Rfid based inventory system and method

Abstract

An inventory management system and method using RFID tags for the tracking and management of individual items of inventory or work-in-process. The system uses a cloud-based service device to manage inventory at a facility via a communications hub. RFID printers, RFID readers, and antennas located at the facility relay information through the communications hub. Movement of items is monitored by tracking RFID tags associated with each item. Information on the tracked items may be recorded, displayed, and used to generate reports and notifications by the cloud-based services device. Historical tracking records may also be displayed.

What is claimed is: 
     
         1 . An inventory management system, comprising:
 a cloud-based services device comprising a processor and a memory, the memory including a program that, when executed, configures the cloud-based services device to operate as a control system;   one or more RFID readers in communication with the cloud-based services device, wherein the control system is configured to transmit a configuration change to at least one of the one or more RFID readers; and   one or more antennas in communication with the one or more RFID readers, where each of the one or more antennas is located in one of a plurality of work areas with a perimeter defined by the control system, where each of the one or more antennas is uniquely associated with one of the one or more RFID readers, and where each of the one or more RFID readers is configured to interrogate RFID tags through its associated antenna when the respective RFID tags are within the corresponding perimeter of the one of the plurality of work areas without the need for entry or exit checkpoints to said work area:   wherein the control system is configured to store information about inventory with RFID tags and inventory information is not stored on the RFID tags.   
     
     
         2 . The system of  claim 1 , further comprising an RFID printer. 
     
     
         3 . The system of  claim 1 , wherein at least one of the one or more RFID readers has an integrated visual display configured to display information received from the cloud-based services device. 
     
     
         4 . The system of  claim 1 , wherein the one or more antennas comprise a plurality of antennas, and a first antenna of the plurality of antennas is physically remote from a second antenna of the plurality of antennas. 
     
     
         5 . The system of  claim 4 , wherein the first antenna is located in a first work area and the second antenna is located in a second work area. 
     
     
         6 . The system of  claim 5 , wherein the one or more antennas comprise a first antenna located in a first work area of the plurality of work areas and a second antenna located in a second work area of the plurality of work areas, and wherein the first work area is configured for a different process step than the second work area. 
     
     
         7 . A method of managing a production process comprising the steps of:
 detecting at least one of one or more RFID tags with at least one antenna disposed at a known location in a work area with a perimeter defined by a control system residing on a cloud-based services device;   reading the at least one of the one or more RFID tags with an RFID reader that is in communication with the at least one antenna when the one or more RFID tags are within the perimeter of the work area without requiring the one or more RFID tags passing through an entry/exit checkpoint;   transmitting information from the at least one of the one or more RFID tags and identification information for the at least one antenna to the cloud-based services device;   receiving the information about the at least one of the one or more RFID tags and the identification information for the at least one antenna by the cloud-based services device; and   determining the location of the production item based on the information about the at least one of the one or more RFID tags and the work area associated the at least one antenna; wherein the location information of the production item is not stored on the at least one of the one or more RFID tags.   
     
     
         8 . The method of  claim 7 , further comprising:
 generating a request at a cloud-based services device for production of the one or more RFID tags based on a production order;   transmitting the request to an RFID printer physically remote from the cloud-based services device;   printing the one or more RFID tags;   physically associating each of the one or more RFID tag with one or more production items; and   associating each of the one or more RFID tags with its corresponding production item within the cloud-based services device.   
     
     
         9 . The method of  claim 8 , further comprising:
 receiving the production order at the cloud-based services device.   
     
     
         10 . The method of  claim 8 , further comprising:
 generating the production order at the cloud-based services device.   
     
     
         11 . The method of  claim 7 , further comprising:
 displaying the location of at least one of the one or more production items.   
     
     
         12 . The method of  claim 7 , wherein the information about the at least one of the one or more RFID tags and the at least one antenna comprises at least one of: 1) a time of initial detection of the RFID tag and 2) a time when detection of the RFID tag ceased. 
     
     
         13 . The method of  claim 12 , wherein the one or more production items comprises two or more production items, and further comprising:
 estimating an average interval between time of initial detection and cessation of detection by the at least one antenna for the RFID tags associated with the two or more production items.   
     
     
         14 . The method of  claim 12 , wherein the at least one antenna comprises a first antenna and a second antenna, and the one or more production items comprises a plurality of production items, and further comprising:
 estimating an average interval between at least one of the detection or cessation of detection for each of the RFID tags associated with the plurality of production items by the first antenna and at least one of the detection or cessation of detection of each of the RFID tags associated with the plurality of production items by the second antenna.   
     
     
         15 . The method of  claim 7 , wherein the antenna is one of a plurality of antennas with known locations that are physically separated; and further comprising:
 determining a movement path of the production item using information about the RFID tag and the plurality of antennas over time.   
     
     
         16 . A method of monitoring inventory comprising:
 performing a check-in or the check-out of inventory items associated with one or more RFID tags in an area by reading the one or more RFID tags in the area using a control system on a cloud-based services device that defines a work area with a perimeter including a first antenna in communication with an RFID reader without physically manipulating the inventory items, requiring moving the inventory items through an entry/exit checkpoint, or writing check-in or check-out information to the one or more RFID tags;   uploading the check-in or check-out information to a cloud-based services device;   performing an inventory detection check of inventory items associated with the one or more RFID tags inside the perimeter of the work area by reading the one or more RFID tags using a second antenna in communication with the RFID reader;   uploading the inventory check detection information to the cloud-based services device via the communication hub;   generating an adjusted inventory record based on a previous inventory record stored in the cloud-based services device and the check-in or check-out information; and   comparing the adjusted inventory record with the inventory detection check using control software on the cloud-based services device.   
     
     
         17 . The method of  claim 16 , further comprising:
 generating, if the adjusted inventory record and the inventory detection check do not match, one or more of: a notification and an inventory adjustment.   
     
     
         18 . A method of monitoring inventory comprising:
 detecting a presence of inventory associated RFID tags with an antenna at a location within a work area with a perimeter defined by a control system on a cloud-based services device without the inventory associated RFID tags being required to pass through an entry/exit checkpoint;   performing an inventory detection check with a processor in the cloud-based services device; and   estimating a count of inventory items in the work area based on reading the RFID tags with an RFID reader in communication with the antenna, wherein the RFID tags do not include inventory information;   comparing the count with a selected threshold for the work area; and   requesting additional inventory in real time if the count is below the selected threshold.   
     
     
         19 . The method of  claim 18 , wherein the selected threshold is determined based on one or more of: (a) the historical demand profile of material determined as determined by past RFID tag activity; (b) global-, site-, or bin-level activity and planning parameters; (c) nominal and historical lead time characteristics of the material; (d) forecasted demand; (e) production forecasts; and (f) reservations for material. 
     
     
         20 . The method of  claim 18 , wherein the selected threshold is based inventory for one or more of: a single physical location, an entire facility, multiple facilities, and an entire organization.