Incomplete
Bundle Identification System (IBIS) Application:
The US Postal Service has recently imposed more stringent requirements on
bindery production for postal rate discount qualification.
Disqualification and associated higher mailing rates are a function of how
reordered books are handled in the bindery process. Reordered books in
many cases do not make it into the correct bundle and, therefore, are out of
mailing sequence or even worse, end up in the mixed mail mailbag.
The IBIS enables bindery line operators to efficiently match re-orders to
their correct bundle. The IBIS performs this function by identifying those
bundles with missing (reordered) books and displays the bundle number and
the number of missing books on a large overhead LED display. This
allows the operators at the end of the line to pull those bundles for
insertion with the re-orders when they arrive at their station.
Bundles with missing books are registered within milliseconds of the
identification of an out of sequence condition. New bundles added to
the display blink the number of missing books for thirty seconds to alert
operators to pull the identified bundle. When there are no bundles
with missing books, then the current bundle number
is
only identified on the overhead displayed.
Using the IBIS will mean there is consistently less mixed mail and a
larger number of qualifying bundle counts in your production runs.
Depending upon run size the return on investment in a IBIS can be as quick
as one month based on mailing cost savings alone.
Systemdescription:
The system was designed to:
Take an input from
a 9416 printer interface board (PIB)
Decode the signals
to determine the book sequence number and bundle number
Determine if a book
is missing using the sequence number given.
Display the bundle
number from which the book was missing followed by he number of
missing products for that bundle. The display would scroll old bundles
off the screen as new ones were added.
The system is composed
of three main components; 9416 interface, micro controller, and large moving
LED display.All the parts selected are “off-the-self” components with the
exception of the specific wiring which is unique to the system.The micro controller is programmed with a custom application
that handles the entire system control and monitors the production line.
The moving LED signs
are available in a range of sizes and options.The options are basically either color (red/green/amber) or just red.The size can be either one or two lines with varying number of
characters that can be displayed per line.
Installation:
The stand-alone system
was
designed to be an easy to integrate and install by plant personnel.The elements of installation consists of:
Setup print
controller (tape formatting) to output necessary information <book separator>BUNDLE:SEQUENCE_NUMBER<book
separator>
Connect PIB board
to system interface.
Connect all power
connections.
Connect micro
controller to moving LED display.
Connect micro
controller to 9416 interface device.
Options:
One
Line Displays
Example of 330 LED
display.
SWiSH Movie - IBIS_single_dispaly.swi - www.swishzone.com
The display format
is: Bundle Number / Number of products.
215R/C (red/color)
Series one line
LED Display
- 2.1 inch high
characters
- 1 - 2 bundles displayed
220C (color)
Series one line LED
Display - 2.1 inch high
characters
- 2 - 4 bundles displayed
320C (color) Series One Line
LED Display - 3.1 inch high
characters
- 2 - 4 bundles displayed
330C (color) Series
one line
LED Display - 3.1 inch high
characters
- 3 - 4 bundles displayed
Two
Line Displays
Example of4120R
LED display.
SWiSH Movie - IBIS_display.swi - www.swishzone.com
The display format
is: Bundle Number on upper line and Number of Products on
lower line.
4080C/R (red/color)Series
two line LED Display
- .7 inch high
characters
- 1 – 4 bundles displayed
4120C/R (color/red)
Series two line LED Display - 2.1 inch high
characters
- 3 – 9 bundles displayed
Optional
customization for specific application requirements is also available.
IPS Technologies, Inc.