FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
PROVISIONAL / COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION :
A novel warehousing system

2, APPLICANT:
/
(a) NAME : LARSEN &TOUBRO LTD
(b) NATIONALITY : An Indian Company registered under the
Provisions of the Companies Act, 1956
(c) ADDRESS :PlotNo-5,7,10,ll Talegaon MIDC
Village-Navlakh Umbre, Tal-Maval PUNE-410507
3. PRREAMBLE TO THE DESCRIPTION
PROVISIONAL
The following specification describes the invention.

COMPLETE
The following specification, particularly describes the invention and the manner in which it is to be formed.

Title :
A novel warehousing system
Field of the invention :
The present invention relates to a system for warehousing of materials. More particularly, it relates to a system for automated storage & retrieval of materials with a computerised control mechanism to allow/block release (issue) of material selectively as per the Theory of Constraints methodology. Further it is related to a user-friendly visual control interface, an RFID-based tracking of receipt & issue of materials, and an instant communication of the availability & inventory status information to the concerned. The invention relates generally to all types of industries but particularly to the heavy engineering industry wherein the materials consist mainly of metallic types.
Background :
The Theory of Constraints (TOC) is a management philosophy propounded by Dr. Eli Gcldratt. This theory calls for managing 'flow' as the number one criterion for success in operations in any industry. It emphasizes the importance of avoiding start-&-stop mode of operations, wherein management deploys resources to work on materials in the order of availability, rather than demanding / pulling material in the order of production flow requirements; often resulting in building up a lot of unnecessary Work-In-Progress (WIP) while the throughput does not happen, since the output of this kind of approach is a lot of partly finished products.
The present invention embodies this TOC advice Into a warehousing system wherein - Production personnel indicate the product-wise priority in which the materials are required on shop floor, and also they define 'full-kit' requirements in the system to specify the sets of items that are required by them in the specified sequence. This information is made available to the upstream functions (particularly Warehousing and QC), so that the processing of incoming material can take place in the desired order of priority, sequence & material can be arranged in required sets/kits.
Further the present invention implements the intention by providing a system for automated storage & retrieval of materials that is provided with a computerised control mechanism to allow/block release (issue) of material selectively as per the TOC principle briefly described above.
Prior art:
A detailed patent search, and a general search on other literature in public domain indicates that there have been very many recent works done in the fields this present invention relates to (mentioned above), but separately in each field, and mostly in different contexts & environments. Technically they surely represent the state of the art in the above-mentioned fields (automated storage & retrieval, Theory of Constraints based systems, visual control, automated tracking and instant communication), the prominent amongst them shortly captured as below.
1) US patent number '6,729,482' describes an automated parts storage and retrieval'method. The method includes a frame, a plurality of trays configured to hold a plurality of parts, and a movement method attached to the frame and arranged to move the plurality of trays in a serpentine pattern for retrieval and storage of the plurality of parts. The movement method includes a plurality of sprockets arranged within the frame in a zigzag pattern, at least one chain toothedly engaged within the plurality of sprockets, and a drive motor'con figured to drive one of the plurality of sockets. The plurality of trays are rotatably attached to the at least one chain. The method includes a computer method for controlling the drive motor based on a selection using a parts selection component and position information sent by a position sensor.
2) US patent number '6,501,473' describes a graphical method and system of tracking projects managed in accordance with Theory of Constraints project management techniques. A graph eft project and feeding chain buffer consumption is constructed for at a glance project status review by

