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`
`US007225040B2
`
`(IO) Patent No.: US 7,225,040 B2
`
`c12) United States Patent
`(45)Date of Patent:
`May 29, 2007
`
`
`Eller et al.
`
`(54)METHOD AND SYSTEM FOR REDUCING
`
`LEAD-TIME IN THE PACKAGING
`INDUSTRY
`
`(75)Inventors: Robert J. Eller, Webster, NY (US);
`
`
`
`Joseph J. Cardillo,
`Fairp ort, NY (US)
`
`5,991,783 A 11/1999 Popa et al. . ................ 707 /522
`
`
`
`
`
`
`
`
`
`6,036,345 A 3/2000 Jannette et al.
`6,067,406 A 5/2000 Van Hoof et al. .......... 395/109
`
`
`
`
`
`
`
`6,167,382 A * 12/2000 Sparks et al .................. 705/26
`
`
`
`
`6,247,507 Bl* 6/2001 Soehnlen et al. ... ... .. ... ... 141/2
`
`
`
`
`6,415,196 Bl* 7/2002 Crampton et al. .......... 700/100
`
`
`
`
`
`6,611,727 B2 * 8/2003 Bickley et al. . .............. 700/99
`
`(73)Assignee: Exxon Mobil Oil Corporation,
`
`
`Houston, TX (US)
`
`JP
`WO
`
`
`
`( *) Notice: Subject to any disclaimer, the term of this
`WO
`
`
`
`patent is extended or adjusted under 35
`WO
`
`U.S.C. 154(b) by 928 days.
`
`FOREIGN PATENT DOCUMENTS
`
`
`10320454 4/1998
`
`WO 98/08176 2/1998
`
`WO 99/63452 12/1999
`
`WO 00/60523 10/2000
`
`OTHER PUBLICATIONS
`
`(21)Appl. No.: 09/992,345
`
`
`
`Nov. 14, 2001 (22) Filed:
`
`Mathias Weske, "Flexible Modeling and Execution of Workflow
`
`
`
`
`
`
`Activities," hicss, p. 713, Thirty-First Annual Hawaii International
`
`
`Conference on System Sciences-vol. 7, 1998.*
`
`(65)
`
`
`
`P rior Publication Data
`
`* cited by examiner
`
`
`
`US 2003/0090722 Al May 15, 2003
`
`
`
`Primary Examiner-Michael D. Masinick
`
`
`
`(57)
`
`ABSTRACT
`
`(51)Int. Cl.
`G06F 19/00 (2006.01)
`
`
`(52)U.S. Cl. ........................ 700/100; 700/99; 700/106;
`A system for integrating a packaging supply chain from a
`
`
`700/107
`
`
`
`point that a digital contract proof is available through
`(58)Field of Classification Search .................. 700/99,
`
`
`
`
`
`
`delivery of finished packaging materials to an end user,
`
`
`
`700/100, 106, 107; 705/22-25, 29
`
`
`wherein said system comprises a computer system acces­
`
`
`
`See application file for complete search history.
`
`
`
`sible for interactive communications with users, said com­
`
`puter system comprising a first memory area for storing
`
`
`functionality and data for end user members of the supply
`
`
`chain; a second memory area for storing functionality and
`
`
`
`data for converter members of the supply chain; and a third
`
`
`memory area for storing functionality and data for other
`
`members of the supply chain.
`
`(56)
`
`
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5,231,567 A 7 I 1993 Matoba et al.
`
`
`
`5,559,708 A 9/1996 Turnbull
`
`et al.
`
`5,657,453 A 8/ 1997
`
`Taoka et al.
`
`5,960,164 A 9/1999 Dorfman
`
`et al. ............ 395/110
`
`
`
`5,982,996 A 11/1999
`
`
`
`Snyders ...................... 395/114
`
`36 Claims, 63 Drawing Sheets
`
`System Overview
`
`t.O
`
`2.0
`
`3.0
`
`4.0
`
`Order
`Plan
`Schedule Plan Material
`Production Management Orders Requirements
`
`I
`
`I
`
`I
`
`I
`
`
`-
`
`Resource Requirements/Resource Availability
`
`-
`
`PACKAGE DESIGN
`
`CONVERTER
`
`CiM Ex. 1014 Page 1
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 1 of 63
`
`US 7,225,040 B2
`
`Figure 1
`
`System Overview
`
`
`
`
`
`
`
`
`
`
`
`
`
`Plan
`Production
`
`Management
`
`Schedule
`Orders
`
`Plan Material
`Requirements
`
`Resource Requirements/Resource Availability
`
`
`
`PACKAGE DESIGN
`
`CONVERTER
`
`CiM Ex. 1014 Page 2
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 2 of 63
`
`US 7,225,040 B2
`
`Figure 2
`
`F------------------------------
`Sales History
`;
`Monthly
`:
`———º
`!
`:
`Demand
`Forecasting
`: º
`ProceSS
`:
`By capacity group.
`- S&OP Worksheet
`:
`demand length,
`#jobs
`- S&OP Tables
`
`Market Intelligence
`
`:
`>
`|
`
`- - - - - ---------------------------
`
`
`
`1.1
`S & OP Process
`
`job
`
`3-12 Month Decisions
`‘....:..)
