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Use Case

MATERIAL FLOW TRACKING AND ANALYSIS

Unlock visibility and efficiency with Inpixon RTLS material flow tracking. Gain real-time control over material movements from supply chain to production. Enhance inventory management, streamline production, reduce costs, and improve quality.

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Greater Efficiency with Real-Time Tracking and Analysis of the Material Flow

Our Real-Time Tracking and Analysis system, powered by RTLS (Real-Time Location System) technology and our comprehensive RTLS platform, transforms how businesses monitor and manage their material flow.

With our solution, you gain real-time visibility into the movement of materials throughout your facility or supply chain. Every item is tagged and tracked with precision, allowing you to monitor its journey from point of origin to destination instantaneously.

But it's not just about tracking. Our RTLS platform offers powerful analytics capabilities, providing actionable insights into material flow patterns, dwell times, bottlenecks, and potential areas for improvement. With this data-driven approach, you can streamline processes, optimize resource allocation, and ultimately enhance productivity and profitability.

Moreover, our solution seamlessly integrates data with other systems, ensuring that information flows effortlessly across your organization. Whether it's your ERP system, WMS , or MES, our RTLS platform enables cohesive data exchange, facilitating holistic decision-making and operational synergy.

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Benefits of RTLS for Material Flow Tracking & Analysis

  • Enhance Visibility and Control through Seamless Information Flow
    • Enhance visibility and control over material flow from supply chain to production
    • Improve decision-making and proactively manage material movement
    • Identify and resolve bottlenecks for enhanced process efficiency
  • Redefine Inventory Management
    • Complemented by MFT to monitor material flow and avoid shortages or overstocks
    • Improve overall warehouse efficiency
    • Strengthen decision-making and facilitate flexible responses to dynamic production demands
  • Transform Production Processes
    • MFT supports adaptive control of the production line
    • Identify and eliminate bottlenecks early on
    • Utilize RTLS and MFT for just-in-time production and precise scheduling

  • Optimize Material Flow Analysis
    • Identify and improve inefficient processes
    • Fine-tune material flow tracking with status-based filtering
    • Implement inbound and outbound control from respective zones
  • Drive Cost Reduction
    • Efficient material flow organization reduces warehouse costs
    • Optimize energy consumption and minimizes resource waste
    • Track and record timestamps for streamlined cycle time analysis
  • Enhance Quality Improvement
    • Efficient material flow contributes to improved product quality
    • Reduce bottlenecks and delays in production
    • Ensure more consistent and higher-quality output

Example Uses for
Material Flow Tracking

  • Inventory Management and Tracking of Warehouse Movements.
    Utilize RTLS for precise inventory localization and tracking of assets within warehouses. Implement MFT to monitor material flow, automate inventory updates, and prevent shortages or overstocks. This ensures precise monitoring of material flow from the supply chain to production.
  • Automated Production Line Control.


    Integrate RTLS into manufacturing lines for real-time tracking of production steps. Material flow tracking enables adaptive control of the production line to avoid bottlenecks and maximize efficiency.
  • Just-in-Time Production.


    Utilize RTLS to monitor parts' precise real-time locations, ensuring timely availability for production. Leverage material flow tracking and analysis for precise scheduling, facilitating efficient Just-in-Time production.
  • Traceability and Quality Control.


    Link RTLS with material flow tracking to accurately trace the origin of products and components. In case of quality issues, swiftly respond, identify, and isolate affected batches with MFT.
  • Optimize Material Lead Time in Production.

    Streamline your production process by optimizing the lead time of materials. Monitor the time taken for materials to move from entrance to exit, reducing cycle time and boosting production throughput rate. Take action to accelerate material processing, enhancing your overall efficiency.
  • Streamline Workflow.



    Resolve transportation bottlenecks for seamless material flow and address inventory issues to minimize retrieval delays, optimizing your production processes for greater efficiency.
  • Minimize Downtime and Costs.


    By resolving bottlenecks, minimize downtime linked to production delays, ultimately reducing costs and maximizing profitability.
  • Optimize Inventory Levels and Accuracy.


    Utilize MFT to track inventory movements in real-time, optimizing inventory turnover frequency and reducing inventory costs per unit. This ensures improved inventory accuracy and more precise inventory forecasts, mitigating the risk of stockouts or overstocks.
  • Enhance Quality Control.


    Employ MFT to monitor material flow and identify quality deviations early in the production process. This leads to a higher first-pass quality rate, reduced rework rate, and lower percentage of defective products in the total output, thereby decreasing scrap costs.
  • Streamline Delivery Times and Production Capacity.

    Implement MFT to streamline production processes and ensure on-time delivery by effectively managing material flow. This optimization results in better utilization of production capacity, as evidenced by a higher production capacity utilization rate.
  • Reduce Waiting Times and Downtime.