management.
3) US patent application number 20050097505' describes a method on a computer for providing Theory of Constraints {I critical chain)-based project management across a plurality of projects. The method includes generating a plurality of plans, each of the plurality of plans corresponding to one of the plurality of projects, wherein a project comprises at least one task. The method further includes generating buffers for each of the plurality of projects and reconciling project resources among the plurality of projects. The method further includes executing the plurality of project plans, including allowing a user to manage the buffers across the plurality of projects. The user is further provided with information associated with buffers for the plurality of projects, so as to evaluate the status of the plurality of projects. Additionally, the user is provided with task prioritization for any task of the plurality of projects, wherein task prioritization is calculated across the plurality of projects.
4) Us patent application number '20050229151' describes a method on a computer for providing Theory of Constraints ( critical chain)-based project management. The method includes receiving at least one project plan for a project comprising a plurality of tasks and calculating a task priority for each of the plurality of tasks based on the at least one project plan. The method further includes receiving at least one sub-task for a first task of the plurality of tasks and assigning the at feast one sub-task a task priority identical to the task priority of the first task. In one alternative, the method further includes receiving a new task priority for the first task, assigning the new task priority to the first task and assigning the new task priority to the at least one sub-task of the first task. The method may also include an interface to allow starting of sub-tasks only when the parent task is started.
5) Us patent application number '20060010418' describes a method on a computer for providing Theory of Constraints {j critical chain)-based project management. The method includes generating a list of sequential time periods for a project comprising a plurality of tasks and calculating a number of tasks for each time period. The method further includes generating a graphic that visually indicates the number of tasks for each time period and a priority of each task and providing the graphic to a user.
6) Indian patent application number 7305/CHENP/2006' describes an antenna design for radio frequency identification ("RFID") tags suitable for use in metallic environments. More particularly, this invention relates to design for RFID tags particularly operating in the ultra high frequency ("UHF") operating band. The antenna comprises : i) a first antenna element, where the first antenna element comprises a first conductor and a second conductor and the first antenna element is selected to provide a desired operating frequency range of the antenna ; and ii) a second antenna element, where the first portion is attached to the first conductor and the second portion is attached to the second conductor, and where the second antenna element is selected to provide a desired impedance value of the antenna.
7) Indian patent application number ,238/CHE/2007' describes how the product availability can be determined using radio frequency identification (RFID) by determining whether a RFID tag is detectable by a RFID reader and setting a product availability condition, where the RFID tag is not attached to the product, and where distance between the RFID tag and the RFID reader changes as quantity of the product changes. A system for determining availability of products using RFID can comprise a product display unit, a RFID reader, a RFID tag associated with the product display unit, and a computing device configured to set product availability conditions. In the system, distance between the RFID tag and the RFID reader changes as quantity of the product changes.
8) Indian patent application number '3696/CHENP/2007' describes a Radio Frequency Identification (RFID) receiving method for use with an Enterprise Resource Planning (ERP) system. The method includes reading, at a receiving point, information from RFID tags included on delivered items, which are not recorded on an Advanced Shipment Notification (ASN). An item arrival journal including item arrival lines is generated. By calling a mapping form, the item arrival lines are displayed along with RFID tag information indicative of delivered items. Then, mapping form logic is used to automatically map at least some of the delivered items corresponding to the RFID tags to item arrival lines to thereby match delivered items with ordered items.
9) Indian patent application number '5826/CHENP/2007' describes a wireless system that includes a plurality of objects. The wireless system includes a controller and a radio frequency identification (RFID) read-write (RW) device. Each of the objects includes an RFID device and a transceiver. An

