number in the window 122. Alternatively, a selection menu can also be used using a mouse, as illustrated in Figure 6b, when scrolling up and down within the selection menu. Then a user can select the appropriate part from the known parts that are listed within the system 10. Once selected, the CPU 50 retrieves the predetermined packing functions associated with the part identified from the memory (e.g. 78 of hard disk or external unit 72) and refills the windows 124, 126 and 130. The user can then verify the instructions by evaluating the preview window 130 and select the appropriate option in the preview acceptance window 134 . If the packer selects "accept" in the preview section window 134, the packaging system 10 begins the packing process by using the recovered packing instructions to control the packing material generator 12 and P1739 / 99MX provides visualization instructions such as providing pre-package instructions such as the selection of the appropriate container, instructions regarding how to use the generated packing material, and post-packing instructions such as properly sealing the container and where to send the finished package (steps 108 and 110, respectively). An exemplary display instruction corresponding to step 110 is illustrated in Figure 6c. In Figure 6c, the peripheral output device 18 exhibits an enlarged packing display window 144 having, for example, two regions 146a and 146b of graphic display and a region 146c of text explanation. The graphic regions 146a and 146b may consist of one or more images and / or textual annotations illustrating how the packaging material that is produced by the packaging material generator 12 is used to secure the identified piece within the selected container. Text explanation window 146c preferentially identifies what step within the packaging process is running, what pad for the step is being illustrated (where multiple pads are being used for a single step), and the length of the pad that is being used. it is produced. In addition, the 146c window may include additional text instructions to help P1739 / 99MX in addition to the operator in the packaging of the identified piece. Finally, the packaging display window 144 includes a stop / finish function region 148 that allows the user to stop the process or indicate that the packaging step is completed. Preferably, the packaging display window 144 uses text and graphics to communicate and explain the packaging step to the operator. Alternatively, the packaging instructions may additionally include video and / or audio data, and therefore, the display window 144 may include a video illustrating the packaging procedure with accompanying audio instructions. Once the operator clicks or otherwise activates the stop / finish regions 148, the CPU 50 returns the operator to a display window 120 similar to Figure 6a. A detailed flow chart illustrating the steps involved in the provision of the recovered packing instructions (step 108 and 110) to the packaging material generator 12 and the peripheral output device 18 is provided in Figure 7. The CPU 50 starts in the first piece to be packed in step 150. In some cases, instead of simply packing an individual piece, it will be necessary to pack a plurality of identical pieces (see window 128 of Figure 6a).

P1739 / 99MX The present invention contemplates the provision of instructions for either an individual piece or multiple pieces to be packed, as may be desired. The CPU 50 then begins in the first step of the packaging process (step 152) where it begins to provide the packing instructions for the first step in the packaging process in step 154. As illustrated in Figure 6a, for example, The first step can include forming an individual pad that is 60"long on a roll and placing the roll in the packing container so that it is below the piece to be packed inside the container. the provision of the packaging instructions in the peripheral device 18 to the operator, the CPU 50 transmits the appropriate control signals of the controller 14 in step 156 to generate the appropriate packing material to complete the first step, which is to generate a pad that has a length of 60". After determining the first step, the CPU 50 determines whether all the steps are completed in step 158. Since the packing process for the part in that particular example includes 3 separate packing steps, the method proceeds to step 160 where the CPU 50 increases to the next step of the packaging process (ie, step 2). In the second step of the packaging process, P1739 / 99MX CPU 50 provides the packing instructions for the second step in step 154. As illustrated in FIG. 6a, the second step may include the formation of an individual pad having a length of 60"on a roll and placing the roll in the case so that it is also below another portion of the piece to be packed inside the container In conjunction with the sending of the packaging instructions to the peripheral output device 18, the CPU 50 transmits the appropriate control signals from the controller 14 in step 156 according to the packaging instructions to generate the appropriate packing material to complete the second step After completing the second step, the CPU 50 again determines whether all steps are completed on Step 158. Since the packing process is not yet complete, the method proceeds to step 160 and again provides packing instructions in steps 154 and 156, respectively. After completion of the three steps, the CPU 50 determines that the steps are completed in step 158 and then the packing process for that particular part is terminated and the method continues to step 162, where the CPU 50 asks if all the pieces that need to be packed are finished. If additional pieces remain to be packed, the method continues to step 164 and CPU 50 P1739 / 99MX is incremented to the next piece and again the packing process step begins in step 152. If all the pieces to be packed are finished in step 162, the CPU 50 continues to step 166 and the process of packed is finished. As noted above, the CPU 50 retrieves the packing instructions and constitutes a packaging control methodology that is associated with the identified part to be packaged. The packaging instructions that are retrieved by the CPU 50 in response to the identification of the piece to be packaged include both control instructions to control the operation of the packaging material generator 12 and instructions to assist the operator in properly using the package. packing material, generated to efficiently pack the part inside the specified container. In addition to the above packaging instructions, the packaging instructions may additionally include handling instructions for the packaging material that provide control functions in addition to the generation of the packaging material. For example, the handling instructions for the packaging material may include instructions for activating a reel to take a cushion pad that has been produced by the packaging material generator 12 and form a roll with the pad for use in the packaging.

P1739 / 99MX packed the piece inside the packing container. Alternatively, the handling instructions can activate a selection and positioning apparatus to perform an automated system to take a generated pad and place it in a packaging container without the need of an operator. In yet a different alternative arrangement, an automated choice mechanism such as a choice and placement apparatus, a robot or a pad insertion system can be used in conjunction with the operator to improve the productivity of the packaging station. Although a winding operation and a choice and placement control functionality are provided as two examples for handling instructions for the packaging material, additional handling instructions for the packaging material may also be included and are contemplated within the scope of the present invention. invention. As in the packaging instructions, the handling instructions for the packaging material are predetermined and associated with the particular piece to be packed and are therefore recovered by the CPU 50 after the piece has been inserted in a manner appropriate Returning now to Figure 8, a flowchart illustrating an exemplary flowchart is described by which the CPU 50 recovers the P1739 / 99MX packing instructions that include the instructions for handling the packing material and how the packaging material handling instructions are used by the system in the provision of additional control functionality. Figure 8 illustrates a method 170 by which additional control functionality is provided using the packaging instructions retrieved from the CPU 50. As discussed, the CPU 50 retrieves the packing instructions corresponding to the part to be shipped. pack and send the control instructions to the packaging material generator 12 in step 108. The packaging instructions also include the handling instructions for the packaging material. In step 172, the CPU 50 asks whether the material being generated by the packaging material generator 12 is to be wound up. If the packaging instructions indicate that the packaging material is to be rolled (SI), a reel, which is functionally coupled to the packaging material generator 12, is activated in step 164 of the packaging material, which has been generated, which has a length in accordance with the packaging instructions is rolled up in step 176 using the furling apparatus which is functionally coupled to the packing material generator. After it is wound up in step 176, there are two options, which depend on the control instructions. In a P1739 / 99MX case, the rolled packing material is simply made available to the operator to manually take and use the roll in the piece packing in step 178. In another case, the packing instructions additionally include control instructions that initiate a selection and positioning control apparatus for example, in step 180. The control instructions dictate a control routine that allows the choosing and placing apparatus to take rolled packing material and place it automatically inside the packaging container. Alternatively, if in step 172 the packing instructions do not contain any control signal that requires the generated packing material to be rolled (NO), the packaging material, generated can simply be made available to the operator for the use in the packaging of the piece identified in step 182. Alternatively, however, the packaging instructions may include control instructions for the operation of a choice and placement apparatus for use in an automated packing routine in step 184. An example winder and apparatus of choice and placement are illustrated and described in greater detail below. Figure 9a illustrates a winding apparatus 250 according to the invention.

P1739 / 99MX present invention. The winder 250 can be physically attached to the cushioning conversion machine 12 near its outlet 42, as illustrated in Figure 9b. The winder 250 includes a U-shaped frame 152 securely attached to the cushioning conversion machine 12 via a bolt assembly 253. Preferably, the winder 250 is pivotally mounted to the cushion conversion machine 12, as illustrated in Figure 9b, to allow the reel 250 to move in and out of the flow path of the exit pad as desired. A rotating mechanism 254 is rotatably mounted to the frame 252 in the feed path of the output roller in a first position, and when the frame 252 moves from this operating position, the rotating mechanism 254 is not aligned by more time with the outlet 42, and the cushion conversion machine 12 can be used without the reel 250. The rotation mechanism 254 is rotatably mounted to the frame 252 and includes a rotation shaft that forms the center of rotation for the reel 250. A capture device 260 is attached to, and rotated with, the shaft, and a power source 268 is provided to rotate the shaft. The rotation shaft extends through an opening in a support panel and protrudes in a direction that P1739 / 99MX is transverse to the feed path of the exit pad. The capturing device 260 is fixedly attached to the projecting ends of the shaft 214, whereby it is aligned with the outlet 42 of the cushioning conversion machine 12. The capture device 260 is designed to capture the leading end of the cushion strip when the reel 250 is in the ready condition for winding. The capture device 260 illustrated includes a connection center and at least two capture members 262 projecting therefrom. The center is a rod or elongated rod attached to the tree and rotated by it. The capture members 262 are positioned symmetrically to extend from the center in the output path of the exit pad. The capture members 262 are made one size and are separated so that they have a length that is about as wide as the cushion product strip (i.e., the pad produced by the cushion conversion machine). When the reel 250 is in a ready to roll condition, the capture members 262 of the capture device 260 are aligned in a plane that is perpendicular to a travel path of the cushion material strip, as issued from the machine 12. of padding conversion, so that the guide end of the strip P1739 / 99MX of the cushioning product will pass between the capture members 262. When the tree and thus the capture members 262, tours are made, the capture members 262 capture the end of the strip so that the remaining portions of The strip can be wound around it. The power source 268 for driving or rotating the shaft is mounted on the support panel on the side facing away from the outlet 42 of the cushioning conversion machine 12. The power source 268 is preferably a motor, more preferably an electric motor and even more preferably a motor of a low speed DC torque. The power source 268 having an adjustable current limit is preferable because the torque of the motor is proportional to the motor current, whereby the current limit is actually an adjustable point of the force pair to control the tightness of the spiral / roll. It should be noted that the adjustable torque point can also be adjusted under the control of the controller 16 of the packaging system and thus to produce spiral / roll configurations with different cushioning characteristics according to the packaging instructions. Alternatively, a fluid power source with a pressure regulator can also be used to adjust the P1739 / 99 X torque. Another option is to incorporate a slip clutch into the drive unit to maintain a constant winding tension in the cushion product strip. The reel 250 may additionally include a tape device (not shown) for supplying tape to secure the trailing end of the strip of the cushioning product to the roll. The tape device can be designed to manually distribute the tape and manually place the tape on the roll, however, the automated tape device is also possible with, and contemplated by, the present invention. When it has been fully tested that the roll of cushion product has been completely formed, it can be removed from the reel 250 by pulling the roll in a transverse direction away from the support panel. This removal is easily accomplished, especially if the capture device 262 capture members 260 are in the roll-up position where they are aligned in a plane perpendicular to the relative travel path of the cushioning material as issued from the conversion machine. of cushioning. Alternatively, an automatic ejection system (controlled, for example, by controller 14) is possible with, and contemplated by, the present invention.

P1739 / 99MX As discussed previously, the cushion conversion machine 12 includes a controller 14 that controls the operation of the cushion conversion machine 12. In addition, the controller 14 also controls the reel 250 based on the packaging instructions provided by the controller 16 of the packaging system of Figure 1. In one aspect of the present invention, the controller 14 operates in conjunction with an indicator of strips preferably including a strip sensing mechanism that senses whether a strip of cushion product is being emitted from the outlet 42 of the cushion conversion machine 12. In this embodiment, the strip product indicator includes an upstream strip sensor (not shown) in the cushion conversion machine which senses whether the strip is present at an upstream location at the outlet 42 and the strip sensor 264. downstream that perceives if the strip is present in a downstream location. The upstream strip sensor is mounted in an upstream portion of the support panel or in the cushion conversion machine 12 itself. The downstream strip sensor 274 is preferably mounted on the winder frame 152 and, thus, the downstream location is positioned to ensure that the guide end of the attaching product strip is correctly positioned with P1739 / 99 X relating to the capture device 260. The controller 14 activates the reel 250 (ie, energizes the motor 268 of the rotation mechanism 254) when both sensors (the sensors upstream and downstream) perceive that the product strip of cushioning is present both in the upstream location and in the downstream location. This ensures that the guide end of the cushion product strip is correctly positioned relative to the capture device 260 and that the strip of the cushioning product is long enough to be rolled. The controller 14 deactivates the reel 250 when the upstream sensor senses that the strip of the cushioning product is no longer present (i.e., trailing end has passed the upstream location) after a period of time corresponding to a unnecessary period of time to ensure that the drag end portion of the coupling product strip is wound and properly aligned to a capture device. In this way, the winding apparatus 250 can operate in conjunction with the cushioning conversion machine 12 to provide additional handling control to the packaging material in accordance with the packaging instructions retrieved by the CPU 50. The orientation of an apparatus of P1739 / 99MX winding is also described in U.S. Patent Application Serial No. 60 / 071,164 entitled "Cushioning Conversion System and Method for Making a Coil of Cushioning Product", which is incorporated herein by reference in its entirety . As discussed above, an alternative apparatus for handling the packaging material may include a system 300 of choice and placement of packaging material, as illustrated in Figure 10a. The selection and positioning system 300, according to an example embodiment, includes the cushion conversion machine of Figure 2 and the mounting and positioning assembly 302 having an outlet side drive unit 304 that feeds a pad of cushioning generated to a sorting conveyor system 306. The outlet drive unit 304 contacts a pad produced in the outlet 42 and pulls the pad away from the outlet 42 of the machine and over the conveyor system 306. The conveyor system 306 preferably includes a supporting frame 306a and a conveyor belt 306b that receives a pad produced from the drive unit 304 on the output side and transfers the pad through the conveyor belt 306b to a charging station 307 where the unit of choice is located and P1739 / 99MX placement 308, as illustrated in Figure 10b. The selection and positioning unit 308 has an arm 308a that grasps the pad produced in a first position 309a as (illustrated in Figure 10b) and rotates the arm 308a 1802 to a second position 309b (as illustrated in Figure 10c) and releasing the pad, thereby placing the pad in a container (not shown). In addition, the conveyor belt 306b preferably includes a chain band with 306c that creates a gap for aligning and holding the cushion pads in the band 306b during transportation to the area 307 of choice and placement organization. The conveyor belt 306b also allows multiple cushion pads to accumulate between the machine 12 and the organizing area 307. Alternatively, the system 300 of choice and placement may include a unit 308 of choice and placement directly on the outlet 42 of machine. In this case, the selection and positioning unit 300 seizes the pad produced in the outlet 42 of the machine and rotates the pad 902 and places the pad in an appropriate packing container. The system 300 of choice and placement is controlled by the packing instructions which are retrieved by the CPU 50 of the controller 16 of the packaging system and transmitted to the controller 14 of the machine 12 of P1739 / 99MX cushion conversion. The controller 14 also controls the motor 304b of the output side drive unit 304, the conveyor belt 306b of the conveyor system 306 of the choice and placement unit 308, respectively. Other types of choice and placement systems are also contemplated by the present invention such as that described in U.S. Patent No. 5,749,821 entitled "Cushioning Conversion System for Converting Paper Stock into Cushioning Material with a Staging Area and to Pick and Place. Assembly ", which is incorporated herein by reference in its entirety. The handling control feature of the packaging material of the present invention has been analyzed in conjunction with the reels 200 and 250 and the control system 300 of choice and placement of Figures 9a-9c and Figures 10a-10c, respectively. These handling characteristics of the packaging material, however, are exemplary only and this feature extends to other manipulation control functions such as robotic control functionality for automated tying. Other types of stowage handlers and handling techniques include the pad insertion and unloading apparatus shown and described in U.S. Patent Application No. 60 / 059,290 filed on 18 P1739 / 99MX September 1997, which is hereby incorporated by reference in its entirety. Further, although the analysis of the handling control characteristic of the packaging material was described in conjunction with the cushion conversion machine 12 of Figure 2, this feature extends to other types of packaging material generators and / or distributors. which are contemplated as falling within the scope of the present invention. The packaging system 10 of Figure 1 can also be used to provide an inventory control feature that tracks the consumption of the various packaging items or materials in conjunction with their automated generation and supply of packaging material. An example method 350 for providing this inventory control (which can alternatively be considered a consumption monitoring) is illustrated in FIG. As discussed previously in conjunction with Figure 4, the packaging system 10 identifies the piece to be packed in step 102 and the CPU 50 retrieves the packaging control methodology consisting of the packaging instructions in step 104. Using the packaging instructions, the packaging material generator is controlled in step 108 while an operator is concurrently receiving graphic and textual packing instructions in a peripheral output device 18, P1739 / 99MX such as a CTR screen, in step 110. As each piece is packed, several items associated with the packaging process are consumed. For example, each piece is packed inside a particular packaging container or box and each piece uses a specified amount of packaging material. In addition, the packaging of the piece also includes the use of a specified amount of packaging tape depending on the specified size of the container as well as other materials such as the insertion of warranty cards, manufacturer's documentation, etc., in the packaging container . As these various packaging materials are consumed during the packaging process, inventories of these items are depleted. The present invention monitors the consumption of these packaging items and automatically generates requests for refills of orders when the inventory control level of the packaging material has fallen below a pre-established value, thus ensuring that inventories do not They run out completely at inopportune times. The method 350 monitors the amount of packaging materials consumed by the packaging material generator 12 in step 352, where, for example, the controller 16 of the packaging system keeps track of the number of each type of packaging container used in step 354, calculate P1739 / 99MX the amount of the packaging material used by the machine 12 in step 356, and keeps track of the other various packaging items in step 358, respectively. In an example of the present invention, step 354 is performed when the packing instructions have been retrieved by the CPU 50 and confirmed by the operator. Since the packaging instructions preferentially identify the appropriate packaging container, the CPU 50 updates a list within a memory such as an inventory database to indicate that one of the identified containers has been used. Similarly, since the packaging instructions will dictate the amount of packaging material to be generated and used for packaging the identified piece (eg, three pads each having a length 60"in Figure 6a) the CPU 50 calculates the total packing material to be used and updates the list within the memory Finally, for each identified piece, the packing instructions will dictate preferably the amount of packing to be used as well as what additional items such as As the warranty cards and documentation are to be packed inside the container, the CPU 50, using the recovered packing instructions, then updates a list within the memory.