`
`------------------------------
`Rates & Efficiencies
`—- ;
`:
`Monthly Production
`:
`:
`-
`:
`Forecasting
`:
`lº
`!
`
`Operating Sched
`
`
`
`-
`Capacity
`By month.
`by line,
`available hours
`rtainteriance Hours
`"other" inqurs
`holiday hours
`
`- S&OP Reports
`
`4 - 2 Month Cecisions
`(eg. delay i accelerate outages...}
`
`
`
`
`
`
`
`
`
`
`
`2.3
`Place An Order
`
`
`
`Request
`Quantity &
`Cale
`
`
`
`1.2
`MPS Process
`
`
`
`- See Section IV
`
`- MPS Worksheet
`
`- MPS Tables
`- MPS Reports
`
`Actual Demand
`
`Actual Mfg Perf
`
`Line Availability—
`
`CiM Ex. 1014 Page 3
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 3 of 63
`
`US 7,225,040 B2
`
`Figure 3
`
`
`
`1.1.1
`Load Demand Into
`S&OP Model
`
`1.1.2 & 1.1.3
`Load Availability
`And Rates Into
`S&OP Model
`
`1.1.5
`Inventory Build Or
`{}raw
`
`1.1.6
`Adjust Line
`Allocation To
`Capacity Groups
`
`1.1.2
`Adjust Line Hrs
`
`1.1.3
`Adjust Line Rates
`and Efficiencies
`
`1.1.1
`Adjust Demand
`
`1.1.4
`S&OP Model
`
`- Copy Last Months Loading To This Month
`- Adjust Loading To Balance Utilization
`- Checksum Column Should Be 100%
`
`Are Cap Grps in
`Balance?
`
`Yes
`
`To 1.2 MPS
`
`: M
`:
`Demand
`; :... : ::
`—- Forecasting :
`: "...
`!
`:
`!---------------->
`
`
`
`
`
`
`
`:
`:
`> Pº ;
`t
`* :
`Forecasting :
`
`Line output
`- Rates By Product & line
`- Material Eff By Prodict & Line
`Line Availability
`- Hrs. Mon By Line
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`CiM Ex. 1014 Page 4
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 4 of 63
`
`US 7,225,040 B2
`
`Figure 3A
`
`
`
`Plan Capacity - S & OP Demand
`
`CONFIDENTIAL
`
`saenre Plan 1.1.1
`
`CiM Ex. 1014 Page 5
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 5 of 63
`
`US 7,225,040 B2
`
`Figure 3B
`
`
`
`Plan Capacity - S & OP Line Availablilty
`
`Plan Capacity - 8 & OP Line Availability
`
`6
`
`º
`
`#EEEE
`#
`o #:
`
`of 4
`
`Qi
`
`CONFEDENTHAL
`
`CiM Ex. 1014 Page 6
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 6 of 63
`
`US 7,225,040 B2
`
`Figure 3C
`
`
`
`CONFIDENTIAL
`
`sever No Plan 1.1.3
`
`CiM Ex. 1014 Page 7
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 7 of 63
`
`US 7,225,040 B2
`
`Figure 3D
`
`
`
`Plan Capacity - S & OP
`
`TET
`:
`i class of Demand
`ipemandi Length i &
`# 10s
`6,500 :
`i
`8S
`5,000
`#TESTET2.505. TIET:
`; Pool
`35,000
`210 ;
`
`CONFIDENTIAL, DO NOT DUPLICATE
`
`saeen N. Plan 1.1.4
`
`CiM Ex. 1014 Page 8
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 8 of 63
`
`US 7,225,040 B2
`
`Figure 3E
`
`
`
`Plan Capacity - S & OP Inventory Bulld Or Draw
`
`Plan capacity-s & OPimentory Draw or Build
`
`CONEIDENTHAL
`
`CiM Ex. 1014 Page 9
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 9 of 63
`
`US 7,225,040 B2
`
`Figure 3F
`
`
`
`Plan Capacity - S & OP Line Allocation To Capacity Groups
`
`CONF#DENTIAL
`
`No. Plan 4.1.8
`
`CiM Ex. 1014 Page 10
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 10 of 63
`
`US 7,225,040 B2
`
`Figure 3G
`
`
`
`Plan Capacity - S & OP Display Capacity Group Demand Averages
`
`Plan Capacity - 8 & OP Display Capacity Group Demand Averages
`
`CONFIDENTHAL
`
`CiM Ex. 1014 Page 11
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 11 of 63
`
`US 7,225,040 B2
`
`Figure 4
`
`:
`:
`
`MPS
`Process
`
`:
`:
`
`:
`:
`
`Take
`Orders
`
`
`
`1.2.1
`MPS Display
`- Review Cap Group Loading
`
`
`
`
`
`
`
`
`
`
`
`1.29
`Display Bucket
`Detail
`
`Display Bucket
`Detail
`
`Are Cap Grps in
`Balance?