object and methods of tracking objects are also disclosed.
10) Indian patent application number ,818/DELNP/2008' describes an invention that relates to a method for scheduling communications over a wireless communication subsystem and a radio frequency identification (RFID) communication subsystem, said method comprising determining one or more periods of activity of the wireless communication subsystem; deriving one or more periods of non-activity on the basis of the one or more determined periods of activity; synchronizing an operation of the radio frequency identification (RFID) communication subsystem with the one or more periods of non-activity; and triggering the operation of the radio frequency identification (RFID) communication subsystem in accordance with the one or more derived periods of non-activity to enable substantially concurrent communications operation of the wireless communication subsystem and the radio frequency identification (RFID) communication subsystem.
11) US patent number 7,356,495' describes a system to monitor item placement and item movement on surfaces includes an identification system embedded in one or more surfaces and a computer. The identification system periodically scans the surfaces to generate data related to items placed on the surfaces. The data includes item type, item location on each surface, and number of items placed on each surface. The computer receives and processes the data to monitor item placement and item movement on the surfaces.
12) Indian patent application number ,1630/WUMNP/2007' describes a system that includes a request module adapted to receive a request from an initiation interface initiated by a user and a user profile module adapted to associate the request with a user profile of the user. The user profile includes at least a payment plan selected by the user and an identification number of the user. The system also includes a payment interface adapted to submit a payment demand to the payment plan and a mobile communication interface adapted to transmit a confirmation to a mobile communication network for transmission to a wireless device associated with the identification number; In the system, the initiation interface may be a wireless device, a magnetic swipe reader, a wireless barcode reading device, an RFID interface, a website, and/or a web banner interface. A method of operating a server is provided. A computer-readable storage medium containing a set of instructions for a processor is provided.
13) Indian patent application number v01l3/DEL/2005' describes embodiments of an invention that relate to methods, systems, and computer-readable media for mobile device messaging. Mobile device messaging comprises collecting from an originating system information including content data to be sent to the mobile device. One or more short messages are generating for encapsulating the content data. The one or more short messages are formatted to be readable by a web service and the content data is formatted to be readable by the mobile device. The one or more short messages are sent to the web service for delivery to the mobile device.
14) US patent number 6,843,415' describes.methods and apparatus, including computer program products, for communicating item disposition information between publishers and subscribers such as RFID tag readers and item tracking systems. Event routers can be used to distribute the information and an extended object naming service can be used to locate event routers. The items being tracked can have a hierarchical relationship with each other. Subscribers can choose to subscribe only to events relating to items at a particular level of the hierarchy.
15) US patent number 7,403,788' describes a system and method to enable a user to initiate a communication with an organization using a mobile communication device by means of a trigger system. A system and method to enable an organization to acquire a user mobile device address by means of a trigger system. A system and method to enable an organization to respond to a user by means of a trigger system and a message application server. A system and method to enable organizations to deliver mobile messages, coupons, offers and promotions to users mobile device by means of a combination of a trigger system, a message application server and an offer application.
16) US patent number 7,497,370' describes a supply chain (or other process) visibility solution that combines RFID technology with a data visibility architecture to provide real-time or near real-time supply chain information at various stages of the supply chain (or other process). The system uses a data gathering architecture which collects data from multiple sources about an object. The sources of data include RFID tags, scanners and manual input. The data from the RFID tags is used to correlate the gathered data to attributes associated with the object (e.g., name, description or price). The gathered data and attributes are stored in a data store according to a customizable schema and published for consumption by one or more business processes.