P1739 / 99HX continuously lists within the memory, the CPU 50 takes each item within the list and compares them with the predetermined refill thresholds of orders either continuously or periodically, as desired. If an item in the updated list satisfies its associated order refill criteria or threshold, the CPU 50 generates a request for refilling orders in step 360 (Figure 11). In addition, the CPU 50 can generate a consumption report using the list updated in step 362 for revision as desired. Preferably, the refill thresholds of orders can be adjusted as desired. Therefore, if, for example, the procurement procedures change so that orders can be refilled at lower levels of inventory, the order refill threshold can be adjusted, thus making the packaging system dynamic. The order refill thresholds can also be dynamic in the sense that the threshold is a function of the packaging ratio. For example, if the controller 16 of the packaging system via the CPU 50 identifies that the consumption ratio of the various packaging materials is above a certain rate, the controller 16 of the packaging system may increase one or more thresholds to ensure that a request for replenishment of orders is generated in a sufficiently prompt manner for P1739 / 99MX ensure that inventories do not become unduly depleted. Likewise, if the consumption rate falls below a predetermined rate, the controller 16 of the packaging system may decrease one or more thresholds to ensure that a request for order refill is generated at a later time, since the time required for consuming the remaining inventory will be greater and in this way it will prevent excess inventories from being generated. In accordance with the present invention, the method 350 can provide a request for replenishment of orders in various ways. For example, when the CPU 50 determines that a packaging item such as a packaging tape must be refilled (e.g., the amount of remaining packaging tape falling below the associated order refill threshold), the CPU 50 may send the order refill message, requesting that the packaging tape be requested from the peripheral output device 18 (for example, the screen) so that the operator can communicate the order refill request to the personnel in a control department of Inventory. Alternatively, the CPUs can, using the network adapter 90 of Figure 3, transmit the request for refilling orders directly to the inventory control or the purchasing department over a local network. In yet another alternative aspect of the present invention, the P1739 / 99MX CPU 50 can, using a modem, for example, transmit the request for refilling orders directly to the appropriate inventory distributor or to a manufacturer of packaging materials for production planning purposes. In any case, the present invention provides a system and method of automated inventory control to continuously monitor the consumption of one or more packaging materials and refill the materials before their complete exhaustion. Preferably, the CPU 50 updates the packaging materials at various times instead of being continuously. For example, instead of the CPU 50 decreasing a quantity of paper each time a padding conversion machine produces a stowage length, the CPU 50 may alternatively decrease the amount of paper each time a roll of paper is completely consumed. paper and is replaced by a new roll. This function can be performed by a sensor that identifies the end of a roll. Similarly, the CPU 50 can update the BOM each time a ribbon roll, etc. is completely consumed. In yet another aspect of the present invention, the method 350 of Figure 11 can operate in conjunction with multiple generators 12 of packaging materials. In this case, the memory that contains P1739 / 99MX the updated list is shared on a computer network that links the controllers 16 of the packaging system of each packaging system 10. Since each packaging system consumes several packaging items, the list is global then it is updated in a keep going. An example method for monitoring the packaging materials (step 352 of Figure 11) and implementing the order refill control is illustrated in Figure 12a. According to this method, the packaging system 10 via the CPU 50 stores a value representing an initial inventory quantity for the various packaging materials in the memory, which represents the quantity of the materials available. As the various packaging materials are consumed, the CPU 50 updates a consumption list by decreasing the number associated with the article in memory. For example, if fifty (50) type 1 packaging containers are in inventory ("50" stored in a memory location associated with type 1 containers), and the packaging system 10 dictates that one of the type 1 packaging containers is used, CPU 50 decreases the inventory number of type 1 packaging containers in memory to forty-nine (49) The CPU 50, then verifies constantly or periodically to see if the inventory list used meets a refill criteria of P1739 / 99MX orders (for example, fall below a predetermined threshold of order refill) and generates a request for refill orders, if appropriate. In step 361, the CPU 50 determines whether it is time to analyze whether an order replenishment criterion is satisfied. As noted above, the analysis time can be constant (that is, each time one or more packaging materials are consumed) or it can be periodic (for example, every hour, every change, every day, etc.). If the CPU 50 determines according to the instructions programmed in the memory, that it is time to analyze the inventory, the CPU 50 checks one or more inventory levels in the inventory list against an order refill point (i.e. order refill threshold) in step 362. If none of the items in the inventory list satisfy or fall below their associated order refill threshold, the CPU 50 takes no action. However, if they satisfy one or more of the order replenishment criteria, the CPU makes a list of items to be refilled that may include the replenishment quantities of orders, specified, in step 363 that transmits the replenishment list of orders in step 364 via, for example, modem 91, the Internet, facsimile, etc. The order refill request can be sent directly to the operator, to the inventory personnel, P1739 / 99MX to a distributor of packaging materials or to the manufacturer of packaging materials for production planning purposes. According to a preferred embodiment of the present invention, the CPU 50 allows the operator to manually adjust one or more parameters within the inventory list in the case, for example, that one of the materials is inadvertently destroyed and can not be used. in the packaging process. In addition, the CPU 50 decreases the inventory list each time one or more packaging materials are consumed, however, inventory monitoring can be provided in a variety of different ways that are each contemplated as falling within the scope of the present invention. Another alternative, alternative method for monitoring the packaging materials (step 352 of Figure 11) is illustrated in greater detail in Figure 12b. In step 370, the CPU 50 initializes the list to be updated within the memory to zero so that a number of containers as well as several associated supplies indicate that none of the supplies have been consumed yet. Likewise, the CPU 50 in step 372 initializes the length of the packing material (eg, cushion conversion products such as Padpak stowage material) so that the updated list within the memory indicates that it has not been consumed yet. the material of P1739 / 99MX packing. In step 374, a packaging step is performed in accordance with the packaging instructions retrieved by the CPU 50. As previously discussed, the packing step includes the consumption of a particular amount of the packaging material. In step 376, the CPU 50 updates the amount of packaging material consumed by taking the present quantity into the memory (at that particular time = 0) and adds to that quantity the amount of packaging material used in the step of packed. For example, if the packaging step comprises the consumption of a 60"piece of the cushion conversion product, the length within the updated list will be updated to 60" in step 376. Once the length in the Step 376, the CPU 50 compares the quantity of the consumed material to an order refill threshold in step 370. If the order refill threshold is exceeded or exceeded, an order refill message is generated in step 380. Alternatively, the comparison function can be performed periodically, as desired. Once the packing step is completed, the CPU 50 in step 382 asks if the packing process is finished. If the packing process is not finished (NO), the CPU 50 goes to the next packing step in step 384 and updates the list again within the memory according to the quantity P1739 / 99MX of packaging material used in the next packing step. Steps 376, 378, 382 and 284 are shown until all packing steps are completed. The method 352 then proceeds to step 385 in which the CPU 50 increments each of the supplies that are used in the packaging in the previous part. For example, the packaging container specified to tie the piece to be packed is increased so that the updated list indicates that one of the selected containers has been consumed. Likewise, the various packaging supplies such as the packaging tape, warranty cards, etc., used in the packaging of the identified piece are also updated in the step list 385. Each time supplies increase step 358, the CPU 50, in step 386, performs a comparative function in which the various supplies in the updated list within the memory are compared to the predetermined refill thresholds of orders. If the various updated supplies do not meet or exceed the replenishment order thresholds, the CPU 50 does not take any additional action, and the method continues. However, if one or more supplies in the updated list meets or exceeds an associated replenishment order threshold, the CPU 50 generates a request replenishment request message in step 380.

P1739 / 99MX In addition to increasing supplies (step 385) after the completion of all the steps in step 382 (SI), the CPU 50 also asks in step 382 if all the parts to be packed have been packed. If all the parts that have been packaged (YES), the method 352 ends in step 390. However, if it is determined by the CPU 50 that the additional pieces remain to be packed (NO), the CPU 50 begins packing the a new piece via step 394. Therefore, the packing steps for the next piece to be packed are done and the monitoring function continues as previously analyzed. In this way, the method 352 provides an inventory monitoring of an automatic order refill function. According to yet another aspect of the present invention, a packaging productivity monitoring system can also be incorporated into the packaging system of Figure 1. A method 400 is illustrated in Figure 13 to provide this monitoring capability of productivity. As discussed previously, the packaging system 10 of the present invention identifies a part to be packed in step 102 and retrieves a packaging control methodology via a predetermined set of packaging instructions associated with the part identified in step 104. The CPU 50 then transmits the recovered packing instructions P1739 / 99HX to controller 14 to provide proper control of the packing material generator in step 108. As can be seen, the time required to pack the piece consists of the time required to complete each of the necessary packing steps. The present invention provides a synchronization mechanism to determine the time required to pack each identified piece and the time taken to execute each of the steps in the packaging process. In accordance with the present invention, each piece of collected time data is saved in a memory associated with the CPU 50 and used to generate a productivity report for productivity analysis purposes. In Figure 13, when the packaging system 10 identifies a part to be packed, the method 400 initiates, via the CPU 50, a global packing timer in step 402, which is used to determine the amount of time required to pack each piece. In one embodiment of the present invention, a timer 50a associated with the CPU 50 is used. In addition, once the packaging instructions initiate control of the packaging material generator (step 108), the method 400 starts via the CPU 50 one or more timers to determine the amount of time required to complete each step of the process P1739 / 99MX packing predetermined for the piece identified in step 404. Once the packing of the piece identified in step 406 is finished, the global timer is stopped in step 408. In this way, the global timer indicates the amount of time required to tie an individual piece. After the packing of each piece is completed, the CPU 50 takes the time data for each piece of packaging and saves them in a memory such as the hard drive unit 78 of Figure 3. In addition to the time data, the CPU 50 also records other pertinent information such as the identification number of the packaging material generator, an operator identifier, and a code indicating which predetermined set of packaging instructions are associated with the time data. The CPU 50 can then use the saved data in the generation of the productivity report in step 410. Alternatively, the CPU 50 can be programmed to mark the time and mark the date at each step and program additionally to process the various marks of time to finish the time data. The productivity report generated in step 410 can appear as a report 412 as illustrated in Figure 13. In the generation of this report 412, the CPU 50 performs operations P1739 / 99HX mathematics in some of the data according to the instructions programmed to generate the additional productivity features that are useful in the evaluation of higher productivity. For example, for the packaging of a plurality of identical pieces, an overall average time can be calculated according to known techniques to evaluate the average time a given operator takes to finish packing a particular piece. In addition, an average time can be calculated for each step of the packaging process. Therefore, the 412 report allows to analyze which packing steps need to be addressed to improve packaging productivity. Finally, productivity data can be used to document various processes and procedures such as ISO 9001 certification, etc. In addition, the time collected can be normalized in several ways. For example, the time data can be standardized with respect to the particular packing process uniquely associated with the identified piece to allow productivity comparisons through various packaging processes. Using this data you can focus on the particular packaging processes that need improvement. In addition, time data can be normalized across all the various operators to allow direct comparisons between P1739 / 99MX the various operators that perform different packaging processes. This normalization, for example, a 1.0 will indicate an average productivity of packaging while numbers greater than 1.0 will indicate a lower productivity than the average and numbers less than 1.0 will indicate a higher than average productivity. Finally, collected time data can be dated and used to generate productivity trend information to monitor changes in packaging productivity over time. Although the previous example analyzed several steps within the process that can be measured with respect to time, the present invention also contemplates measurement with several other characteristics that can be associated with productivity. Each of these features is contemplated as falling within the scope of the present invention. In addition, while several example mathematical operations are described (and performed by the CPU 50) to generate the productivity characteristics, it is understood that other types of statistical techniques and mathematical operations can also be used to provide other types of criteria. of productivity measurement. Each form of productivity measurement and data manipulation is contemplated as falling within the scope of the present invention.

P1739 / 99MX An example method by which the packaging system 10 can monitor the time required to execute each step for each piece of the packaging process (step 404 of Figure 13) is illustrated in greater detail in Figure 14. A Once the CPU 50 has retrieved the packing instructions associated with the part identified in step 104 of Figure 13, the CPU 50 initiates two count variables ("i" which represents the number of pieces that need to be packed and "j"). "representing the number of steps required to pack each piece) in step 420. In step 422, the CPU 50 transmits the recovered packing instructions to the controller 14 of the generator 12 of the packing material that begins to generate the packing material for the first piece (i = 1) using the first step in that packing process (j = 1). When the first step is started, the CPU 50 initiates a timer in step 424 for part i = 1 and in step j = 1. The CPU 50 then monitors whether the first step (step j = 1) is completed in the step 426. When it is indicated that the first step (step j = 1) ends, (YES) the CPU 50 stops the timer which is measuring the time duration of the first step (step j = 1) in step 428 and stores the value of time in memory. The controller 14 of the packaging generator 12 then continues to the next packing step in step 430 (j = j + 1; j = 2).

