In manufacturing environments, real-time location systems provide asset tracking and positioning capabilities that enable facilities to identify the presence, precise location, and status of equipment, vehicles, and goods. Whether it’s machinery, inventory, tools, vehicles, or even team members, there are multiple use cases where companies benefit greatly from the ability to monitor and identify the location of assets.
The manufacturing space faces its own unique challenges that make real-time location awareness important. For example, in many facilities, significant customization of production workflow must happen on the fly. This is a challenge in a production environment wherein production processes must be completed manually without error. Workflow and asset tracking are required for workers to know the correct operation and tool calibration required for each sub-assembly. There are a variety of pain points that RTLS solutions have the power to address, but first, we must address what an RTLS is and how it works in this context.
What is RTLS?
RTLS (Real Time Location System) detects the current geolocation of an asset based on signals received from that asset, whether it’s a smartphone, an RTLS tag, or a badge.
Modern RTLS solutions are based on wireless technologies, such as Wi-Fi, BLE, UWB, Chirp, and Active RFID, and essentially work by determining a device’s presence (is it physically in the building?), its proximity (what is it near within the building?) or position (what is the asset’s current and constant location within the building?).
RTLS usually excludes GPS because it is generally not available indoors, and its latency means it is not truly real-time.
How Does RTLS Work?
An RTLS platform consists of a transponder (RTLS tags/badges), a receiver (RTLS anchors), and a location engine (RTLS software) to interpret the data from each tagged asset. Location data is sent wirelessly by transponders (e.g., the tag, which is the mobile part of the RTLS) to devices attached to the ceilings/walls (e.g., Anchors, the fixed infrastructure of the RTLS). The data is sent wirelessly (or via ethernet cable) from the Anchors to a Server, with the location engine software calculating the position. The location data can then be visualized on a digital twin and accessed in a variety of ways, including via cloud-based APIs, mobile apps, or integrated software.
For example, Inpixon offers RTLS tags, anchors, and a location engine to get organizations set up with an RTLS solution. In addition, there is a location engine that filters the positions to improve accuracy, can help present tags on a map, has search and location history functionality, and geofences can be implemented. Inpixon is unique in offering two types of radio: UWB for higher accuracy and our proprietary 2.4 GHz Chirp Spread Spectrum (CSS) for a much longer range than UWB. In addition, Inpixon´s RTLS platform can integrate other tracking technologies such as LiDAR, WiFi, GPS, Wirepas, and more.
How Manufacturing Organizations Use RTLS
As manufacturing facilities continue to grow and evolve, the need for real-time location systems has become increasingly important. RTLS technology provides manufacturers with a valuable tool to track assets, streamline operations, and improve overall efficiency.
Asset Tracking
One of the most significant advantages of RTLS in a manufacturing facility is material flow and asset tracking. Whether it’s raw materials, work-in-progress goods, or finished products, RTLS ensures that manufacturers can keep track of their assets at all times. By using RFID tags or other tracking devices, manufacturers can monitor the movement and location of assets, which helps to reduce theft, prevent loss, and identify inefficiencies.
Inventory Management
RTLS technology significantly enhances inventory management in manufacturing settings by tracking the movement of goods and materials throughout facilities. This capability enables manufacturers to optimize inventory processes, maintain optimal stock levels, and effectively prevent stock-outs. By minimizing overstocking, RTLS helps reduce waste and associated costs. Additionally, real-time visibility provided by RTLS improves efficiency by reducing search times and facilitating proactive management actions based on accurate location data.
Quality Control
RTLS technology enhances quality control in manufacturing facilities by tracking the movement of goods throughout the production process. This allows manufacturers to swiftly identify and address potential quality issues, minimizing defects. RTLS automates component plausibility checks by verifying correct sequence and compatibility. Real-time warning messages promptly notify of any deviations or errors in the component sequence. This capability helps pinpoint exact locations of defective parts, reducing waste and enhancing overall product quality. RTLS supports efficient quality management, ensuring products consistently meet high standards during production.
Compliance
RTLS ensures compliance in manufacturing facilities by:
- Enabling Real-Time Tracking: Continuous monitoring of the location of products and materials to ensure proper handling.
- Ensuring Proper Conditions: Monitoring environmental conditions (e.g., temperature, humidity) and access controls to comply with storage and transport regulations.
- Automating Documentation: Comprehensive logging and easy reporting for audits and inspections.
- Enhancing Process Safety: Monitoring hazardous materials and assisting in emergency evacuations.
- Improving Training Documentation: Tracking attendance at mandatory training sessions and documenting completion.
RTLS provides transparency, control, and efficiency to ensure compliance with regulatory standards.
Safety and Security
RTLS enhances safety and security in manufacturing facilities by:
- Tracking Movements: Monitoring employee and asset movements to identify and mitigate potential safety hazards proactively.
- Preventing Unauthorized Access: Restricting access to sensitive areas to prevent theft and protect valuable assets and data.
- Emergency Response: Providing real-time location data to facilitate efficient evacuations and emergency responses.
- Monitoring Compliance: Ensuring employees follow safety protocols and procedures through continuous oversight.
RTLS improves overall safety and security, safeguarding both personnel and assets.
Process Optimization
Finally, RTLS technology can help manufacturers to optimize their production processes. RTLS optimizes production processes in manufacturing by:
- Identifying Bottlenecks: Tracking the movement of goods and assets to pinpoint and address process slowdowns.
- Removing Inefficiencies: Analyzing movement patterns to eliminate waste and improve workflows.
- Streamlining Operations: Coordinating asset and material flow to enhance operational efficiency.
- Integrating Automation: Automating data collection and decision-making processes based on real-time location data.
This integrated approach reduces production costs, increases throughput, and improves overall efficiency in manufacturing facilities.
By providing real-time tracking for tools and other critical parts and equipment, every step of the manufacturing process will benefit greatly. RTLS solutions lead to increased productivity through better coordination of tools and equipment, a reduction in time wasted searching for products, and reduced operational costs through more efficient calibration and preventative maintenance.
Book a consultation with our sales team to learn how RTLS can benefit your organization today!