`
`
`
`
`
`
`
`
`
`Yes
`
`1.2.2 Inventory
`Build Or Draw
`(Adj Hours)
`
`1.2.3 Adjust Line
`A??ocation To
`Capacity Groups
`
`
`
`1.2.6
`Move Orders
`
`CiM Ex. 1014 Page 12
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 12 of 63
`
`US 7,225,040 B2
`
`Figure 4A
`
`
`
`Plan Capacity - Master Production Schedule (MPS)
`
`st----enal Servic--
`
`Lotsawaii. i.i.
`Hota used
`
`.144.144.444
`1211 114|| 4 do
`
`CiM Ex. 1014 Page 13
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 13 of 63
`
`US 7,225,040 B2
`
`Figure 4B
`
`
`
`Plan Capacity - MPS Inventory Bulld Or Draw
`
`Plan Capacity. MPS Invertory Draw or Bulid
`
`CONF#DENTHAL
`
`CiM Ex. 1014 Page 14
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 14 of 63
`
`US 7,225,040 B2
`
`Figure 4C
`
`
`
`Plan Capacity - MPS Line Allocation To Capacity Groups
`
`Ptan Capacity • MPS Lins Allocation To Capacity Groups
`
`sºil. IIHFI IIHEIILIHEIT
`U.
`º.
`
`GONFIDENTIAL
`
`CiM Ex. 1014 Page 15
`
`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 15 of 63
`
`US 7.225,040 B2
`
`:
`:
`:
`
`MPS
`Process
`
`:
`:
`:
`
`m)
`
`12.
`:
`: MPS Display
`i.…~~~~
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Figure 5
`
`
`
`1.2.4
`Adjust Line
`Availability
`
`1.2.5
`Adjust Line Rates
`and Efficiencies
`
`Re AFP Orders?
`
`1.2.8
`---
`ReATP Orders
`
`6.1.8
`Adjust Slotting Alg
`
`
`
`End
`
`CiM Ex. 1014 Page 16
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 16 of 63
`
`US 7,225,040 B2
`
`Figure 5A
`
`
`
`Plan Capacity • Line Ava?tability
`tino Availability (hours)
`
`Line Category
`
`* | * is | 20 23
`138||1881.185
`of
`Qi
`o
`
`a a as 25 as
`E. O
`
`o
`
`o
`o
`
`rtual Informatiºn
`
`§
`
`Riaint Hºrs
`
`il?3.138:168
`to
`12:
`G
`
`1884.168; 163.1881.138
`188!I.
`d
`24
`O
`o
`o
`o
`
`CONFIDENTIAL, DO NOT DUPLCATE
`
`screen tº
`
`Plan *,2,4
`
`CiM Ex. 1014 Page 17
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 17 of 63
`
`US 7,225,040 B2
`
`Figure 5B
`
`
`
`Plan Capacity - MPS
`
`Plan Capachy • MPS, Ratºs and Effickenches, Averages
`Process stop ?ºming
`:
`ºf Bucket
`17
`:
`Year
`
`-
`
`CONFEDENTHAL DO NOT DUPLICATE
`
`CiM Ex. 1014 Page 18
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 18 of 63
`
`US 7,225,040 B2
`
`Figure 5C
`
`
`
`Plan Capacity - Capacity Group Setup
`
`Plan Capacity - Capacity Group Setup
`Process Step
`Bºrº -
`--- -
`y Group Abreviation 193—3
`‘sºci:
`capacity Go
`---
`-
`-
`s:tºs Capacity Group Description [Tºsaton
`º -
`
`CONFIDENTIAL, DO NOT DUPLBCATE
`
`CiM Ex. 1014 Page 19
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 19 of 63
`
`US 7,225,040 B2
`
`Figure 6
`
`End User Processing
`
`:
`
`Converter Processing
`
`i-—
`
`
`
`
`
`Processed
`Orders
`cº
`
`-
`
`2.5
`Process
`Orders
`- saleci ºrders
`• Check ATP y Aroc
`
`Itern tº
`
`:
`
`2.7
`Interface To
`Legacy
`AManagement
`
`Comyerter
`legacy
`ERP
`Systern
`
`
`
`
`
`2.3
`Acquire timage
`
`CiM Ex. 1014 Page 20
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`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 20 of 63
`
`US 7,225,040 B2
`
`Figure 7
`
`End User
`:
`Packaging
`:
`: Requirements
`
`|tern Exist?
`
`No
`
`2.2
`{Create ?tern
`
`Yes
`
`2.1.1
`Place Order
`
`2.4, 1
`Run Auto ATP f
`Alloc Check
`
`Pass ATP/
`Alloc?
`
`No.
`
`
`
`
`
`2.5
`Process Pending
`Crders
`
`Yes
`
`2.7.1
`Update Legacy
`OMS Systern
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`No
`
`2.5
`Process Pending
`Orders
`
`CiM Ex. 1014 Page 21
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 21 of 63
`
`US 7,225,040 B2
`
`Figure 7A
`
`
`
`Place Order - End User
`
`Place order . End user
`
`Sold To Custorner #
`555 TZ3-E.
`
`Actual information
`
`Date Req
`Cuantity
`Cºuantity
`Cuantity
`
`[375,000. Tºs. Tº
`53.467 - M.