P1739 / 99MX The CPU 50 then asks in step 432 if all the steps of the packing process are finished by comparing the incremented variable j (in this case j = 2) to a threshold value that when satisfied indicates that it has been exceeded the maximum number of steps in the particular packaging process. If all the steps are not completed, the variable j is considered equal to the threshold value, and the method 404 will return to step 422 and the controller will generate the packing material for the second step (j = 2) of the first part (i = 1). Similarly, steps 424, 426, 428, 430 and 432 will continue until all the steps in the packing of the first part are finished (YES in step 432), at which point the CPU 50 stops the timer that measures the time total required to pack the piece in step 434. The data regarding the amount of time required to pack the first piece is then stored in the appropriate memory for further analysis. The counter 14 then proceeds to the packing of the next part in step 436 (i = i + 1; i = 2) and the CPU 50 asks in step 438 if all the parts to be packed have been finished (i.e. , if i is equal to a threshold). If all the parts to be packed are not finished, (NO), the method 404 proceeds to step 440, where the CPU 50 resets the variable j of the return step counter to j = 1 and starts the synchronization process for a second piece in step 422, P1739 / 99MX where i = 2 and j = 1. The synchronization of the several steps for the second part (i = 2) then continues with steps 424-432. After the times for the various steps of the piece i = 2 are measured, steps 434 through 438 are repeated again until all the pieces to be packed are finished (equal to the threshold value in step 438) and the method 404 terminates at step 442. The CPU 50 then takes all the data that has been saved for each step j and each part i and saves the data in the appropriate memory for use in generating the productivity report in step 410 which may have a display output similar to report 412 of Figure 13. As discussed above with reference to Figures 1-14, the packaging system 10 of the present invention provides optimized, efficient packing of the various pieces upon identification a piece to be packed, retrieving the predetermined packing instructions associated with the identified package and using the recovered instructions packaged to provide control of the packaging material generator and provide provide graphic / textual packaging instructions to the operator via a display screen. Still another modality in which you can P1739 / 99HX providing functionality is discussed below in conjunction with Figures 15a-15b. The operation of the packaging system 10 in general, and specifically the functions performed by the controller 16 of the packaging system, are described below in detail with reference to the flow diagrams illustrated in Figures 15a-15d. Initially, during the execution of the programmed instructions within the controller 16 of the packaging system, a display is provided on the peripheral output device 18 such as a CRT monitor in step 500, inducing the operator to identify the part that is going away. to pack, such as by providing a part number as well as the number of pieces to be packed. (As used herein, solid lines in the flow chart generally represent a flow of program steps and broken lines indicate the flow of data or messages.) In addition, while the program flow is represented as linear or serial for purposes of simplicity of description, it is recognized that the program is preferably executed in a case-driven manner with the steps that are executed in a time division manner). In the initialization of the operation of the program, a database 501 of the piece and the corresponding packing information is made P1739 / 99MX accessible in step 502, and provides the piece information to the program in an accessible format 504 and the initialization of flags, indicators, containers and / or other program control variables is performed in step 506. The operator then it can indicate to the packaging system 10 the number of the piece or pieces to be packed and the number of pieces to be packed in step 508. Based on the identification of the piece to be packed, the program will retrieve the information for a packing process from the database 501 and provide the operator, as a confirmation, with a description of the piece that the operator identified to pack in step 510. A description may be in the form of the name of the piece or preferably an image of the piece to be packed. The operator then confirms that the program has identified the correct part to be packed in step 512 and the program begins the process of producing pads (in the case where the packaging material generator is a cushion conversion machine) and instructs the operator regarding the proper or recommended packing of the part. First, a flag or monitor indicator is set to one (1) to indicate that the display in monitoring 18 has not been updated then to reflect the beginning of the packaging sequence in P1739 / 99MX, step 514. The program then verifies, as shown in Figure 15b, that the required number of pieces have not yet been packed in step 516. Assuming that the required number of pieces have not yet been packaged, and , as in this example, this is the first time through the program, the program will initialize the current step counter equal to one in step 518, meaning that the correct number of pads of the correct lengths will be produced by the first step in the process of packaging the identified piece. The number of steps that have been executed in the packaging process is then examined in step 520 and if the current step is less than 4 (for a piece-packing process that has three packing steps) and the number of pads that is to be produced is greater than zero in step 522, a code of attention is provided to the controller 14 of the machine in step 524. The purpose of the attention code is to inform the controller 14 of the machine that it starts looking for the appropriate instructions from the controller 16 of the packaging system. Prior to receipt of the attention code, the controller 14 of the machine will ignore any of the codes, such as those generated in a random manner by the noise at the input port of the controller 14 of the machine so as not to take any action not proposed in the case that the noise in the P1739 / 99MX line corresponds to one of the instruction codes to the machine controller in step 524. Once the attention code has been sent to the machine controller in step 524, a synchronized dialog function is implemented through steps 526 to 532 which ensures that the controller 16 of the packaging system of the container 14 of the machine communicates correctly. The dialogue function includes the start of a timer in step 526, which expects to receive a message in step 530 of controller 14 of the machine and verifies any received message to determine whether the received message is the proposed message, for example, the "Ranpak" word in step 532. In the event that the message is not received from the machine controller 14 within the appropriate time, the timer will be interrupted in step 528, an error code will be displayed in step 534 and the The package controller will ask the operator if he attempts to reestablish communication with the controller 14 of the machine in steps 536 and 538. If the operator does not re-establish control of the machine controller 14, the program is terminated, otherwise the program will move in circle again at the start with step 520. Assuming that the message from controller 14 of the machine was received in steps 530 and 532 before the timer stops and the message P1739 / 99 X is the appropriate message, the controller 16 of the packaging system will instruct the controller 14 of the machine as to the number of pads to be produced and its generation order (step 540 of Figure 15c). Alternatively, instead of providing the length of the pad and the number of pads to be produced to the machine controller 14 in one step, the program code section may execute through a circuit in which the The controller 14 of the machine instructs to produce a pad of the appropriate length as many times as necessary to produce the correct number of pads. The communication between the controller 16 of the packaging system and the controller 14 of the machine are coordinated in order through a synchronized dialogue function through steps 542 to 548, similar to the dialogue function described above in relation to the steps 524 to 532 to confirm that the controller 14 of the machine receives the length and number of pads that will be produced. Accordingly, after the controller 14 of the machine has been instructed to produce a pad of the appropriate length in step 540, the timer will be started in step 542 and the program monitors whether a message is received in step 546 before stop the P1739 / 99MX timer in step 544. If the message is received, the message will verify to determine if it was the proposed message. In this case, the proposed message may be a carriage return 548, for example. If the timer is stopped before the message is received, the incorrect message will display an error code in step 534 of Figure 15b and the operator will be notified as to whether the controller 16 of the packaging system should attempt to reestablish communication with the controller 14 of the machine in step 536. Assuming that the appropriate message was received from the controller 14 of the machine, the controller 16 of the packaging system is executing the first packing step for the piece to be packed in step 550, the appropriate display of the monitor 18 will be presented in step 552 and an image of the piece being packaged according to the first step will be displayed in step 554. If this is not the first time in the program for this piece to be packed (NOT in step 550), a delay of 5 seconds is established in step 556 before the image of the piece being packed, according to the next step in the packaging process, is and xhiba in step 554. The purpose of this 5-second delay is for the operator to have time to examine the display of the first step in packing the part before the display is displayed.

P1739 / 99MX visualization by the display screen that corresponds to the second step of the packing of the piece. Concurrently with the display or display of the image of the part being packaged, the controller 16 of the packaging system will begin to request the controller 14 of the machine in a set time interval to provide the status to produce the requested pad or pads (steps 558, 560) and the synchronized dialogue function begins again (steps 570-76), as discussed previously. If the message from the controller 14 of the machine has been received, the message is examined to determine if an error has occurred in the production of the pad in steps 578 and 580 of Figure 15d. If an error has not occurred, the message will indicate either that the cushion conversion machine is still in the process of producing a pad or pads (steps 578 and 580), and the controller 16 of the packaging system will again ask about the production status of the pads (steps 558-576) until it has been determined that the required pads have been produced. The timer is then disabled in step 582 and the controller 16 of the packaging system will continue the next step on the packaging process by incrementing the counter of the packing step in step 584 and adjusting the flag will indicate the display to indicate that an image P1739 / 99MX of the part being packaged is currently being displayed in step 586. The machine controller 14 will then begin the process of producing the pads of the next packing step by providing the package recommendation to the operator (steps 520-586). ). If three packaging weights have been completed for the identified part, as indicated in the step counter which is equal to 4 in step 520 of Figure 15b, the counter of the number of parts is decreased in step 588 and the controller 16 in the packaging step will determine whether the same parts have been packed or not (step 516). If not, the controller 14 of the machine will again produce the necessary pads and will instruct the operator with the recommendations. If similar parts have been packed, the display or display of the peripheral output device 18 is returned to the display indicating the operator of an indication of the next type of piece to be packed (step 590, Figure 15a) and the process is processed. represents for the next piece. In the first embodiment of the present invention, the packaging system is used in conjunction with one or more known parts. A predetermined set of packing instructions is associated with each of the part numbers or identifiers and is retrieved from a memory P1739 / 99MX in response to notification of the piece to be packed. In another embodiment of the present invention, a packaging system is described in which the piece to be packed is unknown. In this context, an unknown part means that the part, together with the predetermined packing instructions associated with the part, do not reside within the associated memory. And instead, the packaging system, according to the alternative embodiment of the present invention, identifies one or more characteristics of the piece to be packed and uses the identified characteristics to determine (instead of recovering) an optimized packing methodology to pack the piece. According to the alternative embodiment of the present invention, an operator who does not have packaging experience can employ an optimized packing of the piece that guarantees the prevention of packaging damage while simultaneously avoiding the use of excess packaging material, reducing the minimum in this way the packing costs for a given piece. According to another aspect of the present invention, once the optimized packing methodology is determined, a prior packing list is provided in the output peripheral device such as a display screen. The packaging preview allows the operator (that is, a user or client) to see the process P1739 / 99MX determined packing to verify that the specific packaging methodology is appropriate. In addition, once the optimized packaging methodology is determined, the packaging system exhibits the costs associated with both the packaging and the shipment of the piece and allows the operator to accept the packing and shipping costs or alternatively discontinue the process. In yet another aspect of the present invention, the packaging system provides packaging options associated with the particular methodology used for packaging both the packaged material generator and the operator and even a peripheral output device. The packing instructions are used to generate an appropriate amount of packing material in a sequence specified by the use of packing the piece. Concurrently, the packaging instructions are used to provide step-by-step explanatory instructions to the operator, preferably via a display screen, in a graphic and textual form. The explanatory instructions illustrate how to properly use the packaging material, generated, in the securing of the piece in the appropriately identified container, thus ensuring that the piece is packaged in an appropriate manner according to the optimized, determined packaging process.

P1739 / 99MX In accordance with one aspect of the present invention, the packaging system controller that determines an optimized packaging methodology includes an expert system. An expert system includes a knowledge base consisting of a plurality of rules and data related to packaging that are applied to the data supplied by the operator that are related to the piece to be packaged to form a conclusion (ie, the optimized packaging methodology). Preferably, the rules consist of "yes, then" rules, although alternate schemes of rules such as the use of "frames" can be used instead of, or in conjunction with, the "if, then" rules for generate conclusions using both the internal data and one or more characteristics associated with the part. These characteristics may include, but are not limited to, the following: the size, shape, weight and fragility of the piece, the shipping method and a preference of whether the packing methodology will be used with respect to the costly packaging. According to yet another aspect of the present invention, the packaging system includes an inventory monitoring system that maintains a list of packaging materials. As the various packaging materials are used according to the particular packaging methodology for the parts, the inventory monitoring system P1739 / 99 X updates the inventory list and compares the updated quantities to one or more order refill thresholds. If any of the order refill threshold conditions are satisfied (for example, equal to less than one threshold or alternatively greater than or equal to a threshold), the packaging system automatically generates an order refill request to prevent the Inventory of the packaging material becomes unduly exhausted. A packaging system 590 according to the alternative embodiment of the present invention is illustrated in Figure 16a. The packaging system 590 includes a controller 592 of the packaging system which is coupled to the generator 12 of the packaging material, which in the preferred embodiment of the present invention is a cushion conversion machine, as illustrated in Figure 2. A peripheral device 18 is coupled to controller 592 of the packaging system. The peripheral output device 18 may include one or more components and preferably includes a freight cost or postage meter 18a to generate the appropriate cost of shipping or postage in response to the identified shipping destination and the shipping weight (including the piece, the packing container and the packing material). In addition, the peripheral output device 18 preferably includes a P1739 / 99MX printer 18b to print a postmark in accordance with the instructions provided by the operator. Finally, the peripheral input device also preferably includes a display screen 18c such as a CRT to provide graphic and textual instructions, step by step in parallel with the generation of the packaging material to assist in the proper packing of the part. The packaging system 590 of Figure 16a also includes a peripheral input device 20 which is coupled to the controller 592 of the packaging system. The input peripheral device 20 may include one or more components and preferably includes a balance 20a for measuring the weight of the article or piece to be packaged. In addition, a dimension measurement apparatus 20b is preferably included to identify the size and shape of the piece to be packed. The dimension measuring apparatus 20b can be a simple device such as a ruler that measures the height, length and width of the piece respectively. However, since many pieces have more detailed three-dimensional shapes than a cube, a measurement apparatus 20b of more complex dimensions can be used. For example, the apparatus 20b may include one or more robotic arms that may find that a plurality of pieces about P1739 / 99MX the piece and record the locations of the various pieces in contact in the three-dimensional space (x, y, z). The apparatus 20b, in conjunction with the CPU 50 of the controller 592 of the packaging system (or using its own processor) identifies the shape and size of the part. In yet another alternative, the dimension measurement apparatus 20b may include a Cubiscan MR measuring system provided by Quantronix, P.O. Box 929, Farmington, Utah 84025, U.S.A. The input peripheral device 20 may also include a keyboard / mouse type input device 20c or touch screen type display, as commonly used with personal computers or a microphone. The keyboard and mouse can be used to enter various features of the part to be packed and / or can be used to access the various selection menus to identify the part or indicate items within a database that are similar to the piece. In addition, the keyboard / mouse 20c can be used to identify the shipping destination, the shipping method (e.g., truck, air or rail) and other types of shipping and / or packing preferences. Collectively, the balance 20a, the dimension measuring apparatus 20b and the keyboard / mouse 20c collect several pieces of data that serve to characterize the piece; The pieces of data include, for example, the weight, size, shape and P1739 / 99MX fragility. Figure 16b is an idealized side view of the packaging system 590 of Figure 16a. The packaging system 590 includes a personal window computer since the 592 controller of the packaging system which is below a desktop work area 593 for packaging. Also under the work area 593 is the printer 18b and the cushioning conversion machine 12. At the top of the work area 593 is the balance 20a, the dimension measurement apparatus 20b, the display screen 18c and the keyboard / mouse 20c. Also in work areas 593 are a series of reservoirs marked 594 for housing a variety of containers or packaging boxes (not shown). At one end 595 of the work areas 593, there is an exit channel 596 for the cushion pads that are produced by the cushion conversion machine 12. A method 600 for packing an unknown piece that is used, for example, the packaging system 590 of Figures 16a and 16b is illustrated in the flow chart of Figure 17. Method 600 begins with the step of identifying a piece that is going away. to pack at step 602. Although the word "identify" is used to describe step 602, it should be understood that method 600 contemplates a function P1739 / 99MX wide to find out one or more characteristics that characterize the piece to be packed while not necessarily identifying the piece itself. Therefore, although step 602 may in some cases be able to collect enough data to fully identify the piece to be packed, in many cases a complete identification of the piece will not be made, and instead the packaging methodology will be will determine based on the various pieces of data that characterize the piece such as weight, size, shape and fragility. Once the piece is identified in step 602, the method 600 proceeds to step 604, where the controller 592 of the packaging system takes the data collected in step 602 and uses it to determine an optimized packaging methodology. And as will be discussed in more detail below, the controller 592 of the packaging system preferably determines the optimized packing methodology using an expert system. Alternatively, however, an indistinct logic circuit, binary decision trees and neural networks can be used in the packaging completion process; and each is contemplated as falling within the scope of the present invention. After the packaging methodology is determined in step 604, the packaging methodology is displayed together with its associated costs of P1739 / 99MX packaged and shipped in step 606. Step 606 is similar to steps 112 and 114 in Figure 5 (see also Figure 6a) while the packaging technology can be previewed by the operator. Although the determination process of step 604 is preferably performed using an expert system, these processes are limited since the rules can not exist for each situation that may cause an incorrect conclusion. In addition, if any of the data is provided via the peripheral input device 20 incorrectly, the packaging system 590 can base its conclusion on erroneous data. Therefore, step 606 of displaying the packaging methodology allows the operator to provide a "reasonableness check" to ensure that the packaging method that has been determined is correct before the generation of any packaging material. In addition, controller 592 of the packaging system, when determining the packaging method in step 604, calculates the packaging costs by adding together the cost of the selected container, the cost of generating the appropriate amount of packaging material and the cost of packaging. the different ones such as the packing tape. The 592 controller of the packaging system also uses the shipping destination, the combined weight of the part and the shipping materials, the shipping method to calculate the shipping costs.