This prior art search reveals that although excellent technological advancements have been made recently in each related field, there has been no integrated attempt to provide a Theory of Constraints based system for an automated warehousing of materials, with a visual knowledge & physical control over availability & release of materials, applicable in any industry but particularly in the heavy engineering industry; and wherein an automated tracking of material status & instant communication about the same are provided fcr.
Drawbacks of Prior Art :
There are several drawbacks in the prior art, that can be noticed if we take a look at the following challenges faced by the manufacturing, assembly & integration industry, particularly the heavy engineering industry :
- The purchasing and hence receiving of materials required for various products being manufactured, assembled or integrated; usually happens in a bulk manner i.e. the various items are clubbed together for commercial advantage usually. This is in conflict with the requirements of the downstream functions (particularly Production functions) that require the items as per the manufacturing, assembly or integration requirements of each individual product, the requirements being typically specified in engineering drawings referred by those functions.
- The receiving of materials & receiving inspection of the same are typically carried out by Warehousing and QC functions. These functions are not necessarily aware of the (dynamic) priority, sequence & sets/kits in which the items are required by the downstream functions (particularly Production functions).
- The information about the status of required items in Warehouse i.e. whether they are received, whether they are inspected, whether they are accepted by QC, or whether they have been kitted may not be readily available to downstream functions (particularly Production functions).
- The above-said information may be availabie in computer systems like ERP, but the updating of the information depends on Warehousing personnel doing it regularly. Also the said information can be obtained by downstream functions only after accessing a computer & going through a series of tasks to be performed in the ERP system like logging in, searching, opening various screens/sessions in a specific order, finding the required information and then logging out. The downstream functions (particularly Production functions) are usually unhappy about this kind of activity (accessing computer systems like ERP) as they see no value being added there to their core function which is to produce goods.
- Warehousing function can.use RFID tags & hand-held RFID writer-cum-reader so as to update the status on computerised systems quickly, however normal RFID tags do not function properly in metallic environment typically prevalent in heavy engineering industry.
- Even if RFID set-up as above is put in place, there is no quick graphical / visual indication of the status in the commonly available ERP systems.
- Even if a graphical / visual indication is provided for by a suitable add-on computer system, the information about status of required material and the status of WIP inventory on issue of material, to the downstream functions is available only in 'pull' mode, which is perceived to be non-value adding activity as mentioned above.
- Even if supposing all the above problems are addressed, and procedures/guidelines & soft controls are provided, there is no guarantee that the Production functions themselves will withdraw & process materials in the prescribed manner only.
- When this Warehousing activity is outsourced, typically causing the Warehouse to be located at some geographical distance from the Production shop floor, it is extremely difficult to know the correct status & give timely feedback as required, unless the information is made available to the concerned through an on-line event monitoring & messaging system.
To address ail the above challenges together, an integrated & fool-proof solution was desired. The present invention provides for such a solution, in the form of an integrated system.
Objects of the Present Invention :
The object of the present invention is to provide an integrated system for an automated warehousing (storage & retrieval) of materials.

It is a further object of the invention to provide a Theory of Constraints based system wherein the warehousing activities are aligned with the downstream requirements in the production chain.
It is still further an object of the invention to provide a non-negotiable control on release (issue) of material only in line with the TOC principles.
It is stil! further an object of the invention to provide the said material status information in an easy color-coded format for quick understanding of the users.
It is stili further an object of the invention to provide an RFID-based tracking of receipt & issue of materials.
It is still further an object of the invention to provide a solution generally applicable in all types of industries, but more particularly in the heavy engineering industry, where the materials consist mainly of metallic types.
It is still further an object of the invention to provide this information to the concerned people instantly.
Figures of the Present Invention ;
Figure 1 shows the schematic arrangement of the Present Invention, in its preferred embodiment. Figure 2 shows the flow -chart of the Present Invention.
Device and Method of the Present Invention :
The device and method of this invention in its preferred embodiment has a schematic arrangement as depicted in Figure 1 and is explained below.
The present Invention, in its preferred embodiment, as depicted in Figure 1 above, consists of an automated storage & retrieval system (101) provided with a user interface; a Radio Frequency I Denotation (RFID) read-write (RW) device (102), RFID tags (103); a computer system (104) to store, process & transmit the information related to items that are tagged with the said RFID tags (103), and related to the signals received from the said device (102), and related to the messages sent to or received from mobile phones (105); a transceiver for mobile phone communication (106), a means (107.) of wired or wireless communication between the said device (102) and the said computer (104), and a means (108) of wired or wireless communication between the said computer (104) & the said transceiver (106).
Description of the Present Invention :
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the preferred embodiment.
The system of the Present Invention uses a computer-controlled automated system for storage & retrieval of materials, it draws cues from the Theory of Constraints, takes advantage of recent developments in the field of RFID, provides for a computer system to manage warehousing information & to present the same in a graphical / visual manner, and utilises the 'push' mode of dissemination of required information to the concerned on their mobile phones. The following is a sequential description of how the invention serves all these purposes.
1) Theory of Constraints angle :
The present invention embodies this TOC advice into a computer system wherein - Production personnel indicate the product-wise priority in which the materials are required on shop floor, and also they define 'full-kit/ requirements in the system to specify the sets of items that are required by them in the specified sequence. This information is made available to the upstream functions (particularly Warehousing and QC), so that the processing of incoming material can take place in the desired order of priority, sequence & material can be arranged in required sets/kits.
2) Visual / graphical presentation of information :
The information about receipt and about receiving inspection is visually presented in the said