    Utilize MFT to reduce waiting times and downtime by maintaining continuous material movement throughout the production process. By maximizing machine utilization and minimizing average waiting time, companies can achieve higher productivity levels and reduce operational inefficiencies. 

How Material Flow Tracking & Analysis Works with Inpixon RTLS

Material flows and their relationships can be analyzed in real-time or retrospectively using Inpixon RTLS. Inpixon records precise timestamps (day/hour:minute:second) for the entry and exit of each zone, accurately calculating dwell time to the second. The final status provides total transit time across all zones and intermediate transit times per asset/package/material flow relationship.
By leveraging historical data on completed transports and dwell times at nodes, comprehensive process optimizations of material flows can be conducted. This data is seamlessly transferable to various systems like MES, ERP, or other planning software for in-depth analysis and decision-making.

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Material Flow Tracking & Analysis Building Blocks

Your solution is unique to your business. That’s why we’ve built our comprehensive platform to be flexible and dynamic, allowing you to leverage multiple types of technologies to power a wide array of use cases, build tailored location-aware hardware and solutions, and seamlessly integrate with asset management applications, IoT platforms, and other external systems to solve your unique problems.
  • Inpixon RTLS Platform-1

    RTLS Platform & Factory — Material Flow module

    Inpixon's RTLS platform empowers real-time material flow tracking, enhancing supply chain visibility. The Factory — Material Flow module meticulously oversees material entry and exit points, delivering precise dwell time calculations for meticulous control and optimization. With real-time location data for materials and transport flows, immediate visibility is ensured, facilitating streamlined operations.

  • UWB-RTLS-NODE

    RTLS Node UWB

    The RTLS NODE UWB stands out as a fixed antenna system designed for real-time indoor positioning, particularly suited for forklift tracking. This robust UWB positioning antenna provides precise ±40 cm location accuracy and includes an internal accelerometer and temperature sensor.

    As a low-maintenance and cost-efficient RTLS anchor, the RTLS NODE UWB offers remarkable scalability for indoor applications. It seamlessly complements GPS or chirp technologies. With its rugged and waterproof housing, this solution is a durable choice for demanding industrial deployments, ensuring reliable and accurate vehicle tracking in various environments.

  • RTLS-ANCHORS-NANOANQCHIRP

    Inpixon nanoANQ Chirp

    The Inpixon nanoANQ Chirp is a deployment-ready, industrial-grade RTLS anchor built for long-range location tracking applications across indoor and outdoor environments. It leverages unique Chirp RF technology to deliver long-range positioning of up to 500 meters with 1-2 meter location accuracy.

  • Mask group (4)-1

    VehicleTAG+

    The VehicleTAG+ is a cost-effective industrial tag designed for tracking forklifts, autonomous industrial vehicles, and AGVs. This multisensor tag enables real-time tracking using UWB, GPS, and optional LiDAR technology. It provides seamless indoor and outdoor tracking and includes integrated sensors for temperature, humidity, movements, and shocks.

    With enhanced connectivity through CAN-Bus, Wi-Fi, BLE, and optional sensors like fork RFID readers, the VehicleTAG+ is well-suited for various industrial applications. Engineered to optimize overall equipment effectiveness (OEE), it enhances quality and flexibility in production and intralogistics. Easy to install on material transport vehicles, it is hardwired to a power source for consistent operation.

  • asset-tag-pro

    AssetTAG Pro

    The AssetTAG Pro is a powerful UWB tracking tag. With superior battery life support for wide temperature ranges, this robust tag is ideal for real-time rack and load carrier tracking applications, mobile robots, production skids, indoor navigation, and more.
  • asset-tag-compact

    AssetTAG Compact

    The AssetTAG Compact is a versatile ultra-wideband (UWB) tag. This compact and robust tag was designed to address a wide range of applications including identification, presence detection, asset location tracking in complex industrial warehouse and manufacturing areas, real-time location tracking of load carriers, indoor navigation, yard management, smart building, autonomous driving, and more.
  • asset-tag-micro

    AssetTAG Micro

    The AssetTAG Micro is a lightweight and low profile ultra-wideband (UWB) tag designed to track the real-time location and movements of small assets including tools, load carriers, small boxes, and the like across large facilities.
  • RTLS-Asset-Tag

    Inpixon Asset Tag

    The Inpixon Asset Tag is a long-range, industrial-grade chirp spread spectrum (CSS) tag that accurately tracks the real-time location and movements of critical mobile assets across large facilities such as warehouses, factories, hospitals, and other process-driven environments. Its 2.4Ghz CSS technology enables reliable indoor and outdoor applications with no license required.
  • rfid icon

    RFID

    Automated Data Capture: RFID tags attached to assets or inventory items enable automatic data capture without requiring line-of-sight scanning. This significantly reduces manual intervention and human error, streamlining the tracking process.

    Real-Time Visibility: RFID readers continuously communicate with RFID tags, allowing for real-time visibility of assets as they move through various stages of the material flow process. This visibility enables timely decision-making and enhances overall operational efficiency.