P1739 / 99MX A display of the packaging costs and shipping costs on the 18c display screen, the operator has the opportunity to proceed to 608 if the operator determines that the costs are acceptable. Alternatively, the operator may choose to finish the process or start at step 608. If the operator chooses to proceed with the packing of the part according to the determined, optimized packaging methodology in step 608, the controller 592 of the packed 592 (via CPU 50) then sends the packing instructions that are associated with the particular packing methodology to the cushion conversion machine 12 in step 610 and to the peripheral output device 18 in step 612. The instructions for package sent to the cushion conversion machine 12 in step 12 to 610 are control signals dictating the number of cushion pads to be produced, their respective lengths and their order of manufacture, similar to the description given above in connection with Figure 7. Likewise, the packing instructions sent by the controller 592 of the packaging system via the CPU 50 to the device p eriferic 18 output are control signals that automatically generate the appropriate amount of postage via postage meter 18a, generates a shipping label with the address P1739 / 99MX appropriate via the printer 18b and provide step-by-step packing instructions on the display screen 18c. The packaging instructions on the display screen 18c preferably include graphic displays that illustrate how to use the generated packing material to properly secure the part within the specified container. In addition, textual explanations are also preferably included to further assist in the proper packing of the part. Finally, the packaging controller 16 via the CPU 50 can identify a shipper via a communication link (e.g., modem 91 or interface 90) to pick up the packaged item. The step of identifying the piece to be packed (step 602) is illustrated in greater detail in accordance with an example embodiment of the present invention in Figure 18. Step 602 starts with either the weighing of the piece that is being packed. will pack in step 650 using, for example, balance 20a or by instructing the user to enter the weight via a peripheral input device. The value of the weight is then saved in the memory associated with the CPU 50 of the controller 592 of the packaging system, such as the RAM 60 (see Figure 3). Then, the dimensions, (ie, the size and shape) of the piece are measured and / or are provided in step 652 or the P1739 / 99MX operator by the dimensions. This step by itself may include one or more steps. For example, the packaging system 590 can automatically measure the cubic dimensions of the part using the dimensional measurement apparatus 20b and then asking the operator for the general shape of the object (e.g., it is a cube, a pyramid, or a sphere). , etc) . Alternatively, as described above, a robotic apparatus can be used to correlate the outer contour of the object. In yet another alternative, a pen or mouse apparatus may be used to sketch the general form of the object of step 652. Any method and apparatus for measuring or ascertaining the size and shape of the part is contemplated as falling within the scope of the present invention. The next step in the identification of the piece is to determine the fragility of the piece in step 654. This step can be achieved in a variety of ways, as illustrated in Figures 19a-19c. In Figure 19a, the fragility of the part is identified using a plurality of selection menus. A first selection menu 652 includes a listing of the general categories 664 within which the part may correspond. By highlighting one of the 664a categories, (for example, household items) using for example, the mouse 20c, a second listing of the sub-category 666 is displayed, in P1739 / 99 X where each of the sub-categories 666 are related to the previous selected category 664a (for example furniture and kitchen ranges are considered both household items). The operator can then select one of the sub-categories 666a (ie cookware) using the 20c mouse or alternatively the touch display screen to reveal another more detailed list of the 668 items (eg, pots and pans, dishes, etc.). This process can be continued further until the user selects the actual piece or a piece that is similar to the piece to be packed depending on the fragility. Each end object that is displayed in the selection menus on the display screen 18c has a fragility ratio associated with the part that is stored within a memory associated with the controller 592 of the packaging system (e.g., unit 78). of hard disk) that is used subsequently in the determination of the packing methodology. According to a preferred embodiment of the present invention, the fragility of a product is measured in "G" words which is a measure of the maximum acceleration (ie, the rate of change in velocity over a measured period of time) that The piece can resist without incurring damage. (G is calculated as the ratio of the acceleration of the PX739 / 99MX article packed at the acceleration of gravity, G = a / g). Therefore, the smaller the G factor, the more delicate the piece will be. In an exemplary manner, the G factor for several pieces is determined by subjecting the various products to a series of gradually more severe decelerations (ie, bumps) in order to determine the lowest value at which the damage occurs. Another method for determining the fragility of a part is illustrated in Figure 19b. Figure 19b provides a categorization of fragility from the most delicate (ie, extremely fragile) to the least sensitive (ie, robust), using six categories of fragility 669a. An operator, by selecting one of the 669th categories, will see a variety of example 669 items that fall within the selected 669a frailty category. When comparing the example articles in each category, the operator can have an approximation of the fragility of the piece. Once selected, the CPU 50 saves the G factor associated with the piece in memory such as RAM 60. As illustrated in Figure 19b, the six categories of fragility can be categorized as follows: (I) extremely fragile (approximately 15-25G); (II) very delicate (approximately 25-50 G); (III) delicate (approximately 40-60 G); (IV) moderately delicate (approximately 60-85 G); (V) P1739 / 99 X moderately robust (approximately 85-115 G); and (VI) robust (approximately 115 G and more). It is noted that the categories 669a provided in Figure 19b are exemplary only and few or more categories may be provided as needed. However, it is preferred that the number of categories be sufficient to avoid excessive "educated assumptions" of fragility, since an estimated G factor that is too low results in a package that will be overdesigned and thus unnecessarily increases the costs of packed. Likewise, if a G factor of fragility is estimated too high, the packaging of the product will be sub-engineered, and may result in damage to the product during shipment. Still another way to determine the brittleness (step 654) of the product is illustrated in Figure 19c where automated techniques are illustrated. Step 654 begins upon viewing the object using a viewing apparatus such as a digital camera in step 670. The data comprising the image of the part is then subjected to various forms of image processing using, for example, a processor. images to identify the attributes of the piece that provide indications of fragility in step 672. This image processing may include, for example, segmentation and filtering, as well as the passage of the complete image or P1739 / 99MX image segments through trained classifiers as is well known to those skilled in the art of image analysis. This classification, for example, may include pattern recognition (step 672a), the use of an expert system (step 672b) or in the application of the image to one or more neural networks (step 672c). Other alternatives may include, for example, binary decision trees and the use of an indistinct logic circuit. In addition to step 672, controller 592 of the packaging system can assist the operator or user (not shown) with additional data to fill gaps in the sorting / completion process. These questions may include for example, "Is the object solid?", "Is the object hollow?", "How thick is a piece of the object?", "Is the object made of plaster, ceramic, or glass? ?", etc. The controller 592 of the packaging system then uses the information provided to conclude the fragility of the piece. It is pointed out that the real fragility can not be determined without destroying the piece that is going to be packed, which is obviously undesirable. Therefore, the present invention uses the above example method to include the fragility of the article. If, after asking for additional information, the controller 502 determines that the separations that exist within the data prevents a P1739 / 99MX conclusion within a specified degree of certainty, the controller 502 of the packaging system sends a message to the operator via a display screen 18c that a conclusion can not be drawn regarding the fragility of the product and that it asks the operator to Contact a service representative for additional consultation. Returning now to Figure 18, once the fragility of the part is determined in step 654, the controller 592 of the packaging system asks the operator regarding the packing destination in step 656. In many cases, the operator has the sending destination information in your hand and you can normally enter the data using, for example, the keyboard / mouse 20c or touch type screen. Alternatively, if the operator does not have the information of the sending destination, the user can have access to an address database that resides in a memory such as, for example, the hard drive 78 or a resident CD ROM. in disk unit 72 (see Figure 3). Once the appropriate destination information is established in step 656, the CPU 50 saves the data in memory such as RAM 60. Preferably, the packaging system 590 also asks the operator regarding the desired shipping method by inducing the operator to select, for example, one of aerial, by truck, P1739 / 99MX by ship and rail in step 658. The selection may be generic or may be tailored more specifically, for example, by identifying the particular freight shipping company. The CPU 50 then saves the data in the working memory such as RAM 60 for use in determining the optimal packing methodology. The data collected in step 658 can be used subsequently to determine the height from which the product can be dropped during shipping as well as the effects of vibration, which will be discussed in more detail below. The information can then be used to determine the appropriate packaging methodology. Finally, the packaging system 590 allows the operator to select an optimization option in step 660. For example, as will be discussed in greater detail below, in some cases several packaging options may be available. In these cases, when selecting a packaging optimization preference or a cost optimization preference, the packaging system will select a different packaging method. For example, a selection of the cost optimization preference may allow the system to use a lower certainty threshold in determining the fragility of the product. Alternatively, when a curve is applied P1739 / 99MX cushioning that resides in the memory of the data to a set of rules to determine the appropriate amount of packaging, etc., a selection of a preference can dictate a different point in the cushioning curve, as will be discussed in more detail infra. In yet another embodiment of the present invention, the packaging system 590 can determine two packaging methodologies, wherein one is optimized to ensure a high degree of certainty in the prevention of damage to the shipment while the other is optimized to provide a reasonable degree of certainty in the prevention of shipping damage while seeking to minimize packaging costs. The controller 592 of the packaging system then displays both options on the display screen 18c along with its associated packaging and shipping costs to allow the user to compare and thus select one of the packaging methods. The present invention thus allows substantial flexibility for the operator in selecting an optimization preference in step 660. In addition, the packaging system 10 may also include a user-defined, variable (or alternatively fixed) margin of safety. ) that takes the determined fragility and increases the quantity by a predetermined amount (for P1739 / 99MX example, 20%). With this feature, a margin of safety can be achieved for the purposes of securing the package, for example. This margin of safety can be set by the owner of the packaging system or alternatively by the user through an interactive type menu, as desired. Once the various features of the part and the shipping information are ascertained and saved in the memory associated with the CPU 50, in step 602 of Figure 18, the CPU 50 (alternatively a specialized processor (not shown) operating in conjunction with the CPU 50) determines the optimized packaging methodology in step 604 of Figure 17. According to a preferred embodiment of the present invention, the optimized packaging methodology is determined using an expert system. An expert system is an information system that supports or automates decision making in well-defined situations that require expert knowledge. In this way, an expert system supports or automates decision making in areas where recognized experts do better than non-experts. Consequently, expert systems are well suited for packaging design since an optimized packaging design requires a substantial amount of experience and technical skill. For example, in the design of an appropriate packaging methodology, not only P1739 / 99MX finds a box that is long enough to hold the piece, and then roll or wrap the piece with an arbitrary amount of packing material and subsequently fill in any remaining gaps. On the other hand, an efficient packing design takes into account the fragility of the piece to be packed as well as its size, shape and weight and customizes the packaging method to ensure that the blows expected by the material are absorbed sufficiently. of packaging (for example, cushion pads). In addition, a packaging design can take additional factors into consideration such as comprehensive flow of packing material, the impact of expected temperature conditions on the cushioning ability of the packing material, the possibility of lateral pressure and vibration effects. The present invention takes the expert knowledge and data provided by the experienced packaging designers and separates the information into a set of rules with the appended data in conjunction with the data provided by the operator in step 602 of Figure 17 (which characterizes the piece to be packed) to determine the optimized packing methodology. The expert system of the present invention pros conclusions that dictate a packaging methodology based on the data received from the P1739 / 99MX operator. The conclusions follow from the application of the set of rules and the appended data provided within the expert system (which is often called the knowledge base) to the data or information provided by the operator. In this way, knowledge of the expert system is a combination of instincts, ideas, rules and procedures that guide actions and decisions. In accordance with one aspect of the present invention, the knowledge base can be built into an expert system envelope that is a commercial computer program pro that allows the efficient creation of an expert system. The envelope or expert system environment provides pre-programmed modules for entering rules and data as well as modules for performing calculations and presenting various pieces of information to the user or operator. The expert system can represent knowledge in a variety of ways. Preferably, knowledge is represented in the form of "if, then" rules. Rules of yes are established, then in the form of SI one or more particular conditions are true, THEN some conclusions must be drawn. An example rule of the expert system of the present invention can be illustrated as follows: P1739 / 99 X IF the part occupies a volume V, THEN do not consider packing containers that have a volume less than V.

The previous rule is used in the determination of the appropriate packing containers for the piece to be packed. In the present example, the data necessary to draw the conclusion is provided by the operator in step 652 of Figure 18. However, in many cases the expert system of the present invention will use various approaches to determine whether the given condition is true . As shown above, the data can already be provided by the operator and therefore reside in the database. Alternatively, the system can find out if the condition is true by using the data within the database plus other rules. Finally, the expert system can actively seek additional data by asking the operator questions and / or using other rules to draw a conclusion. Preferably, the expert system of the present invention is like a human expert working on a problem. The expert system uses the knowledge within the knowledge base to draw provisional conclusions based on whether the information is currently available, even if the information is incomplete. When it is not reached P1739 / 99MX a conclusion, use knowledge in the knowledge base to ask questions to ask or determine what data it retrieves in order to make more progress in the search in the packing conclusion. As noted above, you can use yes rules, then to represent knowledge in the knowledge base. Not only can the rules of yes, then be taken in the form given above (ie, naming conditions and conclusions), the rule may contain a certainty factor (eg 0.75) which indicates that a conclusion has a particular probability, but, however, it is uncertain. The certainty factor can then be used as another fact and can be applied in additional rules to arrive at a conclusion and in this way imitate the uncertainty that is often inherent in much of the work that the expert does. Another type of knowledge representation can also be used to build a knowledge base to determine an optimized packaging methodology. This type of knowledge representation is often called "frameworks" that organize the information to make sense of the information and identify any of the unexpected features that are presented. Frames provide a way to organize data around specific situations. By P1739 / 99MX example, when you enter a room your mind processes the visual data and compares it to what your mind expects. In addition, their expectations are different in different types of rooms. For example, when you walk into a kitchen you expect to see a refrigerator, stove, sink and cabinets. However, when it does not, expect to see a computer or filler cabinet in the kitchen although it may already exist in some limited circumstances. Therefore, a framework is a data structure that represents an entity such as a concept, article or class. The framework consists of fields that identify the attributes for that kind of identity. Each field has an entry or value for each attribute that is being considered. Frames can be used in the determination of brittleness in the unknown part by finding a frame that comes closest to the piece. That is, a fragility value or an unknown piece can be derived if a substantial number of attributes very similar to a piece having a known fragility value. Similarly, frameworks that comprise pre-designed packaging methodologies for parts that have specified attributes can be used as a starting point for the design of an optimized packaging methodology. Although yes rules have been described, P1739 / 99MX then and frameworks as example rules and structures to represent knowledge within a knowledge base, it is understood that other structures or methods can also be used to represent expert knowledge and these structures and methods are contemplated as falling within of the scope of the present invention. An example structure for the expert system 700 of the present invention is illustrated in Figure 20. As discussed briefly above, the expert system 700 may reside within the CPU 50 of Figure 3 or may exist as a processing component. separated within the controller 592 of the packaging system of Figure 16. The expert system 700 may include a knowledge base 702, a database 704, a completion machine 706, an interface 708 and an explanation module 710. Although the Figure 20 suggests that the components are physically separate components, this is not required. In contrast, the components of the expert system 700 can be considered as functional components within a processor. In yet another alternative mode, the expert system may be remote and accessed via the network interface 90 or other communication means of Figure 3, thereby making the input / output device a dummy-type terminal.