`2,557
`Kg
`
`Status
`
`Ferding
`
`:
`
`via Fermo, 26
`61:00 Pesaro (Italia)
`
`Auto Processing
`
`Cn
`
`TTTTTTTTTTTH
`
`WIEEE-º:
`
`CCN: FIDENTHAL
`
`CiM Ex. 1014 Page 22
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 22 of 63
`
`US 7,225,040 B2
`
`Figure 7B
`
`
`
`Automatic ATP Allocation
`
`SCREEN
`
`CONFEDENTIAL
`
`CiM Ex. 1014 Page 23
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`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 23 of 63
`
`US 7,225,040 B2
`
`Figure 7C
`
`
`
`SCREEN
`
`CONFEDENTIAL
`
`CiM Ex. 1014 Page 24
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 24 of 63
`
`US 7,225,040 B2
`
`
`
`Figure 8
`
`CiM Ex. 1014 Page 25
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 25 of 63
`
`US 7,225,040 B2
`
`Figure 8A
`
`
`
`Item Definition - frnage
`
`Itern Definition - Image
`
`CONFIDENTHAf.
`Sultana is a registered trademark of Verkade and United Biscuits.
`
`CiM Ex. 1014 Page 26
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`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 26 of 63
`
`US 7,225,040 B2
`
`Figure 8B
`
`
`
`Acquire Image - Extract EU Metadata
`
`SCREEN
`
`CONFIDENTIAL
`
`CiM Ex. 1014 Page 27
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 27 of 63
`
`US 7,225,040 B2
`
`Figure 8C
`
`
`
`item Definition - Image
`
`?tern Definition - trnage
`:
`|Remº
`?IE755735i
`:
`Customer # 458891g
`Wise
`{{#Eß | images ?º-TG 99-Bºzealancha
`#(ººº--" Status
`Approved
`# ºfflº width
`300mm cutoff
`450 mm
`
`sº A
`
`CONFIDENTIAL
`Sultana is a registered trademark of Verkade and United Biscuits.
`
`CiM Ex. 1014 Page 28
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`

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`U.S. Patent
`
`May 29, 2007
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`Sheet 28 of 63
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`US 7,225,040 B2
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`'v'r.a.7i: unis"
`
`Figure 8D
`
`CONFFDENTEAL
`
`CiM EX. 1014 Page 29
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`CiM Ex. 1014 Page 29
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`

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`U.S. Patent
`
`May 29, 2007
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`Sheet 29 of 63
`
`US 7,225,040 B2
`
`Figure 8E
`
`
`
`Acquire Image for Display
`
`CONFIDENTIAL
`
`CiM Ex. 1014 Page 30
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 30 of 63
`
`US 7,225,040 B2
`
`Figure 9
`
`Pending
`Çrdºr:
`
`
`
`2.5.1 .
`Process Pending
`
`-
`
`Orders
`
`
`
`View Order?
`
`2.5.3
`Display Order
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`1s ?tern
`Complete?
`
`2.5
`Create Itern
`CV Data
`
`Nºw Qrder
`
`2.5.5
`Create Crder
`
`2.5.2
`Check ATP &
`Allocation
`
`Pass ATP f
`Alloc?
`
`Yes
`
`2.7.1
`Interface To
`Legacy OMS
`
`2.5.4
`Change Crder
`
`CiM Ex. 1014 Page 31
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`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 31 of 63
`
`US 7,225,040 B2
`
`Figure 9A
`
`
`
`Process Pending Orders - Pending Orders
`
`: : |
`
`5
`
`CONFIDENTIAL
`
`CiM Ex. 1014 Page 32
`
`

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`U.S. Patent
`
`May 29, 2007
`
`Sheet 32 of 63
`
`US 7,225,040 B2
`
`Figure 9B
`
`
`
`Taks ordar-check ATP. Alloc
`order No.: LP32514
`- Lº?
`
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`System Response
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`s §
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`cºncers Fin'
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`Alp
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`..Besi Proposal
`Full ouantity
`10may00
`476,000 Imps
`* 5 days
`$300! Kg
`
`Altomate,Proposal
`Partial Quartity
`04mayoo
`394,000 Imps
`52 £ 3,
`$3,504 Kg
`
`CiM Ex. 1014 Page 33
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 33 of 63
`
`US 7,225,040 B2
`
`Figure 9C
`
`
`
`Display Order
`
`OR516–2345
`Crder?Jo
`p;########".
`167887-001
`I were:- item No
`Dale Req 04may00
`Irps
`Quantity
`475,000
`Guantity
`2.557 kg 63,487 m
`Ink Sys
`PA
`PA
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`2707
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`6 oz Regular Potato Chips
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`cylinder width
`
`CONFEDENTIAL, OO NOT DUPLICATE
`
`CiM Ex. 1014 Page 34
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 34 of 63
`
`US 7,225,040 B2
`
`Figure 9D
`
`
`
`change Order
`ºf
`order No.: [CKST8:345T
`
`Cylinder #
`Color # Inksys
`2757, FAT IV:2535
`FAT TY:355–
`[75]3-.
