Cushioning conversion system and method

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.

1 - 18 . (canceled)  
   
   
       19 . The packaging system of  claim 66 , wherein the system controller functions comprise at least one of inventory consumption maintenance, automated inventory ordering, consignment billing, and production planning notification.  
   
   
       20 . The packaging system of  claim 66 , wherein the packaging material generator comprises a controller in communication with the packaging controller for implementing packaging material generator control functions in response to commands from the packaging controller.  
   
   
       21 . The packaging system of  claim 20 , wherein the packaging material generator controller functions comprise at least one of initiating a generation of a selected amount of packaging material, severing the packaging material, and providing the packaging material for packaging the part to be packaged.  
   
   
       22 - 25 . (canceled)  
   
   
       26 . A method of packaging parts, comprising the steps of: 
 identifying at least one part to be packaged;    retrieving packaging instructions associated with the at least one part to be packaged; and    controlling a packaging material generator using the packaging instructions.    
   
   
       27 - 36 . (canceled)  
   
   
       37 . The method of  claim 26 , wherein the step of controlling the packaging material generator comprises operating a cushioning conversion machine to produce a quantity of cushioning material dictated by the packaging instructions.  
   
   
       38 . The method of  claim 37 , wherein the step of controlling the cushioning conversion machine further comprises the step of ordering the formation of pieces of cushioning material to correspond to a predetermined packaging order.  
   
   
       39 - 47 . (canceled)  
   
   
       48 . The method of  claim 26 , further comprising the step of monitoring a consumption of one or more materials used in packaging parts.  
   
   
       49 . The method of  claim 48 , wherein the step of monitoring the consumption comprises counting a number of containers used in packaging the parts.  
   
   
       50 . The method of  claim 48 , wherein the step of monitoring the consumption comprises calculating an amount of packaging material used in packaging the parts.  
   
   
       51 . The method of  claim 48 , wherein the step of monitoring the consumption comprises calculating an amount of supplies used in packaging the parts, wherein the supplies include at least one of packaging tape, operating instructions, warranty cards, and address labels and identifying where the parts are destined.  
   
   
       52 . The method of  claim 48 , further comprising the step of generating a consumption report indicating the consumption of the one or more materials.  
   
   
       53 . The method of  claim 52 , further comprising the step of sending the consumption report to at least one of an inventory supplier and an inventory prediction planner.  
   
   
       54 . The method of  claim 48 , further comprising the step of generating a consignment billing report based on the amount of packaging materials consumed.  
   
   
       55 . The method of  claim 48 , further comprising the steps of: 
 comparing the consumption of the one or more materials to one or more re-order thresholds; and    generating a re-order request if one or more of the re-order thresholds are satisfied.    
   
   
       56 . The method of  claim 48 , wherein the step of monitoring the consumption of the one or more materials comprises the steps of: 
 initializing a variable representing an amount of packaging material in inventory;    calculating an amount of packaging material used in a packaging step;    decrementing the variable representing the amount of packaging material in inventory by the calculated amount of packaging material;    comparing the decremented variable of packaging material to a packaging material re-order threshold; and    generating a re-order request if the decremented variable meets or falls below the re-order threshold.    
   
   
       57 . (canceled)  
   
   
       58 . The method of  claim 55 , wherein the step of generating a re-order request comprises automatically placing an order for additional materials with at least one of an inventory distributor and a production planner through a communications link.  
   
   
       59 . The method of  claim 53 , wherein the consumption report is utilized for production planning purposes so that an inventory producer can produce needed inventory before an inventory supplier orders the needed inventory.  
   
   
       60 . The method of  claim 55 , wherein the step of generating a re-order request comprises providing a re-order message on a display.  
   
   
       61 - 65 . (canceled)  
   
   
       66 . A packaging system, comprising: 
 a packaging material generator; and    a packaging system controller for providing packaging instructions related to a part to be packaged and instructing the packaging material generator to produce the packaging material.    
   
   
       67 - 127 . (canceled)  
   
   
       128 . The packaging system of  claim 66 , further comprising an inventory management system associated with the packaging system controller, wherein the inventory management system monitors a consumption of packaging materials and provides an indication if any of the packaging materials fall below a pre-determined level.  
   
   
       129 . The packaging system of  claim 128 , wherein the packaging materials includes at least one of packaging containers, cushioning material, and packaging tape.  
   
   
       130 . The packaging system of  claim 128 , further comprising a communication apparatus coupled to the inventory management system for transmitting a re-order request for one or more packaging items if the one or more packaging items are determined to have fallen below the pre-determined level.  
   
   
       131 . The packaging system of  claim 128 , further comprising an apparatus for identifying where the parts are destined.  
   
   
       132 . The method of  claim 128 , wherein the inventory management system is operable to generate a consignment billing report based on the amount of packaging materials consumed.  
   
   
       133 - 159 . (canceled)