P1739 / 99MX Knowledge base 702 is a section of memory that contains one or more data sets that relate to packaging material such as cushion pads and a plurality of rulers and / or frames that are supplied by an expert . The database 704 is another section of memory used to store facts and / or characteristics of the piece to be packed provided by the operator via any of the peripheral input devices 20a-20c. In accordance with the present invention, the database 704 may contain the various pieces of data collected in step 602 of Figure 18, as illustrated in Figure 21. The various pieces of data within the database 704 include enunciatively data 712 of the package weight, data 714 of the package dimension (size and shape), fragility information 716, packaging handling information 718, packaging transport information 720, and other packaging data 722, miscellaneous such as compressive creep data, temperature effect data (thermal coefficient), lateral bending data and vibration information. In addition, the data characterizing the piece to be packaged may include a preference 724 for cost / packaging optimization and the data 726 for the dynamic cushion curve for one or more types of packaging material and configurations of the packaging.

P1739 / 99MX packing material. The conclusion machine 706 applies the rules and data within the knowledge base 702 to any of the facts that are provided in the database 704 to decide which question to ask next, either to the operator or back to the database 704 and the knowledge base 702. What questions are then queried by the completion machine 706 depends on the overall objective of the completion machine 706. For example, if the conclusion machine 706 has identified five different facts that must be true in order to to confirm a current work hypothesis, the conclusion machine 706 can ask for these five questions in turn. If either of the answers is negative, the conclusion machine 706 can then leave the current line of reasoning for another. The interface 708 may consist of the display screen 18c the keyboard mouse 20c functionally represents the manner in which the expert system 700 interacts with the operator, if this action is necessary. The 708 interface can operate as a set of text and response questions or can be graphical (or a combination) as desired. Explanation module 710 is optional and is not included in the preferred embodiment of the present invention. The explanation module 710 P1739 / 99MX is made available to the operator via the display screen 18c as a way for the operator to know how a particular conclusion or fact was inferred, or why a particular question is being asked in order to explain the sequence of conclusions that produced a particular conclusion. Figure 22 is an exemplary expert system flow chart 800 illustrating a method in which an expert 700 of the present invention determines the optimized packaging methodology using the packaging material generated by the conversion machine 12. padding of Figure 2 (fitting pads) for an unknown piece. As discussed previously in conjunction with Figures 16-21, the packaging system 590 identifies the piece to be packed (step 604) by obtaining a variety of pieces of information that relate to the piece to be packed ( see Figure 21). Using the data of Figure 21 (ie, the database 704) the expert system 700 applies the data to the various rules within the knowledge base 702 as illustrated in Figures 20 and 22. Initially, the conclusion 706 removes one or more packaging containers 802 from further consideration using data 714 of size and shape of database 704. For example, P1739 / 99MX if the part is 24"long, 12" wide and 12"deep, then any packaging container that contains a volume (V) of less than 24" x 12"x 12" (3,456"cubic) it can not contain the piece and thus is eliminated from further consideration.In addition, given the desired method of sending and the sending destination data 702, the completion machine 706 searches the knowledge base 702 for any of the data 704 of shipping regulation that may prevent or require certain kinds of shipping containers, thereby further reducing the remaining, available containers The completion machine 706 then moves to another analysis since additional information is needed in order to make progress in the selection of the appropriate packaging container The above step 802 is exemplary only and may include additional rules, as desired, then the expert system 700 determines the fall height that the You can find during shipment 806 so that you can continue a considerable analysis regarding what quantities, styles, etc. of knowledge pads will be needed to properly protect the part. The drop height is calculated by the completion machine 706 using the height information 712 within the database 704 and the packaging handling information 718. Using the information 718 of P1739 / 99MX packaging handling, the completion machine 706 can determine if one or more individuals will carry or pull the package and, in conjunction with the height information 712, can identify the likely fall height that the packaged part will experience if the piece It is dropped inadvertently during shipping. For example, if a person is carrying the package and the package is light (for example, approximately 10-20 pounds), the height at which the package can be dropped inadvertently is high (for example, approximately 36"). However, if two individuals are carrying the package and it is heavier (eg, approximately 50-100 pounds) the height of which the package can be dropped inadvertently is lower (eg, approximately 24"). In the above manner, the completion machine 706 using the data within the knowledge base 702 and the data provided by the user within the database 704 determines the potential fall height that the piece may experience in the shipment. The fall height data may then be used by the completion machine 706 in the selection of data 726 from the appropriate dynamic cushion curve in the database 702 when determining the weight of the data from the functional cushioning requirements in case 808. The determination of what class and P1739 / 99MX configuration of cushioning materials will be functionally appropriate (step 808) is preferably performed by the completion machine 706 using a variety of pieces of information. According to an exemplary embodiment of the present invention, a plurality of cushioning curves (graphically shown as Figures 23a, 23n with reference number 810) consist of the data 726 residing from the knowledge base 702. The curves of cushion 810 are evaluated and if any of the curves contain fall heights that do not correspond to the determined fall height of step 806, then they are removed from further consideration with the completion machine 706. A plurality of dynamic cushion curves 810 , of example is given in Figures 23a-23n. Typically, there are many more cushioning curves 810, however, in this example the determined drop height is 30", and therefore, only the cushioning curves 810 having the data at the falling heights of 30" are consider in the subsequent analysis undertaken by the completion machine 706. A dynamic cushion curve 810 illustrates how a packaging material (for a particular configuration of the packaging material) behaves at different levels of impact. The curves of Figures 23a-23n were generated by dropping one P1739 / 99 X series of known weights on a cushion pad configuration sample (not shown) and measuring the amount of blow that the sample allowed to be transferred (i.e., transferred to the piece to be packed). In other words, drop tests simulate falling parts from their expected drop height (step 806). Each point on the curve represents how much load a known part of weight will apply to the cushion pad configuration, and how much blow the cushion will allow it to transfer to the product. The completion machine 706 uses the brittle data 716 and calculates the static charge data 816 using the data of the packaged invention 714 in the database 704 to evaluate which padding configuration sufficient for each orientation piece (since each of the pieces can provide a different static charge value). The cushioning curves of the figures 23a-23n were developed in the following example manner. A 10"by 10" by 4"heavy laminated wooden box was used to simulate the piece to be packed and packed into a 12" by 12"by 12" corrugated container. Several configurations of cushion pads were placed on the bottom of the corrugated container and the heavy product was then placed on the P1739 / 99MX upper of the cushion pad configured. This exemplary cushion pad configuration includes a roll coil configuration that is a length of the cushion material that is wound into a spiral shape, a transverse shape that includes two lengths of cushion material that cross each other and a star configuration including a plurality of lengths of the cushion material that cross each other. In addition, other types of individual pad length configurations were also anticipated as falling within the scope of the present invention and dynamic cushioning curves can be generated for each of these configurations. Still, in addition, the cushioning conversion material itself can be modified using, for example, different types of paper weight. For example, a 30/50/30 3-layer paper stock consists of outer sheets consisting of 30 weight paper and 50 weight inner sheet, respectively. The product box was then weighed to simulate products from one pound (0.01 pounds per square inch) PSI) to 30 pounds (0.30 PSI), thereby providing the data at different static load values. An accelerometer was attached to the product box to record the acceleration levels (in G) for each fall.

P1739 / 99MX The corrugated container was then dropped from a height of 30"(fall height) for each simulated weight of the product.A minimum of five different weights (static load) were used to generate each curve (using adjustment techniques). the curve, known) and the results of the last four drops for each group weight were recorded and averaged.The peak accelerations (G) against static charges (PSI) were then plotted to generate dynamic cushion curves 810. Using the Fragility data 816 within the database 704, each of the cushioning curves 810 is evaluated to see if the cushion pad configuration provides sufficient cushioning to absorb the potential blow for an identified fragility. This relationship is illustrated in Figure 24 which illustrates a spiral / roll cushion pad configuration for a fall height of 30". The fragility data 716 within the database 704 indicates, for example, that the part can only withstand up to 35G without incurring damage. In this way, a horizontal line 812 is drawn, at 35G crossing the cushioning curve 810. If the curve 810 passes through or below the horizontal line 812, then it is confirmed that the cushioning product (the spiral configuration) can not transfer more blow P1739 / 99MX to the piece that the product can withstand with certain conditions of static charge. Then, one or more vertical lines 813 are plotted from the point or points 814 where the horizontal fragility threshold 812 crosses the cushioning curve 810. The vertical lines 813 establish the highest and lowest values of static load at which the configuration of the cushion pad will provide adequate protection. In the example of Figure 24, the values of each statics are 0.03 and 0.24, respectively. It is noted that the static load is defined as the force exerted by the piece to be packed in the padding configuration and is determined by dividing the weight of the piece by the surface of the side of the piece that is coupling the piece. packed material It is pointed out that since the products frequently have different surface areas depending on the orientation, their static charges can also differ according to their orientation. Using the static load data from the weight data 712 and the size / shape data 714, the completion machine 706 is removed from further consideration by any of the cushion pad configurations that can not provide adequate protection for static load 816, determined. The conclusion machine 706 then uses the P1739 / 99MX data collected from the curvature conversion curve 810 to calculate the cushion support area that is the weight of the piece divided by the static load (in this case it is some value between 0.03 and 0.24). To optimize costs, the completion signal 706 will select the configurations that exhibit the highest static load (and thus the lowest cushion support area) because less cushioning product will be suitable for protection and thus reduce the costs of packed. However, since the present invention allows a cost optimization preference to be selected whether packaged, a larger cushion support area can be selected using a lower static load value that increases the packaging protection. It is pointed out in Figure 24, the lowest amount of blow is transferred to the piece at a static load of approximately 0.1; therefore, an orientation of the part in the spiral configuration that produces this static charge value can be selected by the completion machine 706 if a packing utilization preference has been selected. The task of determining the functional cushioning requirements (step 808) further includes considering the impact of the compliant flow of the packaging material using the comprehensive creep data 722. The creep P1739 / 99MX comprehensive is defined as the loss of thickness of the cushion pad under constant load for a period of time. If the amount of creep is too large (in this example embodiment taken to be about 10%) the ability to properly cushion the piece is damaged. The comprehensive creep data is associated only with the packing material and is maintained in the knowledge base 702. The completion machine 706 compares the overall yield of the cushion material to a predefined limit 818 and the data of the 722 comprehensive creep exceed the limit 818, the cushioning option using the maximum static load 816 (in this way the least amount of cushioning) is illuminated and the cushioning curves using a smaller static load 816 are maintained. The packaging system 590 via the expert system 700, more particularly the completion machine 706, also takes into account the effects of temperature in the determination of the functional cushioning requirements. The completion machine 706 uses the temperature effect data 722 which is a function of the packaged material used (in this particular example, the cushion pads are made of paper stock). The knowledge base 702 P1739 / 99MX provides technical coefficients that characterize the dependence of pad cushioning properties on temperature. If the completion machine 706 determines that the thermal coefficient is too large (positive or negative), then the completion machine 706 evaluates the package transport information 720 provided by the operator residing in the database 704. The information Package transport 720 includes, for example, the shipping destination and the shipping method (for example, rail or truck). The completion machine 706 then uses the packet transport information 720 to eliminate any of the cushioning curves that will not provide adequate protection. For example, if the packing location is in Arizona and the destination location is Alaska, and the packing material has a strong thermal coefficient such that the material loses its cushioning capacity as the temperature remains and shipping method is by truck without no thermal control, the completion machine 706 will eliminate the cushioning options that are close to the maximum static load limits and require adjustments to the amount of cushioning material to utilize the packaging design. The expert system 700 also considers lateral bending using the bending data 722 Lateral P1739 / 99MX within database 704 of Figure 21. Lateral flexure is defined as the uniform compression of the cushioning material. When lateral flexion occurs, the energy or hit of an impact is not evenly distributed throughout the cushioning pad, thus resulting in the potential for a greater number of blows to transfer to the piece. Lateral flexion occurs more frequently when the shape of the cushions or cushion configuration is too high and thin. The completion machine 706 analyzes whether lateral bending is a problem in evaluating the lateral bending coefficient 820 and each remaining configuration of the cushion pad with respect to the expected static load exhibited by the product. The lateral bending coefficient 820 is a ratio of the radius 822 of the configuration of the cushioning product and its thickness 824. The inference machine 706 uses the graphic data of Figure 25 which resides in the knowledge base 702. Since the machine At completion 706, the static load is known, the machine 706 determines the lateral bending coefficient 820 graphically and then multiplies the coefficient by the thickness 824 of the cushioning product configuration (which is known) to determine how wide and long it should be. Be the pad to avoid unwanted lateral bending. The machine of P1739 / 99HX conclusion 706 then further removes any of the remaining packing configurations that have a significant risk of lateral bending (ie, those configurations that fail to provide the desired minimum width of the pad). The expert system 700 may further evaluate the impact of the vibration using the vibration data 722 within the database 704 using the data such as those shown in Figures 26a and 26b. As illustrated in Figures 20 and 22 the conclusion machine 706 uses the data within the database 704 together with rules and data within the knowledge base 702 to draw conclusions regarding which packaging methodologies are acceptable and which ones are acceptable. do not. After determining the functional coupling requirements in step 808, a variety of packaging options will most likely still exist in the completion machine 706, it will not need to apply additional rules to further focus an individual solution. For example, the number of containers available in step 802 can be further reduced by determining whether each of the available containers can facilitate the remaining packing options. In addition, the completion machines 706 use P1739 / 99MX the optimization preference data 724 of Figure 21 to select a smaller sub-set of packaging methods that provide either optimized packaging security (i.e., a minimum amount of damage uncertainty) or optimized cost (ie, methods that use the least amount of packaging materials while providing an acceptable amount of damage uncertainty). If an optimization preference is not provided, the expert system 700 of the present invention selects an optimized cost preference as omission. In addition, another rule can also be used to select the best remaining packaging solution. For example, the completion machine 706 may select the packaging methodology that will result in the least amount of waste from the cushion conversion machine (for example, it will result in the smallest number of packaging material generation steps). or the method that requires the least amount of disposal by the operator when executing the packaging method. Other rules that are contemplated as falling within the scope of the present invention may also be used. Although the preferred embodiment of the present invention uses an expert system 700, other types of intelligent systems can alternatively be used and are contemplated as falling within the scope of the invention.

