Real Time Location Systems in Manufacturing and Indoor-Logistics

For many years the strategy in mass production was clear: Implement the greatest degree of automation possible with the ultimate target of becoming a “lights-out” plant requiring no human presence on-site. Significantly higher investments for automation as compared to manually organised production processes were justified by the assumption of never-ending growth. Why should we suddenly challenge this assumption?

Smart automation (read: real-time location systems) instead of unmanned production is a typical example of playing smarter, not harder. It provides most of the benefits of a fully automated plant at a much lower investment cost and maintains the flexibility of manually controlled production processes.

Digitalisation is ubiquitous and is transforming manufacturing processes. But as for any other industrial investment: Improvements must be measurable. Digitalisation done right, can sustainably improve production Key Performance Indicators (KPI) in tyre manufacturing.

The way forward is to choose an off-the-shelf IIoT solution, which is tailored to the needs of tyre manufacturing from hard- and software design as well as IT and user interfaces. The chosen solution must be low in running cost, maintenance effort and ideally doesn’t require any training for blue-collar personnel at all.

In order to reduce production costs in tyre manufacturing, any IIoT-based solution must help to increase machine utilization, reduce scrap of raw materials, eliminate production errors of the final product and increase labour productivity.

The Asset Agent server application offers standard interfaces to ERP systems as well as other production and material flow management systems for seamless integration into existing IT infrastructure.

Learning and getting insights are the foundation of improvement. For the past centuries, the scientific approach has been an incubator of innovation, propelling human technology and understanding faster than ever. Concepts such as Kaizen rely like science on the availability of data to measure and, eventually, to adapt a hypothesis. Setting operational performance objectives allows you to focus on specific challenges and improve them.

Insight into the nature of business is necessary to look at the critical processes and factors that make or fail a business. Data available to the team will shift the focus to essential aspects and help uncover your operations' true, existing bottlenecks. In manufacturing, an real time location systems solution may be the missing link to solve performance issues.

Whether you're looking to enhance efficiency, reduce costs, improve real time location systems or simply gain a competitive edge, Key Performance Indicators are the key to analyse operational performance. This article highlights the significance of key performance indicators (KPIs) and real-time data in manufacturing.

The United Nations has set 17 ambitious goals to end poverty, protect our planet and ensure prosperity for all people worldwide by 2030 – these are known as the Sustainable Development Goals (SDGs). As citizens and business leaders, it is up to us to ensure that these goals are met in the next decade. It requires a concerted effort from governments, international organizations, businesses and civil society – each with its unique role to play.

In this blog post, we will explore how the Tire Industry can make an impact on sustainable development, discussing their roadmap for achieving the SDGs. Read on to learn more about the Tire Sector SDG roadmap and how they plan to reach their objectives.

Gemba Walk is an important business approach that has become increasingly popular in the world of business. If you’ve heard of it but don’t necessarily understand what it is, this article will explore the meaning of Gemba Walk and why it is so beneficial for both employers and employees.

This article will discuss the origin of the term, the benefits of Gemba Walks, and the challenges that are associated with it. We’ll also go over what employers can do to optimize the impact of the Gemba Walk, and how the employee can benefit from it. Ultimately, this article will give you a comprehensive understanding of the Gemba Walk and why it is a valuable tool for organizations - before you start investing in machinery, automation and change management.

Gemba walks are an invaluable tool that can help companies identify areas of opportunity and maximize the effectiveness of process optimization. With a set of well-defined steps, your business can benefit from this powerful methodology and reap the rewards of consistently improved performance.

This article will provide an essential Gemba Walk Checklist and guide, helping you understand what to consider, how to observe and the steps to ensure a successful Gemba Walk.

Have you ever wondered how businesses become so successful? A lot of times, it’s because they use the right tools and processes to take them to the next level. And one such tool is the Gemba Walk.

A Gemba Walk is a Japanese Lean management tool used to improve processes by observing them on the ‘gemba’, or the place where the work actually happens. It is widely used in the manufacturing industry, but its advantages are widely applicable in different sectors, including healthcare, hospitality and retail.

In this article, we’ll discuss what Gemba Walks are and how you can use a Gemba Walk template to benefit your business. We’ll also provide you with a free, downloadable Gemba Walk template to conduct Gemba Walks at your workplace. So, let’s get started!

Gemba walks are a cornerstone of Lean management and the Toyota Production System (TPS), offering a hands-on approach to understanding and improving processes on the factory floor. By observing workflows, engaging with operators, and identifying hidden inefficiencies, Gemba walks help leaders uncover opportunities for continuous improvement. This article explores real-world examples of Gemba walks in action, showcasing how these practices can reveal hidden issues, strengthen communication, and enhance operational efficiency through practical, actionable insights.

Records provide evidence of conformity to all your legal and customer requirements. For ISO 9001, records must be controlled. In addition, they are essential for product liability reasons in an industrial environment.