`—Y24001:14---
`Y2400398——
`[Y:35:55–
`
`Color
`
`|
`
`CONFEDENTHAL, DO NOT DUPLICATE
`
`CiM Ex. 1014 Page 35
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 35 of 63
`
`US 7,225,040 B2
`
`Figure 9E
`
`
`
`Create Order
`
`cy
`ordar No I.OR516-2772
`
`copy From order No ER575:335.
`
`*Coºrwarter ºats
`
`End user Data
`
`-
`
`- -
`
`-
`
`iziek,
`
`l
`
`t—
`L–
`Cyårder width 1–1180
`mm
`
`CONFEDENTIAL. DO NOT DUPLICATE
`
`CiM Ex. 1014 Page 36
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 36 of 63
`
`US 7,225,040 B2
`
`Figure 9F
`
`
`
`Order Management - Update Legacy OMS System
`
`SCREEN
`
`CONFIDENTIAL
`
`CiM Ex. 1014 Page 37
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 37 of 63
`
`US 7,225,040 B2
`
`Figure 10
`
`2.5
`Process Pending
`Order
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`2.3.3
`Acquire Image -
`Extract CV
`
`2.6,4
`Create ?tem
`(Structure Data)
`
`2.6.1
`Create Itern
`(Cylinder Data}
`
`2.6.2
`Create ?tem
`(Film Data)
`
`2.6.3
`Create ?tem
`(Ink Data)
`
`
`
`CiM Ex. 1014 Page 38
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 38 of 63
`
`US 7,225,040 B2
`
`Figure 10A
`
`
`
`Acquire Image - Extract CV Metadata
`
`NO
`
`SCREEN
`
`CONFIDENTHAL
`
`CiM Ex. 1014 Page 39
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 39 of 63
`
`US 7,225,040 B2
`
`Figure 10B
`
`
`
`Item Definition - Package Structure, Converter Data
`
`itempsfinition. Package 8tructure
`
`Package Structure
`
`General i
`I-
`
`Supplier
`
`Supplier J Coat 1–
`Mäferial TWiTun;
`
`CONFIDENTIAL, DO NOT DUPLICATE
`
`CiM Ex. 1014 Page 40
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 40 of 63
`
`US 7,225,040 B2
`
`Figure 10C
`
`
`
`Item Definition - Enter i Change Item
`
`lism Dennillon . Enter? changstem
`ºn sºn?, IgE in No.; RET-- i. R?z?º
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`COf FiDENTIAL DO NOT DUPLICATE
`
`CiM Ex. 1014 Page 41
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 41 of 63
`
`US 7,225,040 B2
`
`Figure 10D
`
`Item Deflnltlon - BIII Of Materials
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`«_.>.v)...:
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`customer
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`CONFIDENTIAL
`
`CiM EX. 1014 Page 42
`
`CiM Ex. 1014 Page 42
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 42 of 63
`
`US 7,225,040 B2
`
`Figure 10E
`
`Item Deflnltlon - Ink Bill Of Materlals
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`CiM EX. 1014 Page 43
`
`CiM Ex. 1014 Page 43
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 43 of 63
`
`US 7,225,040 B2
`
`Figure 11
`
`Ordº status
`(Partial. Not Run)
`
`3.5
`Update Order &
`Schedule Status
`
`2.3
`ATP # Alloc
`
`
`
`3.3
`Schedule
`Slitters
`
`
`
`
`
`3.2
`Schedule
`Laminators
`
`
`
`
`
`
`
`3.4
`Get Inventory &
`Purchasing Data
`From Legacy
`
`Inventory &
`Purchasing
`Systems
`
`º
`
`:
`
`------------------
`
`CiM Ex. 1014 Page 44
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 44 of 63
`
`US 7,225,040 B2
`
`Figure 11A
`
`
`
`
`
`3.3.4
`Film Availability
`
`
`
`
`
`3.1.5
`Undo Charges
`
`CiM Ex. 1014 Page 45
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 45 of 63
`
`US 7,225,040 B2
`
`Figure 11B
`
`
`
`Schedule Order - schedule Versions
`
`CONFEDENTIAL, DO NOT DUPLICATE
`
`---.
`
`SCH 3.0.1
`
`CiM Ex. 1014 Page 46
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 46 of 63
`
`US 7,225,040 B2
`
`Figure 11C
`
`
`
`Schedule Order - View Scheduled And Unscheduled Orders
`
`lº??IEIRVEETºº LITE REITEIRIGHºº?iº?º?.
`§chedule:Verslöä, V1 Extra jºyºs orders . . . . .
`. . .
`. . .
`.
`. . . UnScheduled
`
`CONFEDENTIAL
`
`CiM Ex. 1014 Page 47
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 47 of 63
`
`US 7,225,040 B2
`
`Figure 11D
`
`
`
`Schedule Order - Schedule Press
`
`E; Joe that yºu clicked on
`
`rhina.
`.
`. . . . . . . .
`. . . .