P1739 / 99MX scope of the present invention. For example, the expert system 700 can be replaced with a neural network-type intelligent system. A neural network is an information system that recognizes objects or patterns based on examples that are used to train the neural network. Each training example is described in terms of a number of characteristics, each of which is introduced into a separate neuron or "node". The neural network then combines these inputs in a way that distinguishes between the different objects included in the training examples. The neural network performs identification and discriminates among the various packaging methodologies available by assigning numerical weights to many characteristics. In this way, neural networks can operate well even when some information is absent. In this way, according to an alternative modality, the neural network is trained, where an expert packer designs optimal packaging methodologies while internally applying many of the expert rules analyzed previously in conjunction with the expert system 700. The packer expert therefore communicates a number of system inputs to the neural network that represents the characteristics of the piece to be packed and provides the neural network with the appropriate output (the resulting optimized packing methodology) for P1739 / 99MX the entries given. The neural network then successfully updates its numeric weights at its various nodes to more closely approximate the appropriate output for the input provided. After a significant amount of training, the neural network provides a function to determine the appropriate packing instructions, but in a way that is different from the expert system. The neural network system does not use defined rules (eg, yes rules) to generate conclusions, but the neural network acts blindly on the inputs provided to generate ("determine") an optimized packing methodology. In addition, an inventory monitoring system can be included with the packaging system 590 of Figure 16a. The inventory monitoring system can operate in a similar way to the inventory monitoring system of Figure 12, by way of example. As each operator provides a piece to be packed and continues with the packaging, the inventory monitoring system counts the consumption of the various packaging materials used in the packaging process and updates a list of packaging materials. The inventory monitoring system then compares the list of packaging materials with one or more refill thresholds of appropriate orders and generates P1739 / 99HX automatically requests a replenishment of orders using the CPU 50 to supply the depleted inventories in a timely manner. As discussed above, the packaging system 590 of Figure 16a determines an optimized packing methodology for a piece to be packed. The optimized packaging methodology includes a set of packaging instructions that serve as control signals to the accommodation conversion machine 12 and application instructions to the operator via the display screen 18c. In addition to the control signals to control the operation of the cushion conversion machine 12, the determination of the packaging methodology may also include handling instructions for the cushioning material similar to those discussed above in conjunction with the Figures 8-10c. The manipulation control signals can be used to activate and control either a reel 250 or an automated insertion device such as a system 302 of choice and placement as dictated by the determined, optimized packing methodology. In the description of the preferred embodiment, above of the present invention, a cushion conversion machine 12 was described. The packaging system 590 of the present invention, without P1739 / 99MX However, it can also be used in conjunction with other types of packaging material generators such as generators of loose packing material and distributors, generators and distributors of air wrapping, cushion of air, generators of defibrated material, and generators and distributors of molded pulp. It is understood that any form of package material generator can be incorporated into the packaging system and is contemplated as falling within the scope of the present invention. Furthermore, in the preferred embodiment of the present invention, the determined packaging instructions are used to provide automated control of the generator 12 of the packaging material. Alternatively, the present invention can transmit the specific packaging instructions only to the user or operator who then uses the instructions to manually control the packaging material generator 12. In the prior embodiments of the present invention highlighted above, the packaging systems primarily prepare the packaging of an individual piece. For example, for an individual known piece to be packed, the packaging system retrieves a predetermined set of packing instructions associated with the piece that is used to generate appropriate amounts of material P1739 / 99MX of packaging. In addition, for an unknown piece that is going to be packed, the packaging system identifies one or more characteristics that characterize the piece. Using the features and an expert system that has a knowledge base, the packaging system determines the packaging instructions and uses the instructions determined to control the packaging material generator. According to another alternative embodiment of the present invention, a packaging system is used to jointly pack a plurality of known pieces. The packaging system identifies the pieces to be packed and retrieves the data associated with the pieces from a database. Using data from an expert system having a knowledge base, the packaging system determines the packaging instructions that represent an optimized packaging methodology to pack the plurality of pieces. According to an alternative embodiment of the present invention, the packaging system is used, for example, in conjunction with an air order company or a warehouse distribution facility. A shipping order is created by a customer requesting a plurality of items (ie pieces). A warehouse management system arranges the shipping order to facilitate an efficient recovery of the various items.

P1739 / 99MX When the recovered items arrive at a packing station, the packer implements a verification of the choice list in which a check is submitted to ensure that all recovered items correspond to the items in the shipping order. Preferably, a totalizer in which the items are retrieved contains a bar code that reflects the shipment request. The packer, using the barcode reader, reads the bar code of the totalizer and a barcode on each of the items retrieved to verify that the article in the shipment order is retrieved in an appropriate manner. Once the verification step of the choice list is completed, the packaging system uses the shipping order to retrieve the data associated with each of the items in the shipment order such as the weight, size and fragility of each one. of the articles. The shipping order itself also contains additional data that can be used by the packaging system such as the shipping destination and the shipping method. The packaging system then applies the retrieved data to a set of rules and packing material data in the expert system database to determine packaging instructions that represent a preferred optimized methodology of P1739 / 99MX packaged for a plurality of parts. It should be noted that the expert system of the present invention can use the data such as the size, shape, weight and fragility of the piece in the determination of the optimized or preferred packaging methodology. In addition, the expert system may use additional information such as the cushioning properties of the various pieces to determine the proper orientation of the various pieces with respect to each other within the packaging container. In this way, according to the present invention, the expert system uses and considers the cushioning properties of the pieces by themselves together with the cushioning properties of the packaging material in the determination of packaging methodology. The packaging system then uses the specified packaging instructions to control the packaging material generator (eg, the cushion conversion machine) and thereby produces the appropriate lengths of packing material in the proper sequence to effect the methodology optimized packing. The packaging system also uses the packaging instructions to provide graphic and / or textual guidance to the packer via a display screen to assist in the proper packing of the various items. For example, the display screen P1739 / 99HX will illustrate the order of packaging of the various items and their proper orientation in the specified container along with the manner in which the generated packing material will be used, thereby making the packaging process simpler and clearer. Once the packing is finished in the appropriate container, the container is weighed and compared to an expected weight that includes the expected weight of the pieces, the container and the packing material. If the measured weight is outside the pre-selected tolerance, a warning message is provided to the packer that allows the packer to evaluate the situation and a judgment as to whether an error has occurred in the packing process. If acceptable, the container is sealed using, for example, the packaging tape and the packaging system prints a mailing label in accordance with the destination data provided in the shipping order and prints a bill of lading containing the information which identifies, for example, the sender, the shipment to the address, the number of containers in the shipping order, and the total weight of the shipment. The packaging system also sends the bill of lading data to a manifest system. According to an alternative embodiment of the present invention, the pieces to be packed are placed directly in the container P1739 / 99MX selected by the packaging system. In the alternative mode, the determined packaging methodology determines the order of the selection list and the packaging generator generates (in advance) all the packing material necessary to pack the pieces. The packer then takes the generated packing material and the selected container along with the route of choice (using, for example, a diagram) and then selects a piece according to the choice list, packs the piece in the container using one or more pieces of the packaging material generated. In the above manner, the packing process becomes more efficient by eliminating the step of placing the pieces in the totalizer and subsequently moving the items of the totalizer and packing them in the selected container. According to yet another embodiment of the present invention, the packaging system is portable (for example, on wheels or a portable cart). The packaging system determines the packing methodology and in this way dictates the order of the choice list. The packaging system produces the appropriate amount of material packed at the location of the appropriate part selection along the route of the choice list. The packer then uses the packaging instructions provided for the device P1739 / 99MX peripheral output to then pack the piece in the selected container. In the above manner, the packaged material is provided when needed and the piece is selected and packaged immediately without being placed in an intermediate totalizer. The packaging system includes an inventory management system that counts the receipt of material in the inventory and counts the consumption of inventory when updating a list of packaging materials. The inventory management system compares the up-to-date list of packaging materials to one or more threshold materials for order prestocking. If they meet any of the order sourcing thresholds, the packaging system generates a request for order replenishment directed toward the sold item to ensure that the inventories are replenished in a timely manner. Alternatively, the system can periodically check the inventory and refill at predetermined times. The packaging system of the present invention also includes a productivity monitoring system that collects and summarizes various productivity statistics. For example, the productivity monitoring system collects the data for several productivity criteria such P1739 / 99MX as, for example, the number of packed orders, the number of packed items, the total packed weight, the average time per order and the average amount of the packed material generated per order. In addition, the various time frames can be collected and additional processing can be used to normalize the various productivity criteria, providing trend analysis, etc. Returning now to Figure 27, an operational flow diagram of the packaging system 900 according to the present invention is illustrated. The system 900 includes a container 901 of the packaging system operably coupled (preferably via an electronic data link) to a warehouse management system 902. The controller 901 of the packaging system transmits a number 903 of the totalizer bar code (RF flag collector) representing a shipment request to the warehouse management system 902 when a packer 904 receives a recovered number of items to be packed. The authorization plate of the totalizer is read and the shipment order is determined from the authorization plate using a search table, by way of example. The totalizer contains the recovered items and the authorization plate is read with a barcode scanner or reader 906, without -1739 / 99MX However, any reading device is contemplated by the present invention. The warehouse management system 902 in response to receipt of the bar code of the totaliser 903, provides the controller 901 of the packaging system with the order information 907 which includes a list of the parts in the shipment order and the information that It is related to each item such as the weight, size, shape and fragility of the item. Using the information 907 provided by the warehouse management system 902, the controller 901 of the packaging system determines the packaging instructions 908 which represents a used packaging methodology. The packaging instructions determined by the packaging system controller 901 have several components. Some of the packaging instructions 908 are provided to the packer 904 as graphic / textual instructions that illustrate how to use the packaging material generated to properly pack the various items. Packaging instructions 908 also include instructions 908b which identify the size and quantity of the specified packaging containers and are transmitted to an erector 909 of boxes for the construction of specified containers. The packaging instructions 908 are also communicated to the material generator 12 of P1739 / 99MX packaging (for example, the cushion conversion machine) as control signals 908c that dictate the number and length of cushions to be produced as well as their generation sequence. The instructions 908 also include the specification of the required tape length 908d to a tape sealer 910, the instructions 908e for the generation of a shipping label to the label printer 18b, and the instructions 908f for the generation of a knowledge of Boarding the printer 18b. Finally, controller 901 of the packaging system sends bill of lading data to a manifest system 912 and monitors inventory consumption. If any of the inventories falls below a predetermined threshold, the container 901 of the packaging system transmits an order refill request 913 to a distributor via communication link 914 such as an added value network, EDI. In accordance with one embodiment of the present invention, the manifest system 912 can be used to keep track of the destination of the packaged pieces for tax or other purposes. For example, in certain European countries there are some tax provisions that relate to taxes in terms of waste materials. The manifest system 912 registers P1739 / 99MX the packaging destination (container) and the amount of packaging material used in the packaging parts so that this information can be used efficiently, for example, to comply with the appropriate tax provisions. A block diagram of the packaging system 900 is illustrated in Figure 28. The packaging system 900 includes the controller 901 of the packaging system coupled to the warehouse management system 902 and the packaging material generator 12. In addition, an output peripheral device 18 is coupled to the controller 901 and may include one or more of a postage meter 18a, a printer 18b and a display screen 18c and a peripheral input device 20 may include a keyboard / mouse 20c and a 20d barcode reader. Other peripheral input / output devices may be included and contemplated by the present invention. A method 1000 for packing a plurality of articles into one or more containers according to the present invention is illustrated in Figure 29. When a totalizer containing a plurality of items to be packed is received at the packing station, the The packer reads an order number associated with the items in step 1002, using for example, the bar code reader 20b. The controller 901 of the packaging system of P1739 / 99MX Figure 28 then uses the order number in step 1004 to access the warehouse system containing a database containing all the items in the warehouse as well as the various pieces of data associated with the items such as the number of items in inventory 1006, the size, shape and weight of article 1008 and the fragility of item 1010. The controller 901 of the packaging system then uses the data (e.g., data 1008 and 1010) together with, for example, the shipment destination data from the shipping order to determine the packing instructions resulting in a methodology optimized in the packaging control in step 1012. Once the packaging instructions have been determined, the packaging system controller 901 uses the packaging instructions to control the generator 12 of the packaging material in step 1014 and provides the instructions to the packer 904 and to the display screen 18c in step 1016. The reading step of the order number (step 1002 of Figure 29) produces more detail in Figure 30. The process begins in step 1020 when the installation The warehouse manager receives an order for a variety of items and the warehouse management system 902 assigns an order number to the order. The order is then fixed in step P1739 / 99MX 1022 by the warehouse management system 902 to optimize the recovery of the various items in the shipping order. A large warehouse has many items located in several different areas in the store. To minimize the amount of backspace, etc., the warehouse management system 902 contains location data for each of the items the data is used to arrange the items in the shipping form to generate and optimize a choice list which minimizes the time required to recover the various items. The various items corresponding to the arranged list of choice are then retrieved in step 1024 and put into the packing station in step 1026. The choice list generated by the warehouse management system 902 is then verified from the following exemplary manner in step 1028. A bar code reader 20d reads the order number (or an authorization plate number) from bar code 903 in the totalizer containing the items retrieved. The packer then reads the barcode of each of the recovered items and matches them with the items in the shipment order using the CPU 50 of the packaging system controller 901. If a match is not found, or if an item is absent the CPU 50 or the management system 902 Warehouse P1739 / 99MX generates a warning message that is provided to the packer on the 18c display screen. Once the choice list is verified in step 1028, the controller 901 of the packaging system sends the order number back to the warehouse management system 902 in step 1030 with a request to retrieve all the times it receives in The database of the warehouse management system is related to the parts of the order of the shipping order. These data include, without limitation, the weight, size, shape and fragility of the articles. The step of determining the packaging instructions (step 1012 of Figure 29) is preferably provided in the same manner to the steps illustrated in Figures 20-20b, where an expert system uses a knowledge base and related data. to the packaging material and the pieces to be packed to determine an optimized packaging solution. In addition, intelligent-type alternative systems can be used, such as binary decision trees, indistinct logic circuits and a trained neural network. The packaging system 900 of Figure 28 of the present invention can alternatively or in addition to the use of the rules of if, then, incorporate cubing rules in the knowledge base. In general, using the concept of P1739 / 99MX cubing, the controller 901 of the packaging system ascertains the cubic volume of each item that will occupy when properly packed. The expert system then uses the various cubic volumes to determine its location and orientation within a selected packaging container to maximize packaging efficiency and thus reduce the need to fill in the extra boxes and boxes. An example method for implementing this optimized cubing concept is taught in U.S. Patent No. 5,430,831 entitled "Method of Packing Rectangular Objects in a Rectangular Area or Space by Determination of Free Subareas or Subspaces", which is incorporated herein. mode by reference. In which manner several cubes (ie, parallelepiped volumes) are arranged in different ways to maximize packaging efficiency is illustrated in Figures 31a-31d. In addition, cubing optimization products are commercially available such as OPTIPAK by Advanced Logistics Systems, Inc., Roche Harbor WA 98250. This cubing product can be incorporated into the 901 controller of the packaging system. Therefore, in the above manner, the packaging system uses the data of the parts from the system 902 of the warehouse system and determines the packaging instructions that represent an optimized methodology of P1739 / 99MX packed. Figure 32 is a functional block diagram illustrating the additional functions of the packaging system. After using the instructions determined to control the packaging material generator (step 1014 of Figure 29), the controller 901 of the packaging system, using the shipping order data, prints a shipping label in step 1100 using the printer 18b of Figure 28. Likewise, the controller 901 of the packaging system uses the data of the shipping order to print a bill of lading in step 1102 using the printer 18b. Using the shipping destination and the expected weight as dictated by the particular packaging instructions, the packaging system controller 901 also generates the appropriate postage using the postage meter 18a of Figure 28 in step 1104. The controller 901 of the The packaging system also generates production statistics and performs inventory control in step 1106 and 1108, respectively. The inventory control in step 1108 is similar to the inventory control of Figures 11 and 12 that can be performed for each packing station individually or centrally for all packing stations by communicating consumption data from inventory to P1739 / 99HX split each controller 901 of the packaging system to the warehouse management system 902. Similarly, the packaging system 900 can provide productivity monitoring as illustrated previously in Figure 13 and briefly summarized in Figure 33. Production statistics generation (step 1106) includes counting the order number packaged for a unit time in step 1120 and the count of items packed by unit time in step 1122. In addition, controller 901 of the packaging system also monitors the total weight of the items packed in step 1124 and calculates the time average required to complete an order and the average amount of packaging material consumed per order in steps 1126 and 1128, respectively. The present invention provides effective and efficient packing of parts. Since the packaging system provides packing instructions for one or more pieces, an inexperienced packer can efficiently pack one or more pieces without wasting packaging materials, thereby providing cost savings of approximately 25-50%. invention has been demonstrated and described with respect to certain preferred embodiments, it is obvious that other alterations and equivalent modifications will be presented for others P1739 / 99MX experts in the art in the reading and understanding of this specification and annexed drawings. With particular regard to the various functions performed by the components described above, the terms (including a reference to a "means") used to describe these components are proposed to correspond, unless otherwise indicated, to any component that performs the specified function of the described component (i.e., that is functionally equivalent), although not structurally equivalent to the described structure performing the function in the example embodiments illustrated in the present invention. In the exemplary embodiments of the invention illustrated in the present invention. Furthermore, insofar as a particular feature of the invention may have been described with respect to only one of the various embodiments, this feature may be combined with one or more features other than other modalities as desired and is advantageous for any given application or particular application.