From early ages to mass production, the quality and quantity of data have increased dramatically. In recent times, information systems and computers empowered industrial players to store, exchange, and analyse such data more comprehensively. However, this information is still recorded and handled manually way too often.

What if you could monitor all processes of your facility at all times? Real-time location systems enable insights that empower unmatched visibility and the ability to see and manage complex set-ups and organizations.

A real-time location system (RTLS) is an indoor/outdoor positioning system gaining popularity in industries to improve efficiency, productivity, and safety. Using RTLS enables accurately tracking and locating assets and people inside industrial premises. Depending on the surrounding materials, RTLS is capable of performing centimetre-level accuracy.

Inefficiencies in manufacturing can lead to significant financial losses. For instance, unplanned downtime costs industrial manufacturers up to $50 billion annually. To address these challenges, integrating advanced systems like pick-to-light (PTL) can streamline operations, reduce errors, and enhance productivity. This article discusses how PTL systems optimise material handling, improve accuracy, and integrate seamlessly with factory IT infrastructure. By implementing PTL, manufacturers can minimise inefficiencies, enhance workflow synchronisation, and significantly boost overall operational performance.

Welcome to the Future Factory! The fourth industrial revolution is upon us, and companies of all sizes and sectors are beginning to embrace Industry 4.0 technologies. From robotics and automation to process automation and data analytics, the aim of Industry 4.0 is to make production faster, smarter, and more efficient.

But how do you go about transforming your production with Industry 4.0? To help you get started, Urban Siller, CEO of Identec Solutions, and Tobias Herwig, host of the podcast "Fabrik der Zukunft", talked on air about the reality of Industry 4.0, the technologies like Real time location systems that are driving it, and the steps you can take to make sure your business is ready to adopt the technologies. So, fasten your seatbelt and get ready to enter the Future Factory!

In the age of Industry 4.0, companies are increasingly turning to smart factories to drive greater efficiency, reduce costs, and remain competitive. From sensors and Artificial Intelligence to real-time location systems, automated production lines and Internet of Things (IoT) devices, the business potential of smart factories is plain to see.

This article delves into what a smart factory is, how to adopt Industry 4.0 technologies and design the digital factory, and explores the potential of Operations 4.0 and the future of smart factories.

Thanks to advances in technology, businesses today can take their digital transformation to the next level by tackling the age-old challenge of legacy processes. By moving away from outdated legacy systems and opting for an Industry 4.0 upgrade, organizations can accelerate their development and become better equipped to face the challenges of a fast-changing digital world.

In this post, we will explore the concept of legacy systems, how they can hinder business growth, and how organizations can overcome legacy processes to switch to an Industry 4.0 upgrade. We'll also discuss some of the main benefits of such an upgrade.

Dive into the world of Automatic Identification and Data Capture (AIDC), the innovative technology suite revolutionising how we identify objects, collect data, and streamline operations across various industries. From the evolution of barcodes to the sophistication of RFID, biometrics, OCR, and NFC, AIDC technologies are at the forefront of reducing manual errors, enhancing efficiency, and improving productivity. Whether it's managing inventory, securing transactions, or tracking assets, AIDC systems offer unparalleled accuracy and convenience. Join us as we explore the core technologies, applications, and the transformative impact of AIDC on businesses and daily life. Embrace the future of digital data capture and analysis—read on to discover how AIDC is shaping the digital economy and driving innovation across the globe.

This article aims to explore the landscape of Automatic Identification and Data Capture technologies—their types, applications, benefits, challenges, and the future that lies ahead. Through this exploration, we can appreciate the integral role AIDC technologies play in shaping the efficiency and effectiveness of modern-day industries and services.

Mobile asset tracking emerges as an exciting alternative regarding effective asset management, enabling your workforce to access essential asset information seamlessly on the go. Since 59% of employees believe their company lags in adopting workplace apps, integrating a handheld process for mobile asset tracking stands out as a mutually beneficial software upgrade. This approach not only enhances asset management but also significantly boosts employee efficiency.

This article delves into the role of Real-Time Location System (RTLS) chips, which are essential components in tracking assets, people, or objects across various industries. It explores the different technologies utilized in RTLS chips, such as UWB, BLE, Wi-Fi, RFID, and GNSS, highlighting their unique features. The article also introduces CHIRP, an alternative RF technology offering long-range communication, strong interference resistance, and low power consumption, making it ideal for diverse and challenging applications.

Efficient storage and retrieval are at the heart of warehouse operations, balancing manual methods with automated solutions. From traditional pallet racks to advanced AS/RS systems, each approach offers distinct advantages depending on operational needs. A standout semi-automated tool is the pick 2 light system, enhancing manual picking accuracy and productivity without full automation. This article covers how warehouses are organized, the differences between manual and automated retrieval systems, and how pick 2 light bridges the gap between the two.