computer system by use of a color-coding corresponding to different statuses. Additionally the color-coding is also extended to indicate the statuses after the material is issued till such time that the same is used up in production. This serves the purpose of quick visual indication about the WIP being built or being converted into Finished Goods (FG).
3) Automated storage & retrieval of materials from a warehouse :
The present invention deploys a computer-controlled storage & retrieval system wherein the control interface allows release (issue) of oniy those sets/kits of material that are full & therefore ready for withdrawal. This access is further controlled by providing a log in-password to access the controlling interface.
4) Easy & quick update of information through RFID technology :
The present invention deploys Ultra High Frequency (UHF) type of RFID tags and corresponding UHF type RFID RW device. These type pf tags function properly in presence of metallic environment, thus are useful in the heavy engineering industry. The said RFID RW device is used to write new status of material on the said RFID tags, when the kit is ready - for example. The said RFID RW device is connected to a computer via wired or wireless communication means, and therefore the changed status of kit can be immediately updated in the above-mentioned computer system. Similarly issue of material & using up of the same in shop floor can be captured using the said RFID RW device to scan the said RFID tags per event; thus causing an update in the inventory (WIP/FG) status in the said computer system.
5) Instant dissemination of relevant information to intended recipients through mobile messaging :
The present invention further deploys a transceiver to send instant messages to specified personnel,
triggered by a change in status of the material / kits. The concerned managers thus get notified, or
alternatively they can query the computer system via same messaging gateway regarding required
information.
While the preferred embodiment of the invention is described as above, there are many other embodiments possible, some of which are mentioned below as examples. This in no way limits the further possibilities of extending the essence of the invention by deploying additional features in it.
In one embodiment of the invention, for example, the said computer system may be integrated with an ERP system in order to have the information about receipt, incoming inspection & issue of materials coming from & going into the said ERP system in a synchronized fashion.
In yet another embodiment, for example, the product structure information can be interlinked with a PLM system, again in a synchronized fashion.
Again, depending on the requirements & limitations specific to a particular situation, the various above-mentioned embodiments can be modified or combined or partially implemented, thus giving rise to further embodiments of the present invention. The present invention being the source of such variations, it pre¬empts & implicitly covers all such usages.
The flow-chart included at the end of this document encapsulates the preferred embodiment of the present invention. The computer system is named as MICOS - Material & Inventory control System, in the flow¬charts.
Advantages of the invention :
There are several advantages of the present invention over the existing art, as described below.
1) As mentioned elsewhere in this document although there are various prior art solutions devised in the fields of automated storage & retrieval systems. Theory of Constraints based systems, visual control, automated tracking and instant communication separately; the present invention provides for a system designed to address all these requirements in an integrated manner.
2) The present invention addresses the requirements of aligning warehousing of materials w.r.t. the requirements of downstream (mainstream) functions in the production chain, and also provides a firm way of ensuring the issue of materials by Production in the prescribed manner.

3) Again, the present invention is designed keeping in mind requirements related to warehousing of materials, particularly in heavy engineering industry where the prevalent environment is mostly metallic.
4) If this Warehousing activity is outsourced, being an Internet-based architecture, this invention can be easily extended to the concerned service providers for using it at their end, while the producers can continue to monitor the status at their end simultaneously and also subscribe to the various mobile alerts. Therefore virtually the outsourced activity can be kept under the Producer's control.
5) Outsourcing as above typically causes the Warehouse to be located at a distance from the Production shop floor. In such situation, it is extremely useful to know the status & give corrective feedback as required, as the information is made available to the concerned through this on-line event monitoring & messaging system.