The Challenge: Lost Hours Due to Misplaced Tools & Dies
In a manufacturing plant focused on producing precision parts, one of the major operational challenges was the lost time caused by misplaced tools and dies. The Plant Manager grappled with the following issues:
- Time Wasted Locating Tools: Specialized tools and dies were often misplaced across the shop floor, resulting in significant time spent searching for them.
- Production Delays: Without readily available tools, production lines experienced extended downtime, directly impacting efficiency and order fulfillment.
- Lack of Real-Time Visibility: The absence of a system to track the location of tools and dies created bottlenecks in maintaining continuous operations.
- Manual Process Sign-offs: Without a real-time digital solution to ensure the correct tool is used for each operation, complex manual processes were required to verify process compliance, leading to slower workflows and reduced efficiency.
These inefficiencies led to increased operational costs, reduced productivity, and frustration among employees tasked with locating misplaced items.
The Solution: Real-Time Tool & Die Tracking Using RTLS
To overcome these challenges, a Real-Time Location System (RTLS) was introduced. By leveraging cutting-edge tracking technology, the plant could achieve real-time visibility and enhance operational efficiency.
Key Features of the RTLS Solution
- Real-Time Tool Tracking: RTLS tags were attached to tools and dies, continuously transmitting their location with sub-meter accuracy. This data was displayed on a live dashboard, enabling instant access for managers and employees.
- Automated Alerts & Notifications: Automated notifications informed managers whenever tools were moved or misplaced. Workers also received alerts about the nearest available tools, minimizing search time and improving accountability.
- Optimized Tool Allocation: With real-time usage data, the system enabled better resource allocation. Tools could be reallocated across production lines dynamically, ensuring operational continuity and minimizing shortages.
- Process Error-Proofing: Leveraging real-time tool tracking data enabled automated error-proofing during operations, ensuring the correct tools were used at every step of the process without manual sign-offs.
Expected Results: A Streamlines and Efficient Facility
Although precise metrics are still being evaluated, the RTLS-powered solution is projected to deliver the following benefits:
- Reduction in Downtime: Real-time visibility ensures quick location of tools and dies, significantly reducing production stoppages caused by misplaced items.
- Improved Workflow Efficiency: With streamlined tool tracking, employees can focus on their core tasks, reducing delays and enhancing overall productivity.
- Enhanced Resource Utilization: The system optimizes the allocation of tools, ensuring they are available where and when needed, thus reducing idle time and improving throughput.
- Automated Process Error-proofing: Utilizing real-time location data from all tools on the plant floor enables automatic error-proofing and streamlines operations that were previously manual, time-consuming, and inefficient.
- Scalable Solution: The RTLS system adapts to the plant’s evolving needs, supporting additional tools, production lines, or facilities without significant reconfiguration.
How RTLS Technology Powers Tool and Die Tracking
How It Works:
- RTLS Tags: Precision tools and dies were tagged with UWB (Ultra-Wideband) or BLE (Bluetooth Low Energy) devices, transmitting location data across the facility.
- Interactive Dashboard: A centralized interface provided live updates on tool locations, movement patterns, and availability, giving plant managers a complete view of assets in real time.
- Predictive Insights: The system’s AI-driven analytics offered actionable insights, such as predicting tool demand or identifying underutilized assets, enabling proactive decision-making.
Scenario in Action
Before implementing RTLS, misplaced tools led to frequent delays and frustrated workers.
After introducing the RTLS system:
- A worker needs a specific die for a production task. Using the dashboard, they locate the die instantly, reducing the time needed to find the die from 15-20 minutes to 30 seconds on average and eliminating idle machine time..
- A supervisor receives an automated notification about a tool being used in the wrong workstation, allowing them to rectify the error before it disrupts production, causing costly downtimes.
- Automating the previously manual sign-off process, ensuring that the correct, calibrated tool is used for the correct operation, resulted in a reduction of 80% of labor time associated with that process.
- Predictive insights help the team identify tools that are underutilized, enabling better resource allocation and reducing redundant inventory by 10%.
- This streamlined process eliminates downtime, boosts productivity, and creates a more efficient manufacturing environment, reducing operating costs by up to 20%.
The Bigger Picture: Advanced Capabilities
This RTLS system not only addresses current challenges but also positions the facility for the future with advanced capabilities, such as:
- Integration with ERP/MES Systems: Seamlessly syncs tool tracking with enterprise systems for enhanced workflow automation.
- Predictive Maintenance: Tags equipped with sensors can monitor tool wear and tear, enabling timely maintenance and extending asset lifespan.
- Worker Safety Enhancements: In addition to tracking tools, the RTLS can also monitor worker locations to ensure compliance with safety protocols.
Ready to Revolutionize Your Manufacturing Facility?
Discover how RTLS-powered solutions can transform tool and die tracking in your plant, reduce downtime, and unlock greater operational efficiency.
Schedule a Demo Today to see how real-time visibility can make a difference in your manufacturing operations!