`Before Last change: 95% 1.7
`- *
`97 : * :
`
`CONF|DENTIAL
`
`CiM Ex. 1014 Page 48
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 48 of 63
`
`US 7,225,040 B2
`
`Figure 11E
`
`
`
`CiM Ex. 1014 Page 49
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 49 of 63
`
`US 7,225,040 B2
`
`Figure 11F
`
`3.3.1
`View Scheduled &
`UnScheduled
`Orders
`
`
`
`3.3.2
`Schedule Slitter
`
`e Yes
`
`3.3.6
`Šawe Schedule
`
`No
`
`CiM Ex. 1014 Page 50
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 50 of 63
`
`US 7,225,040 B2
`
`
`
`: º:
`:
`ventory
`:
`System
`:
`!------------------
`
`
`
`
`
`F------------------- |
`:
`Legacy
`!
`Purchasing
`system
`
`:
`|
`º
`{-----------------
`
`Figure 11G
`
`3.4.1
`
`Get Inventory
`Data From
`Legacy Sys
`
`
`
`3.4.2
`Get Purchasing
`Data From
`Legacy Sys
`
`
`
`
`
`Specific Request
`
`Material #
`Material Description
`Material Quantity
`Material UOM
`
`Specific Request
`
`PC;
`Material #
`Malerial Description
`Manterial Quantity
`Malerial UOM
`ExpbelDate
`
`CiM Ex. 1014 Page 51
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 51 of 63
`
`US 7,225,040 B2
`
`Figure 11H
`
`
`
`Schedule Order - Get Inventory Data From Legacy System
`
`SCREEN
`
`CONFIDENTIAL
`
`CiM Ex. 1014 Page 52
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 52 of 63
`
`US 7,225,040 B2
`
`Figure 11I
`
`
`
`Schedule Order - Get Purchasing Data From Legacy System
`
`SCREEN
`
`CONFIDENTHAL
`
`SCH 3.4.2
`
`CiM Ex. 1014 Page 53
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 53 of 63
`
`US 7,225,040 B2
`
`Figure 11J
`
`Active
`Schedule
`
`
`
`3.0.1
`Schedule Versions
`
`UP 1.0.1
`Update Production
`
`CiM Ex. 1014 Page 54
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 54 of 63
`
`US 7,225,040 B2
`
`Figure 11K
`
`
`
`Schedule Order • Schedule Versions
`
`Comment
`Data
`&15,200 Active schedule
`8/15/2000 Extra Jayes Orders
`8/15/2000 Extra Jayes Orders * Volume Split
`
`CONFIDENTHAL, DO NOT aduPL?CATE
`
`SCH 3.0.1
`
`CiM Ex. 1014 Page 55
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 55 of 63
`
`US 7,225,040 B2
`
`Figure 11 L
`
`
`
`Update Production
`
`R?s?r????
`
`247:33:303
`
`Active Job{A}
`Start ºate
`Start Tirrts
`
`CONFEDENTIAL, DO NOT DUPLICATE
`
`scºre No. UP 1.0.1
`
`CiM Ex. 1014 Page 56
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 56 of 63
`
`US 7,225,040 B2
`
`Figure 12
`
`3.0
`Schedule Orders
`
`4.1
`Update Inventory
`
`Open orders that are
`scheduled with anticipated
`production date
`
`4.4
`Prepare Purchase
`Req
`
`
`
`
`
`4–
`
`:
`: Legacy Inventory
`:
`!
`System
`inventory Data
`:
`----------------------- - Mat #
`- Quantity
`- Quantity UGM
`
`r---------------------- Request PO's
`:
`*— 4.2
`;Legacy Purchasing:
`Update Open
`:
`:
`Purchase Orders
`System
`
`§.