This paper delves into the transformative impact of Automatic Identification (Auto ID) technologies on manufacturing processes. Auto ID encompasses a range of technologies designed to enable machines to identify objects automatically, thereby facilitating automatic data capture and enhancing operational efficiency. The implementation of Auto ID systems in manufacturing has led to significant advancements in product tracking, inventory management, and the automation of manufacturing supply chains. By providing real-time data on products, these technologies support the development of digital twins, enable rapid product customization, and foster the emergence of self-organizing production systems. Additionally, the article explores various Auto ID technologies, such as barcodes, RFID, biometric systems, and NFC, and their applications in improving asset utilization, inventory tracking, and labour productivity. Comprehensive analysis underscores the critical role of Auto ID in driving manufacturing innovation, efficiency, and adaptability in the contemporary industrial landscape.

At its core, you can define Real time location systems as a system that is in place to identify or track machinery, auto-mobiles, equipment, inventory, or even people in real time indoor and outdoor.

Before you plan and use location services within your organization, we answered the fundamental questions about RTLS implementation for you. 

Real-time location systems (RTLS) identify automatically the position of objects in real time, usually within a building or other contained area like a terminal or parking lot.

Real-time location systems may consist of various technologies used at the same time, e.g. RFID, UWD and NFC combined in one system to perform different tasks. It is important therefore to make a proper choice to avoid wrong design decisions already at the early stages. To solve this problem a special methodology for RTLS design space exploration was developed. It consists of such steps as modelling, requirements specification, and verification into a single efficient process.

At its core, you can define RTLS as a system that is in place to identify or track machinery, automobiles, equipment, inventory, or even people in real time indoor and outdoor.

Before you plan and use location services within your organization, we answered the fundamental questions about RTLS implementation for you. This post deals with the basic components and setup of real-time location systems.

The main parts of such real-time location systems consist of three components: a tag or transponder, a receiver (a reader), and a software that calculates the data. Due to the framework of the scenario, the total amount of components will be chosen to create the ideal RTLS.

Brownfield operations are widespread but technically spoken, not state of the art. But they can be upgraded to a relatively fast digital standard without substantial investments. Real-time location systems are the key here. Real-time monitoring and optimisation of production and logistics process significantly improve production systems' efficiency. In this article, we show you where.

Different application possibilities exist in manufacturing departments with real-time location systems. The possible benefits define how to validate the efficiency of an RTLS project. The applied positioning system provides real-time information about where equipment, semi-finished or finished products and specified logistic vehicles or workers are located in the manufacturing area.

Time availability of manufacturing information in the right place is crucial in how production resources are used to impart economic value to the end product. Most organisations have lots of localised information, but, unfortunately, most of this information is not available for immediate use. There is thus a need, within the Computer Integrated Manufacturing (CIM) architecture construct, for a whole and adjustable information flow, capturing the processes for each task. Several Automatic Identification (AIDC) technologies exist to aid in dealing with information capture and dissemination in an automated production environment. This blog post will examine how Auto ID technologies such as bar code technology, radio frequency technologies and others fit into the structure of CIM architecture.

Real-Time Location Systems (RTLS) have emerged as a cornerstone technology for enhancing operational efficiency and visibility in the rapidly evolving landscape of industrial automation. At the heart of this transformation is the ability to track and manage assets and materials in real time, a capability that is particularly critical in complex factory environments. This article delves into the specialised domain of zone-based RTLS, focusing on deploying Radio Frequency Identification (RFID) technology at structural bottlenecks such as doors and hallways. These areas, often overlooked, play a pivotal role in the seamless flow of materials and assets, directly impacting productivity and operational throughput.

The deployment of an Automatic Identification System transponder in manufacturing marks a stride towards optimal asset tracking and management. This comprehensive system, pivotal for Industry 4.0, leverages a blend of RFID technology and advanced software to monitor and manage physical assets essential for operational efficiency. With asset identification and tracking being a critical aspect of an organisation's bottom line and compliance, the Automatic Identification transponder enhances visibility, reduces the risk of asset loss, and facilitates preventive maintenance. This not only streamlines production planning but also substantially curtails downtime. Tailored to meet diverse industry needs, the system underscores the significance of precise asset identification and real-time tracking in fostering a competitive edge in today's market.

In this article, we'll explore how pick-by-light and put-to-light systems are transforming warehouse operations, making them more efficient and accurate. We'll delve into the integration of RFID and RTLS technologies that enhance these systems further. Plus, we introduce Asset Agent, a solution that takes these technologies to the next level, optimizing workflow and improving inventory management. Get ready to discover how these advancements can benefit your operations.

Asset tracking and management are critical for optimizing resource utilization and achieving operational efficiency across industries. While asset management focuses on strategic deployment and maintenance, asset tracking provides real-time visibility into asset location and usage. However, indoor environments pose challenges, such as interference from materials like metal, disrupting traditional tracking systems. By leveraging international standards like ISO 55000 and innovative solutions such as Identec Solutions' Asset Agent, organizations can overcome these barriers and unlock the full potential of RTLS.

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