    Increased Accuracy: RFID technology offers higher accuracy compared to traditional barcode systems, as RFID tags can be read from a distance and even in harsh environmental conditions. This ensures accurate tracking of assets and reduces the risk of errors in inventory management.

    Enhanced Traceability: With RFID, each asset or inventory item can be uniquely identified and tracked throughout its entire lifecycle. This enhances traceability, making it easier to identify the origin, location, and movement history of assets, which is particularly crucial for industries with stringent regulatory requirements.

Material Flow Analysis FAQ

  • What is material flow tracking?

    Material flow tracking is the process of monitoring and managing the movement of materials through various stages of the supply chain and production process. This includes tracking raw materials, components, and finished goods as they move from suppliers to the manufacturing floor and finally to the end customer. By using technologies such as UWB, BLE, or Chirp, companies can gain real-time insights into their materials' location, status, and movement.

  • What is material flow analysis?

    Material Flow Analysis in manufacturing is a systematic approach used to track and quantify the flow and stock of materials within the manufacturing process. This analytical method provides insights into how raw materials, components, and finished products move through different stages of production, from initial supply to final output.

  • What are the key differences between conventional methods and RTLS in measuring material flow?

    Conventional methods often rely on manual or periodic data collection, while RTLS enables real-time tracking for immediate responses to changes. RTLS provides more precise and automated data collection, higher automation, real-time analysis, flexibility, scalability, and seamless integration with other systems.

  • Can MFT help in reducing operational costs for businesses? If so, how?

    Yes, Material Flow Tracking (MFT) can contribute to reducing operational costs by optimizing the flow of materials throughout the supply chain. MFT systems enable better visibility and control over inventory levels, minimizing excess stock and preventing shortages. This efficiency in material management leads to cost savings associated with storage, carrying, and handling of inventory.

  • What role does MFT play in enhancing quality control processes within a production environment?

    MFT plays a crucial role in quality control by providing real-time visibility into the movement and condition of materials during the production process. It allows businesses to track and trace the origin of components, identify potential quality issues early in the production cycle, and take corrective actions promptly. 

  • How does Material Flow Tracking support sustainability initiatives in a company's supply chain?

    MFT supports sustainability initiatives by providing a comprehensive view of the material flow, enabling companies to identify areas for resource optimization and waste reduction. It helps monitor and minimize operations' environmental impact by promoting efficient resource usage, reducing energy consumption, and facilitating responsible disposal practices.

  • Are there specific industries or sectors where Material Flow Tracking is more crucial?

    Material Flow Tracking is crucial in industries where traceability, compliance, and quality control are paramount. Sectors such as pharmaceuticals, where product safety is critical, benefit significantly from MFT. Additionally, manufacturing industries with complex supply chains and high-value goods find MFT valuable for optimizing operations.

    • Electronics Manufacturing:
      In the electronics industry, where precise component tracking and compliance with environmental regulations are crucial, MFT ensures the traceability of materials, components, and products. This is vital for meeting quality standards and managing the complex supply chains inherent in electronics manufacturing.
    • Automotive Industry:
      The automotive sector relies heavily on MFT to optimize the flow of materials in the production of vehicles. Tracking components from suppliers to assembly lines helps enhance efficiency, reduce lead times, and ensure that high-quality parts are used in the manufacturing process.
    • Chemical and Petrochemical Industries:
      For industries dealing with chemicals and petrochemicals, safety and compliance are paramount. MFT plays a critical role in monitoring the movement of hazardous materials, ensuring proper handling, and meeting strict regulatory requirements to prevent accidents and environmental harm.
    • Aerospace and Defense:
      In the aerospace and defense sectors, where precision and compliance with stringent regulations are essential, MFT aids in monitoring the supply chain for specialized materials. This includes tracking the production of critical components, managing inventory for just-in-time manufacturing, and adhering to strict quality standards.
  • What is the significance of dwell time calculation in Material Flow Analysis?
    Dwell time calculation in Material Flow Analysis adds insight by providing information on the time materials spend at different points in the production process. This helps identify areas where optimization can lead to improved efficiency.
  • How does the 'end status' in the material flow analysis contribute to optimizing the workflow?
    The 'end status' defines the total cycle time of materials and enables manufacturers to identify bottlenecks and optimize the workflow. It provides a comprehensive overview of the entire material flow process.
  • Can Material Flow Analysis be applied at different levels within a company or production facility?

    Yes, Material Flow Analysis can be applied at various levels, including individual production facilities, logistical networks, or the entire value chain of a company.

Material Flow Tracking & Analysis Resources
IoT

Optimizing Production with Material Flow Analysis & Automation

15 minute read | April 28, 2022
IoT

Optimizing JIT & JIS Process Quality Control with RTLS

13 minute read | July 20, 2022
IoT

Software-Driven Facilities: The Future of Warehousing & Factories

18 minute read | March 28, 2023
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