`Info
`
`
`
`- Material #
`- Quantity
`- Quamity UOM
`- Expected Date
`
`
`
`
`
`
`
`2.0
`Order
`Management
`(Create ?tem)
`
`Purchase Requisitions
`
`CiM Ex. 1014 Page 57
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 57 of 63
`
`US 7,225,040 B2
`
`Legacy
`Inventory
`System
`
`
`
`
`
`:
`:
`:
`;
`:
`!-------------------- -
`
`
`
`Legacy
`#
`: Plººg
`:
`System
`
`-----------------------
`
`Figure 12A
`
`4.1.1 & 4.1.2
`Update Inventory
`& Purchasing
`From Legacy
`Sys
`
`Inventory Update Request
`
`Material #
`Material Description
`Manterial Quantity
`Material UCM
`
`Purchasing Update Request
`
`PG#
`Material #
`Material Description
`Manterial Quantity
`Materia! UOM
`ExpDe?Date
`
`CiM Ex. 1014 Page 58
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 58 of 63
`
`US 7,225,040 B2
`
`Figure 12B
`
`
`
`MRP - Inventory / Purchasing Interface
`
`Inventory f Purchasing trterface
`Update Inventory
`
`††
`[[: Eggy
`
`Update Purchasing
`last Updated Cn: 21 June 2009 at 14:02
`
`CONF#DENTIAL
`
`screen tº MRP 4.1.18, 2
`
`CiM Ex. 1014 Page 59
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 59 of 63
`
`US 7,225,040 B2
`
`Figure 12C
`
`
`
`4.3.2
`
`Get Orders
`
`4.3.3
`
`Explode BOMs
`
`4.4.1
`
`Prepare
`Purchase Reqs
`
`4.3.5
`
`Consolidate
`Inventory & PO's
`
`4.3.4
`
`Consolidate
`Requirements
`
`:
`
`:
`Legacy
`Purchasing :
`System
`:
`
`CiM Ex. 1014 Page 60
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 60 of 63
`
`US 7,225,040 B2
`
`Figure 12D
`
`
`
`Procure Raw Materials - Run MRP : Choose Parameters
`
`ÇONFIDENTIAL
`
`screen No. MRP 4.3.1
`
`CiM Ex. 1014 Page 61
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 61 of 63
`
`US 7,225,040 B2
`
`Figure 12E
`
`
`
`fMRP - Get Orders
`
`COAJFiDENTiai–
`
`sseen re. MRP4.3.2
`
`CiM Ex. 1014 Page 62
`
`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 62 of 63
`
`US 7,225,040 B2
`
`Figure 12 F
`
`
`
`MRP - Explode BOM's
`
`SCREEN
`
`CONFEDENTIAL
`
`screense. AARP 4.3.3
`
`CiM Ex. 1014 Page 63
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`

`
`U.S. Patent
`
`May 29, 2007
`
`Sheet 63 of 63
`
`US 7,225,040 B2
`
`Figure 12G
`
`
`
`MRP - Conslidate Requirements
`
`CONF#DENTHAL
`
`screen No. MFP 4.3.5
`
`CiM Ex. 1014 Page 64
`
`

`
`US 7,225,040 B2
`
`1
`METHOD AND SYSTEM FOR REDUCING
`LEAD-TIME IN THE PACKAGING
`INDUSTRY
`
`BACKGROUND OF THE INVENTION
`
`2
`usable by the output device for producing output. The print
`processor is operable on the output instruction file to select
`the device driver of one of the at least one output device to
`render the output instruction file, and feed the output instruc
`tion file to the output device driver of one of the at least one
`output device. A corresponding method is also disclosed.
`U.S. Pat. No. 5,982,996 is incorporated herein by reference.
`U.S. Pat. No. 5,960,164 also discloses a method and
`system for producing documents at a first site from database
`information produced at a second site remote from the first
`site has enhanced system flexibility and enhanced data
`handling throughput, which are accomplished by adopting
`standard programming interface or database tables to allow
`a computer at the second site to obtain information neces
`sary to generate all necessary data codes and stream for
`matting information which will be utilized at the first site.
`An object association table, which associates document
`production jobs with specific documents and appropriate
`descriptions, is provided at the first site so that it is acces
`sible—e.g. through an online communications network—at
`the second site. The object association table is accessed at
`the second site in realizing substantially only file names in
`the object association table, to produce database information
`at the second site. The database information is supplied from
`the second site to the first site where it is translated so that
`it may be utilized by a specific print engine at the first site,
`utilizing a job formatting table to build an engine specific
`print stream for one or more print engines. Then the engine
`specific print stream, tailored to the particular print engine
`utilized, electronically controls a specific print engine at the
`first site to image documents having variable information
`from the database information supplied from the second site.
`U.S. Pat. No. 5,960,164 is incorporated herein by reference.
`Packaging is the longest lead-time ingredient for the
`consumer goods manufacturer. Most components that the
`manufacturer uses are commodities with lead-times of hours
`or days. However, packaging is a custom product with
`lead-times of 2–4 weeks for a repeat order and lead-times of
`8–12 weeks or more for a new design. This relatively long
`lead-time creates system-wide bottlenecks; inefficiencies
`and waste; packaging write-offs; barriers to lean manufac
`turing at end user sites; and 4 to 8 weeks of delay in
`launching new products. The long lead-time is the primary
`reason that successful promotions are not fully exploited.
`The long lead-time for packaging is caused by complexity
`of the supply chain, the distance between the parties, and the
`process of manufacturing and delivering the packaging to
`the consumer goods manufacturer. A large lead-time reduc
`tion can be achieved by using the internet to collapse
`apparent distance between the parties and implementing a
`new business process using the internet. Accordingly, it is an
`object of the present invention to provide a method and
`system for reducing lead-time in the flexible packaging
`industry.
`All patents and publications referred to in this application
`are hereby incorporated herein by reference in their entirety.
`
`SUMMARY OF THE INVENTION
`
`60
`
`65
`
`The present invention relates to a method and system for
`linking the various members of the packaging (including
`labels) supply chain. The invention provides an integrated
`order placement, production planning, scheduling, and
`material requirements planning environment for the various
`members of the packaging supply chain. Among the mem
`bers in the flexible packaging supply chain are end users,
`converters, and suppliers of goods and services necessary for
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`The present invention relates to a method and a system for
`reducing lead-time in the packaging industry. This invention
`is particularly beneficial to the flexible packaging industry
`which services the fast moving consumer goods manufac
`turing industry (i.e., producers of snacks, cookies, crackers,
`candies, health and beauty aids, etc.). Currently packaging is
`the longest lead-time item for these companies, and a
`system-wide bottleneck for them. Reducing the packaging
`lead-time allows for waste reduction and revenue enhance
`ment opportunities.