P1739 / 99MX

Claims

NOVELTY OF THE INVENTION Having described the present invention, it is considered as a novelty and, therefore, the content of the following is claimed as property. CLAIMS 1. A packaging system, comprising: a source of packaging material; and a controller of the packaging system for providing packing instructions related to a piece to be packed and instructing the source of packaging material to provide the packing material.
2. The packaging system according to claim 1, wherein the source of the packaging material is a generator or distributor of the packaging material.
3. The packaging system according to claim 2, wherein the packaging material distributor or dispenser is a pads producing or distributing machine, a generator or distributor of loose packaging material to be used as a filler, a wrap generator or distributor. of bubbles, a generator or distributor of defibrated material or a generator or distributor of molded pulp.
4. The packaging system according to any preceding claim, wherein the controller of the P1739 / 99MX packing system retrieves the packaging instructions, which are predetermined and relate to the piece to be packed, from a memory associated with the packaging system controller. The packaging system according to any preceding claim, wherein the package system controller determines the packaging instructions based on at least one characteristic of the piece to be packaged using a set of rules. The packaging system according to any preceding claim, further comprising an expert system associated with the packaging system controller to determine the packaging instructions, wherein the expert system includes a knowledge base containing the rules and associated data with the packaging material, and where the packaging instructions are determined based on an application of the rules and data to the information provided with respect to the piece to be packed. The packaging system according to any preceding claim, wherein a plurality of pieces to be packaged and the controller of the packaging system determines the packaging instructions based on a cubing packing technique. 8. The packing system according to any P1739 / 99MX previous claim, which further comprises a peripheral output device for providing packaging instructions. The packaging system according to claim 8, wherein the peripheral output device comprises at least one of: a screen, a loudspeaker, a printer, a packaging material handling apparatus and a postage meter. The packaging system according to claim 8 or claim 9, wherein the packaging system controller can be operated to communicate the desired functions of the system to the source of packaged material and the peripheral output device in response to the instructions of packed. The packaging system according to any preceding claim, wherein the functions of the system comprise at least one of the iterative packing instructions, a preview of the packaging methodology for at least one identified piece to be packed, control of generation of post-packaging material, maintenance of inventory consumption, automated order of inventories, measurement and analysis of productivity, notification of consignment billing and production planning. 12. The packaging system according to any preceding claim, wherein the instructions Packaging P1739 / 99MX comprise at least one of: the selection of a particular container, the generation of one or more units of packaging material at a given time, and an indication as to how to use the unit or units of material of packaging in a predetermined manner. 13. The packaging system according to any previous claim, wherein the packaging instructions comprise at least one of: a video output, an audio output, a printed output, a text output and a graphic output. The packaging system according to any preceding claim, further comprising a peripheral input device for providing at least one characteristic of the piece to be packed. The packaging system according to claim 14, wherein the peripheral input device comprises at least one of: a keyboard, a mouse, a bar code reader, a microphone, a touch screen, a measuring device of weight, a pattern recognition device and a measuring device for the dimension of the piece. 16. A method for packaging at least one piece, comprising the steps of: identifying at least one characteristic of the piece to be packed; P1739 / 99MX provide packing instructions related to at least one piece; and instructing a source of packaging material to provide the packing material in conjunction with the packaging instructions. The method according to claim 16, wherein the provision of the packaging instructions includes the step of displaying the packaging instructions for review. 18. The method according to claim 16 or 17, wherein the packaging instructions include an identification of a container for adjusting the piece to be packed, an identification of a quantity of packaged material to be used to secure the container part, an illustration of an order in which is placed the packaging material and the piece inside the container or an illustration of an orientation in which the piece and the packed material are placed and secured inside the container. The method according to any of claims 16-18, wherein the step of identifying at least one feature of a part comprises identifying the part, wherein the step of providing packaging instructions comprises recovering a predetermined set of associated packing instructions. with the identified piece. 20. The method according to any of the P1739 / 99MX claims 16-19, wherein the step of identifying at least one characteristic of the piece to be packed comprises the step of determining at least one of the following: size, shape, weight and fragility of the piece. The method according to any of claims 16-20, wherein the step of identifying at least one characteristic of the piece to be packed comprises the step of determining a destination for the piece or determining a shipping method for the piece . The method according to any of claims 16-21, wherein the step of identifying at least one characteristic of the piece to be packaged comprises the step of determining whether a packaging optimization or an optimization of the cost to pack is preferred. the piece. The method according to any of claims 16-22, wherein the step of providing the packaging instructions comprises the step of determining the packaging instructions using information in a database. The method according to any of claims 16-23, wherein the step of providing the baling instructions comprises the steps of: applying one or more rules to at least one characteristic to arrive at a conclusion; Y P1739 / 99HX use the conclusion to eliminate one or more packaging options. 25. The method according to claim 24, further comprising the step of having access to the data that is related in the packaging material when the rules are applied. 26. The method according to claim 24 or 25, wherein the step of applying the rules further comprises the steps of: determining a height from which the piece can fall; identifying a plurality of cushioning curves of various types of packaging material or packing material configurations having data corresponding to the determined height; and determining whether the type of packaging material or the packaging material configurations that refer to the cushioning curves absorb enough shock for a given frailty regime. The method according to any of claims 16-26, wherein the step of instructing the source of the packaged material comprises the steps of: dictating an amount of one or more portions of packaging material; and dictate an order in which one or more portions of the packaging material are produced. P1739 / 99MX 28. The method according to any of claims 16-26, wherein the step of instructing the source of the packaging material comprises operating the source of packaging material to produce one or more portions of packaged material dictated by the packing instructions. 29. The method according to any of claims 16-28, wherein the step of controlling the instructions of the conversion machine further comprises the step of ordering a formation of portions of the packaging material to correspond to a predetermined order of packaging. 30. A method for illustrating a function of a packaging system for packaging at least one part, comprising the steps of: identifying at least one characteristic of a part to be packed; have access to a database that has packaging design rules to determine a packaging methodology based on at least one characteristic; and display the packing instructions for review. The method according to claim 153, wherein the characteristics of the piece to be packaged comprises at least one of the following: weight, size as a shape and brittleness. 32. The method according to any of the P1739 / 99MX claims 16-18, wherein the step of identifying at least one feature of a part comprises identifying the part. 33. A method for packing pieces, comprising the steps of: identifying a piece to be packed; retrieve the packing instructions associated with the piece to be packed; and control a distributor of packaging material using the packaging instructions. 34. The method according to claim 31, wherein the step of entering the part number comprises: orally indicating by a microphone the information identifying the part; and using speech recognition, convert the information into a digital signal corresponding to the part number. 35. The method according to claim 26, wherein the step of recovering the baling instructions comprises the step of having access to a particular set of baling instructions from a plurality of baling instructions stored in a memory. 36. The method according to claim 26, wherein the step of controlling the cushion conversion machine comprises the steps of: dictating an amount of one or more pieces of P1739 / 99MX cushioning material; and dictate an order in which one or more pieces of cushioning material are produced. 37. The method according to claim 26, wherein the step of controlling the cushion conversion machine comprises operating the cushion conversion machine to produce a quantity of cushioning material dictated by the packaging instructions. 38. The method according to claim 37, wherein the step of controlling the padding conversion machine further comprises the step of ordering the forming of pieces of cushioning material to correspond to a predetermined packing order. 39. The method according to claim 27, wherein the step of providing. Packaging instructions to the operator include indicating a preferred container to pack the piece. 40. The method according to claim 27, wherein the step of providing packaging instructions to the operator comprises indicating an amount of cushioning material required to pack the piece. 41. The method according to claim 27, wherein the step of providing packaging instructions to the operator comprises providing an orientation of one or more pieces of the material of P1739 / 99MX padding inside a container. 42. The method according to claim 27, wherein the step of providing packaging instructions to the operator comprises providing an orientation of at least one piece within the container. 43. The method according to claim 27, wherein the step of providing baling instructions to the operator comprises providing a request to pack at least one piece using a plurality of pieces of cushioning material. 44. The method according to claim 27, wherein the step of providing package instructions to the operator comprises: identifying a container for accommodating at least one piece; identifying one or more pieces of cushioning material to be used to secure at least one piece within the container; illustrate an order in which the cushioning material and at least one piece are placed inside the container; and illustrate an orientation in which at least one piece and the cushioning material are placed and secured within the container. 45. The method according to claim 26, further comprising manipulating the piece of cushioning material. P1739 / 99MX 46. The method according to claim 45, wherein the step of manipulating the piece of cushioning material comprises winding the cushioning material to pack at least one piece. 47. The method according to claim 45, wherein the step of manipulating the piece of cushioning material comprises the steps of: transferring the cushioning material to a container; and place the cushioning material in the container. 48. The method according to claim 26, further comprising the step of monitoring a consumption of at least one or more materials used in the packing of the pieces. 49. The method according to claim 48, wherein the step of monitoring the consumption comprises counting a number of containers used in the packaging of the pieces. 50. The method according to claim 48, wherein the step of monitoring the consumption comprises calculating a quantity of cushioning material used in the packing of the pieces. 51. The method according to claim 48, wherein the step of monitoring the consumption comprises calculating a quantity of supplies used in the packing of the pieces, wherein the supplies include at least one of the following: P1739 / 99MX packaged, operating instructions, warranty cards and address labels and identify where the parts are intended. 52. The method according to claim 48, further comprising the step of generating a consumption report that indicates the consumption of one or more materials. 53. The method according to claim 52, further comprising the step of sending the consumption report to at least one of an inventory provider and an inventory forecasting glider. 54. The method according to claim 48, further comprising the step of generating a consignment billing report based on the amount of packaging materials consumed. 55. The method according to claim 48, further comprising the steps of: comparing the consumption of one or more materials to one or more replenishment thresholds of orders; and generate a replenishment request for orders that satisfy one or more of the replenishment thresholds of orders. 56. The method according to claim 48, wherein the step of monitoring the consumption of one or more materials comprises the steps of: initializing a variable representing a quantity of cushioning material in the inventory; calculate a quantity of material from P1739 / 99MX cushioning used in one packing step; decrease the variable representing the amount of cushioning material in inventory by the calculated amount of cushioning material; compare the diminished variable of the cushioning material to a refill threshold of packing material orders; generate an order refill request if the diminished variable satisfies or falls below the refill threshold of orders. 57. The method according to claim 48, wherein the step of monitoring the consumption of one or more materials comprises the steps of: initializing a variable representing a number of packaging containers used in inventory; decrease the variable that represents the number of packaging containers in inventory when a piece is packed; compare the diminished variable with a restocking threshold of orders of the packaging container; and generate an order refill request if the decreased variable is equal to the order refill threshold. 58. The method according to claim 55, wherein the step of generating a refill request from P1739 / 99MX orders include automatically placing an order for additional materials with at least one of: an inventory distributor or a production planner, through a communications link. 59. The method according to claim 53, wherein the consumption report is used for production planning purposes so that an inventory producer can produce the inventory needed before the inventory provider orders the inventory needed. 60. The method according to claim 55, wherein the step of generating an order refill request comprises providing an order refill message on a screen. 61. The method according to claim 26, further comprising the step of monitoring a time amount of one or more steps associated with the control of the cushion conversion machine using the packaging instructions, thereby providing an indication of the productivity. 62. The method according to claim 26, further comprising the step of monitoring a number of packaged packages within a predetermined amount of time, thereby providing an indication of productivity. 63. The method according to claim 62, wherein the step of monitoring the amount of time P1739 / 99 X associated with one or more steps comprises the step of: (a) starting a timer for a step of packing a piece when an instruction to pack the piece is provided; (b) stop the timer when the step ends; and (c) calculate the amount of time used to determine the steps using the timer; and (d) proceeding to a next step to pack the piece and repeat steps (a) - (c) until the piece is completely packaged. 64. The method according to claim 62, wherein the step of monitoring the amount of time associated with one or more steps comprises the steps of: stamping the date of one or more steps, wherein the date stamp includes the time and date on which one or more steps begin and end; and calculate the amount of time of one or more steps using the time stamps. 65. The method according to claim 62, further comprising the step of generating a productivity report that includes the data that relates to the productivity of the packaging of the pieces that includes at least one of an identifier of the cushion conversion machine. , an identifier and operator, an identifier of the packing routine; an amount of time necessary to determine all packing instructions, P1739 / 99MX an amount of time necessary to determine one or more of the packaging instructions, a total number of packages packed per unit time, a normalized productivity value, and a trend indicator. 66. A packaging system, comprising: a packaging material generator; and a controller of the packaging system to provide packing instructions related to a piece to be packed and instructions to the generator of the packing material to produce the packing material. 67. A packaging system, comprising: a generator of packaging material; a visualization to provide packing recommendations to an operator; and a packaging processor for recovering a predetermined packing requirement for a particular part, instructing the generator of the packing material to produce the packing, and causing packaging recommendations to be provided on the display screen. 68. A method for packing pieces comprising the steps of: identifying a piece to be packed; retrieve the packing instructions associated with the piece to be packed; and control a material generator from P1739 / 99MX packing using the packing instructions. 69. A packaging system, comprising: a cushion conversion machine for converting raw material into cushioning material; and a packaging system controller to detect packaging instructions for a part to be packed, instructing the cushion conversion machine to produce the cushioning material in accordance with the specific packaging instructions, and providing an explanation of packed to an operator. 70. The packaging system according to claim 69, further comprising a peripheral output device for providing the packing instructions to the operator. 71. The packaging system according to claim 70, wherein the peripheral output device comprises at least one of a display screen, a loudspeaker, a cushion material handling apparatus, a franking meter and a printer. 72. The packaging system according to claim 71, wherein the handling apparatus of the cushioning material comprises a winder. 73. The packaging system according to P1739 / 99HX claim 71, wherein the cushion material handling apparatus comprises at least one of the following: a choice and placement apparatus, a robot and a pad insertion system. 74. The packaging system according to claim 69, further comprising a peripheral input device for providing at least one characteristic of the piece to be packed. 75. The packaging system according to claim 74, wherein the peripheral input device comprises at least one of a keyboard, a mouse, a bar code reader, a microphone, a touch-sensitive screen, a device for measuring weight, a device of the knowledge of pattern and a measuring device of the dimension of the piece. 76. The packaging system according to claim 70, wherein the controller of the packaging system can be operated to communicate the desired functions of the packaging system to the cushion conversion machine and the peripheral output device in response to the instructions given. of packed. 77. The packaging system according to claim 76, wherein the functions of the system comprise at least one of the instructions P1739 / 99HX iterative packaging, a preview of the packaging methodology for the piece, the post-control of the generation of packaging material, the maintenance of inventory consumption, the automated order of inventory and the measurement and analysis of productivity. 78. The packaging system according to claim 79, wherein the cushion conversion machine comprises a communication controller with the packaging system controller to implement the control functions of the cushion conversion machine in response to the orders to from the controller of the packaging system. 79. The packaging system according to claim 78, wherein the functions of the cushion conversion machine controller comprise at least one of the following: initiating a generation of a selected amount of cushioning material, dividing the cushioning material and providing the cushioning material for packing the identified piece . 80. The packaging system according to claim 69, further comprising an expert system associated with the packaging system controller to determine the packaging instructions. 81. The packaging system according to P1739 / 99MX claim 80, wherein the expert system comprises a knowledge base containing a plurality of rules and data associated with the cushioning material, and wherein the packaging instructions are determined based on an application of the rules and data to the information provided with respect to the piece to be packed. 82. The packaging system according to claim 81, wherein the plurality of rules comprises action-reaction rules, wherein if a certain condition is updated then a specific conclusion is produced. 83. The packaging system according to claim 81, wherein the data associated with the cushioning material comprises at least one of the following: data of the dynamic cushioning curve, data of the static load, data of the thermal coefficient, data of compressive creep and lateral flexion data. 84. The packaging system according to claim 80, wherein the information provided with respect to the piece comprises at least one of the following: weight, size, shape, fragility, shipping destination and shipping method. 85. The packaging system according to claim 69, further comprising a decision tree associated with the system controller of P1739 / 99MX packaged to determine packaging instructions. 