About the Client
- Region: Thailand
- Industry: Manufacturing
- Area of coverage: 15000 square meters
- Implemented solutions: Bluetooth Low Energy (BLE), Angle of Arrival (AoA), Tool Tracking Software
- Number of tools per facility: 5000 tools (varies by size)
The Problem
Tool Tracking Inefficiencies
There are many tools and equipment moving across different production areas in the facility. Without an accurate tracking system tools are getting lost frequently and causing downtime and production delays. Traditional methods don’t have real time visibility to track tools efficiently.
High Maintenance Costs and Equipment Failures
Without a tracking system, preventive maintenance was difficult to manage. Tools and equipment may go unchecked till they fail and then require expensive repairs and unplanned production shutdowns. Unable to monitor tool usage in real time leads to costly replacements and reduced tool life.
Compliance and Quality Control Challenges
Many industries require strict compliance to safety and quality standards. Inaccurate tracking of tool usage, calibration schedules and maintenance history increases the risk of non compliance which can lead to fines and poor product quality. To mitigate these risks and ensure operational reliability the factory wanted to implement a robust tool and equipment tracking system that will prevent potential compliance issues.
The Goals of the Solution
The aim of a BLE AoA tool tracking system is to:
- Real-Time Tool Availability: Have tools available when needed, reduce downtime and improve workflows. Tools should be visible on a map in real time.
- Predictive Maintenance: Schedule maintenance based on advanced warning to extend tool life and prevent unexpected failures.
- Compliance: Have accurate records of tool usage, calibration and maintenance to meet industry regulations by gathering and analysing historical data.
- Cost Savings: Reduce tool loss, prevent theft and optimize resource allocation to reduce operational costs.
The Solution Offered
A manufacturing equipment and tool tracking software using Bluetooth Low Energy (BLE) beacons and Angle of Arrival (AoA) technology was deployed to increase efficiency and reduce costs. This system provides real-time monitoring of tool locations, usage and condition so manufacturers can optimize production workflows and asset management.
The Tool Tracking Solution Implementation
The tool tracking system was deployed in the manufacturing environment using BLE and AoA technologies:
- BLE Beacons were attached to tools, emitting signals to provide precise location data.
- AoA-Based Locators were installed in the facility to triangulate tool positions with sub-meter accuracy, so real-time visibility of tool movement.
- Navigine Asset Tracking Software was used to provide centralized data and analytics.
- Automated Maintenance Alerts were set up based on tool usage data to schedule maintenance and reduce breakdowns.
The system provided a user-friendly dashboard to show real-time tool locations, movement history and maintenance schedule so managers can track and optimize tool usage.
Navigine chose Angle of Arrival (AoA) for their Navigine Tool Tracking solution because of its high precision, real-time tracking and scalability in industrial environments. Unlike RFID or barcode tracking, AoA provides sub-meter accuracy (as precise as 0.3 meters) so you can know exactly where your tools are in the facility.
AoA is perfect for complex manufacturing environments where tools move between workstations. It minimizes errors and reduces search times, improving efficiency and compliance.
Key Advantages of BLE AoA Tool Tracking System
- Enhanced Accuracy: AoA technology enables precise tracking of tools down to sub-meter accuracy.
- Real-Time Visibility: BLE beacons provide continuous monitoring of tool locations and movement patterns.
- Cost Savings: Prevents unnecessary tool replacements, reduces downtime, and optimizes inventory management.
- Regulatory Compliance: Maintains detailed records of tool usage and maintenance, aiding in compliance with industry standards.
- Increased Productivity: Workers spend less time searching for tools, leading to improved efficiency and reduced workflow disruptions.
- Energy Efficiency: BLE technology consumes low power, ensuring long battery life for beacons attached to tools.
Results
- Less Downtime: Tool search time reduced by 30%.
- Lower Costs: Predictive maintenance reduced unexpected equipment failures by 25%.
- Compliance: Company met regulatory requirements with an auditable tool tracking system.
- Big Savings: Lost or stolen tools saved the company up to $150k per year.
- More Accurate: AoA technology is more accurate than traditional RFID or RSSI-based tracking.
By using BLE AoA tool tracking solutions the manufacturing facility increased efficiency, reduced costs and complied with industry regulations. Advanced tracking technologies provided unprecedented transparency and control over tool usage and operational excellence.
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