`The method disclosed herein comprises an embodiment of
`a business process which may be enabled by the internet and
`capable of exchanging information with other business
`processes.
`U.S. Pat. No. 6,067,406 discloses a method and device
`wherein the output mode of an output device for rendering
`electronic images on an output medium may be character
`ized by different user-selectable settings such as: paper type,
`ink type, etc. Apart from the screen characteristics such as
`screen ruling, frequency and angle, a calibration curve can
`be communicated via the page description language (e.g.,
`PostScript Level 2) for each color component. Sets of
`calibration curves can be prepared for specific types of
`rendering, and be referenced by name. By this name indi
`cation and by naming conventions based upon the output
`mode or screening parameters, calibration changes can be
`introduced quickly and consistently. U.S. Pat. No. 6,067,406
`is incorporated herein by reference.
`U.S. Pat. No. 5,991,783 discloses a system and method
`for generating, storing and transmitting a layout page con
`taining graphical data correlated to at least one graphical
`image which has previously been graphically encoded, such
`that the layout page may be printed either as a complete,
`full-color image, or as individual color separation plates.
`The system and method create a set of master data files,
`having a main master file which stores complete RGB (red,
`green, blue) color data for the graphical image, and a
`correlated set of CMYK (cyan, magenta, yellow, black)
`master files, each containing graphical data for a single color
`separation plate for the graphical image. The main master
`file contains pointers to each of the CMYK master files. The
`system and method also create a set of preview data files: a
`set of CMYK preview files essentially only containing a
`pointer to the corresponding CMYK master file, and a main
`preview file essentially only containing a pointer to the main
`master file, and pointers to each of the CMYK preview files.
`U.S. Pat. No. 5,991,783 is incorporated herein by reference.
`U.S. Pat. No. 5,982,996 discloses an information distrib
`uting apparatus for operating within a computer network
`environment. The information distributing apparatus
`includes a computer having an operating system and is
`configured to operate within the computer network environ
`ment. The apparatus has an application configured for run
`ning on the computer via the operating system, the appli
`cation configured to generate a source job in the form of an
`intermediate file format comprising an output instruction
`file. The apparatus includes a print processor in the form of
`an intermediate executable code for operating on the output
`instruction file. The apparatus also includes at least one
`output device having an output device driver configured to
`convert the output instruction file to output instructions
`
`CiM Ex. 1014 Page 65
`
`

`
`US 7,225,040 B2
`
`3
`the creation of packaging. The method and system of the
`present invention allow members of the supply chain to
`access the additional data they need to integrate their activi-
`ties and reduce packaging lead-times. In addition, the system
`is designed to interface with the converter’s order manage-
`ment, inventory, and purchasing systems to acquire data for
`production planning (e.g. inventory levels), order process-
`ing, and certain other functions. The system is designed to
`interface with digital files containing package designs and
`images to provide information for item creation, production
`planning, and scheduling.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`FIG. 1 is a flow diagram setting forth a system overview
`of the processes of the current invention. See also para-
`graphs [00116]—[00119] of the specification.
`FIG. 2 is a flow diagram setting forth an overview of the
`Production Planning and Order Management processes of
`the current invention. See also paragraphs [00120]—[00125]
`of the specification.
`FIG. 3 is a flow diagram setting forth an overview of the
`Sales and Operation processes of the current invention. See
`also paragraphs [00127]—[00135] of the specification.
`FIG. 3A is an exemplary monitor view of a Demand
`Forecast Table of the Sales and Operation processes of the
`current invention. See also paragraph [00129] of the speci-
`fication.
`
`FIG. 3B is an exemplary monitor view of a Line Avail-
`ability Table of the Sales and Operation processes of the
`current invention. See also paragraph [00130] of the speci-
`fication.
`
`FIG. 3C is an exemplary monitor view of a Lines Rates
`and Efficiencies Table of the Sales and Operation processes
`of the current invention. See also paragraph [00131] of the
`specification.
`FIG. 3D is an exemplary monitor view of line loading
`utilizations of the Sales and Operation processes of the
`current invention. See also paragraph [00132] of the speci-
`fication.
`
`FIG. 3E is an exemplary monitor view of an Inventory
`Adjustment Table of the Sales and Operation processes of
`the current invention. See also paragraph [00133] of the
`specification.
`FIG. 3F is an exemplary monitor view of a Capacity
`Group Assignment Table of the Sales and Operation pro-
`cesses of the current invention. See also paragraph [00134]
`of the specification.
`FIG. 3G is an exemplary monitor view of a Capacity
`Group Demand Averages Table of the Sales and Operation
`processes of the current
`invention. See also paragraph
`[00135] of the specification.
`FIG. 4 is flow diagram setting forth an exemplary over-
`view of the Master Production Scheduling processes of the
`current invention. See also paragraphs [00138]—[00143] of
`the specification.
`FIG. 4A is an exemplary monitor view of a Master
`Production Scheduling Summary Table