86. The packaging system according to claim 69, further comprising a neural network trained and associated with the controller of the packaging system to determine the packaging instructions. 87. The packaging system according to claim 69, wherein the packaging instructions comprise at least one of identifying a particular container generating one or more units of cushion material in a predetermined order. 88. The packaging system according to claim 69, wherein the packaging explanation comprises at least one of a video output, an audio output, a text output, a printed output and a graphic output. 89. The packaging system according to claim 69, wherein the packaging explanation comprises an indication of a cost of packaging and a shipping cost for the packing and shipping of the piece according to the predetermined packaging instructions. 90. A packaging system, comprising: a cushion conversion machine for converting raw material into packaging material; a display screen to provide packing recommendations to a P1739 / 99MX operator; and a packaging processor to determine the packaging requirements for a particular part, giving instructions to the cushioning conversion machine to produce this packing material according to the packaging requirements, and to provide packing recommendations on the screens display. 91. The packaging system, which comprises: a generator of packaging material; and a packaging system controller to determine the packing instructions for a piece to be packed, instructing the packing material generator to produce packaging material in accordance with the specified packaging instructions and provide a packing explanation to an operator 92. The method for packing different pieces, comprising the steps of: identifying at least one characteristic of a piece to be packed; determine the packaging instructions associated with the piece to be packed using at least one characteristic; control a cushion conversion machine using the specified packing instructions to produce the cushioning material. P1739 / 99MX 93. The method according to claim 92, further comprising the step of providing at least a portion of the packaging instructions to an operator as a packaging explanation, wherein the packaging instructions provided indicate how to properly pack the part. . 94. The method according to claim 92, which further comprises the step of providing a preview of the packaging and shipping costs associated with the particular packaging instructions to confirm if an operator wishes to pack the piece according to the certain packaging instructions. 95. The method according to claim 94, wherein the provision of the preview of the packing and shipping costs comprises the steps of: exhibiting the packing costs associated with the example of the piece according to the certain packaging instructions; and display the packaging costs associated with the shipment of the piece according to a selected shipping method and a selected destination. 96. The method according to claim 92, wherein the step of identifying at least one characteristic of the piece to be packed comprises the steps of: determining at least one of a piece size and shape; P1739 / 99 X determine a piece weight; and determine a fragility of the piece. 97. The method according to claim 96, wherein the step of identifying at least one characteristic of the piece to be packed comprises the steps of determining a destination for the piece; determine a shipping method for the piece. 98. The method according to claim 96, wherein the step of identifying at least one characteristic of the piece to be packaged further comprises the step of determining whether a packaging optimization or an optimization of the cost to pack the piece is preferred. 99. The method according to claim 96, further comprising the step of modifying the brittleness determined to provide a safety margin, wherein the modified brittleness is greater than the initially determined brittleness. 100. The method according to claim 96, wherein the step of determining the fragility of the piece comprises the steps of: providing a list of categories having varying degrees of brittleness; provide an indication of what types of items are associated with each category; ask an operator to select one of the categories; and P1739 / 99MX identify a fragility value associated with the selected category in response to the selection. 101. The method according to claim 96, wherein the step of determining the fragility of the piece comprises the steps of: (a) providing a list of generic article categories; (b) select one of the categories with the one that most closely corresponds to the piece; (c) provide a list of sub-categories associated with the selected category; (d) select one of the sub-categories that corresponds closest to the piece; (e) providing another list of sub-categories associated with the sub-classification selected from step (d); (f) select one of the sub-categories of step (e) that corresponds closest to the piece; (g) repeat steps (e) and (f) until the operator identifies the part as a part similar to the piece to be packed; and (h) identify a fragility value that corresponds to the identified piece. 102. The method according to claim 96, wherein the step of determining the fragility of the piece comprises determining the steps of: P1739 / 99MX ask an operator to provide a description of the part; identify at least one feature of the piece in response to the description; and determining the fragility of the piece based on at least one characteristic of the piece. 103. The method according to claim 92, wherein the step of controlling the cushion conversion machine comprises the steps of: dictating a length and an amount of one or more pieces of cushioning material; and dictate an order in which one or more pieces of the cushioning material are produced. 104. The method according to claim 92, wherein the step of controlling the cushion conversion machine comprises operating the cushion conversion machine to produce a quantity of cushioning material dictated by the packaging instructions. 105. The method according to claim 104, wherein the step of controlling the padding conversion machine further comprises the step of ordering the formation of pieces of packaging material to correspond to a packaging order dictated by the particular packaging instructions. 106. The method according to claim 93, wherein the step of providing the instructions of P1739 / 99MX packaged to the operator includes indicating a particular container to pack the piece. 107. The method according to claim 93, wherein the step of providing packaging instructions to the operator comprises indicating an amount of cushioning material required to pack the part. 108. The method according to claim 93, wherein the step of providing packaging instructions to the operator comprises providing an orientation of one or more pieces of accommodating material within a container. 109. The method according to claim 93, wherein the step of providing packaging instructions to the operator comprises providing an orientation of the part within a container. 110. The method according to claim 93, wherein the step of providing packaging instructions to the operator comprises providing an order to pack the part using a plurality of pieces of cushioning material. 111. The method according to claim 93, wherein the step of providing package instructions to the operator comprises: identifying a container to accommodate the identified piece; identify one or more pieces of cushioning material that will be used to ensure the. P1739 / 99MX part identified within the container; illustrate an order in which the cushioning material and the identified part are placed inside the container; and illustrate an orientation in which the identified part and the cushion material are placed and secured within the container. 112. The method according to claim 92, further comprising manipulating the piece of cushioning material. 113. The method according to claim 112, wherein the step of manipulating the piece of the cushioning material comprises winding the cushioning material to at least partially pack the piece. 114. The method according to claim 112, wherein the step of manipulating the piece of the coupling material comprises the steps of: transferring a cushioning material with an automated apparatus; and placing the cushioning material in a container. 115. The method according to claim 92, wherein the step of determining packing selections comprises the steps of: applying one or more rules to at least one characteristic to arrive at a conclusion; and use the conclusion to eliminate one or more P1739 / 99MX packaging options. 116. The method according to claim 115, further comprising the step of having access to the data that relates to the cushioning material when the rules are applied. 117. The method according to claim 115, wherein the step of applying the rules further comprises the steps of: determining a height from which the piece can be dropped; identifying a plurality of cushioning curves of various configurations of the cushioning material having the data corresponding to the determined height; and determining whether the configurations of the cushioning material relative to the cushioning curves absorb sufficient shock for a proportionate rate of brittleness. 118. The method according to claim 117, wherein the step of applying the rules further comprises the steps of: identifying a static load range in which at least one configuration of cushion material absorbs sufficient shock; and calculating a cushion support area using one or more static load values within the range. 119. The method according to claim 118, P1739 / 99MX where the step of applying the rules comprises the steps of: identifying a thermal coefficient of the cushioning material; compare an absolute value of the coefficient to a threshold value; have access to the shipping destination data and shipping data method if the absolute value exceeds the threshold; and adjusting the static charge value if the shipping destination data and the shipping data method indicate that the cushioning material will be subjected to a thermal variation greater than a predetermined threshold. 120. The method according to claim 119, further comprising modifying the brittleness determined to provide a safety margin, wherein the modified brittleness is greater than the initially determined brittleness. 121. The method according to claim 118, wherein the step of applying the rules comprises the steps of: comparing a compressive creep characteristic associated with the cushion material to a predetermined threshold; and adjust a brittleness feature if the threshold is exceeded. 122. The method according to claim 118, P1739 / 99MX where the step of applying the rules comprises the steps of: identifying a static load value for a potential configuration of cushioning material; use the static load value to identify a lateral bending coefficient; use the lateral bending coefficient to establish a minimum dimension for the configuration of cushioning material; and comparing the potential cushion configuration to the minimum dimension to determine if the potential configuration provides sufficient resistance to lateral flexion. 123. A packaging system, comprising: a cushion conversion machine to convert raw material into cushioning material; and a controller of the packaging system for determining the packaging instructions for a plurality of pieces to be packed, with instructions to the cushioning conversion machine to produce cushioning material in accordance with the specified cushioning instructions and to provide an explanation of packed to an operator. 124. The packaging system according to claim 123, further comprising a P1739 / 99MX peripheral output device that includes at least one of a postage meter, a printer, a display screen, a network adapter and a modem. 125. The packaging system according to claim 123, further comprising a peripheral input device that includes at least one of the following: a bar code reader, a keyboard, a mouse, an RF tag reader and a device of recognition of optical characters. 126. The packaging system according to claim 123, further comprising a warehouse management system in communication with the packaging system controller to provide the packaging system with a packing list of items to be packed and the data associated with the items that are going to be packed. 127. The packaging system according to claim 126, wherein the data associated with the articles to be packaged includes at least one article weight, the set of physical dimensions of the article and a fragility of the articles. 128. The packaging system according to claim 123, further comprising an inventory management system associated with the packaging system controller, wherein the P-739 / 99MX management system monitors the consumption of packaging materials and provides the indication if any of the packaging materials falls below a predetermined level. 129. The packaging system according to claim 128, wherein the packaging materials include at least one of packaging containers, cushioning material and packaging tape. 130. The packaging system according to claim 1289, further comprising a communication apparatus coupled to the inventory management system for transmitting an order refill request for one or more packaging items if one or more packaging items is determined to be have fallen below the predetermined level. 131. The packaging system according to claim 128, further comprising an apparatus for identifying where the pieces are destined. 132. The method according to claim 128, wherein the inventory management system can be operated to generate a consignment billing report based on the amount of packaging materials consumed. 133. The packaging material according to claim 123, wherein the controller of the packaging system comprises an expert system for P1739 / 99MX determine the packaging instructions that include a selection of at least one particular packaging container, an amount and order to produce the appropriate lengths of the cushioning material and an arrangement and order to pack the plurality of pieces in at least one container of packed. 134. The packaging system according to claim 133, wherein the expert system comprises: a knowledge base containing a plurality of rules and data associated with the cushioning material; and a conclusion machine to apply the rules and data to the information associated with the pieces to be packed to draw conclusions in the determination in the packaging instructions. 135. The packaging system according to claim 133, wherein the packaging system uses a set of cubing rules to dictate the location of the parts to be packed in the packaging container. 136. A packaging system, comprising: a packaging material generator; and a controller of the packaging system for determining the packaging instructions for a plurality of pieces to be packaged, instructing the generator of the packing material to produce packing material in accordance with the specified packaging instructions and providing P1739 / 99MX an explanation of packaging to an operator. 137. A method for packing a plurality of pieces, comprising the steps of: identifying a plurality of pieces to be packed; recover the information associated with the pieces that will be packed; determine whether packaging instructions associated with the pieces to be packed using the information associated with the pieces; and controlling a generator of the packaging material using the methodology of the packaging control, determined. 138. A method according to claim 137, wherein the step of identifying the plurality of parts comprises the steps of: reading an order number using a bar code reader; and retrieving a list containing a plurality of pieces associated with the order number from a database. 139. The method of claim 137, wherein the step of identifying the plurality of pieces comprises the steps of: receiving a choice list from a plurality of items, wherein the choice view contains an order number; Fix the list of choice to optimize P1739 / 99MX a recovery of the plurality of articles; recover the plurality of items from a warehouse using the arranged pick list; send the recovered plurality of articles to a packed station; and check the list of choice when comparing the recovered parts to the list of choice. 140. The method according to claim 139, wherein the recovery of the plurality of articles comprises the selection of the articles and the placement thereof in a selected container. 141. The method according to claim 137, wherein the step of identifying the information associated with the pieces to be packed comprises the steps of: entering an order number associated with the plurality of pieces in a warehouse management system; identify each piece associated with the order number, have access to a database that has the pieces to be packed and the information associated with the pieces; and retrieve the information of the pieces associated with the order number from the database. P1739 / 99MX 142. The method according to claim 137, wherein the step of determining the packaging instructions comprises the steps of: applying one or more rules within a knowledge base to the information associated with the pieces to arrive at a conclusion; and use the conclusion to eliminate one or more packing instructions. 143. The method according to claim 142, further comprising the step of accessing the data is related to the cushioning material when the rules are applied. 144. The method according to claim 142, wherein the step of applying the rules further comprises the steps of: determining a height at which the piece can be dropped using the data relating to a shipping method; identifying a plurality of cushioning curves of various configurations of cushioning material having the data corresponding to the predetermined height; and determining whether the configurations of the cushioning material that are related in the cushion curves absorb enough shock for a proportion of fragility provided. 145. The method according to claim 144, wherein the step of applying the rules comprises P1739 / 99MX further the steps of: identifying a static load range in which at least one configuration of cushion material absorbs sufficient shock; and calculating a cushion support area using one or more static load values within the range. 146. The method according to claim 145, wherein the step of applying the rules comprises the steps of: identifying a thermal coefficient of the cushioning material; compare an absolute value of the coefficient to a threshold value; have access to the shipping destination data and the shipping method data if the absolute value exceeds the threshold; and adjusting the static charge value if the shipment destination data and the shipping method data indicate that the cushion material will be subjected to a thermal variation greater than a predetermined threshold. 147. The method according to claim 145, wherein the step of applying the rules comprises the step of: comparing a compressive creep characteristic associated with the cushion material to a predetermined threshold; Y P1739 / 99MX adjust a fragility characteristic if the threshold is exceeded. 148. The method according to claim 145, wherein the step of applying the rules comprises the step of: identifying a static load value for a potential configuration of the cushioning material; use the static load value to identify a coefficient of lateral friction; use the coefficient of lateral friction to establish a minimum dimension for a configuration of the cushioning material; and comparing the potential cushion configuration to the minimum dimension to determine if the potential configuration provides sufficient resistance to lateral friction. 149. The method according to claim 147, wherein the step of determining the packaging instructions comprises the steps of: applying one or more location rules to the information associated with the pieces, to arrive at a conclusion; and use the conclusion to dictate an optimized arrangement of the pieces within a specified container. 150. A method to illustrate a function of a packaging system for packing at least one P1739 / 99MX piece, comprising the steps of: identifying at least one piece to be packed; have access to a database that contains information that relates to at least one piece; provide packing instructions related to at least one piece; and display the packing instructions for the review. 151. The method according to claim 150, wherein the step of providing the packaging instructions comprises the step of recovering a predetermined assembly and packing instructions associated with at least one piece. 152. The method according to claim 150, wherein the step of providing the packaging instructions comprises the step of determining the packaging instructions using the information of the database. 153. A method for illustrating a function of a packaging system for packaging at least one part, comprising the steps of: identifying at least one characteristic of a part to be packed; have access to a database that has packaging rules to determine a packaging methodology based on at least one characteristic; Y P1739 / 99MX display packing instructions for review. 154. The method according to claim 153, wherein the characteristics of the piece to be packed comprise at least one of a weight, a size, a shape and a brittleness. 155. A packaging system, comprising: a distributor of packaging material; and a packaging system controller to provide the packing instructions related to a piece to be packed and instructing the distributor of packing material to distribute the packing material. 156. A packaging system, comprising: a distributor of packaging material; and a packaging processor to recover a predetermined packing requirement for a particular piece, and instruct the distributor of the packing material to distribute the packing material. 157. A method for packing pieces, comprising the steps of: identifying a piece to be packed; retrieve the packing instructions associated with the piece to be packed; and controlling a distributor of packaging material using the packaging instructions. 158. A packaging system, comprising: P1739 / 99MX a distributor of packaging material; and a packaging system controller to determine the packing instructions for a piece to be packed, instruct the distributor of the packing material to distribute packing material in accordance with the specific packaging instructions, and to provide an explanation of packed to an operator. 159. A method for packing different pieces, comprising the steps of: identifying at least one characteristic of a piece to be packed; determine the packaging instructions associated with the piece to be packed using at least one characteristic; and controlling a distributor of packaging material using the specified packaging instructions to produce the cushioning material. P1739 / 99MX