About the Project
- Area monitored: 20,000 m² across multiple facility levels
- Objects monitored: Approx. 100+ personnel, zone access points, and IoT-enabled assets (e.g., smart helmets)
- Technology used: Real-time location tracking system integrating Wi-Fi, BLE, and IoT devices; smart analytics platform with digital mapping, heat maps, zone control, and sensor fusion
A leading chemical manufacturing facility operating within a complex, RF-challenging environment required an intelligent tracking solution to improve operational visibility and safety.
The facility's 20,000 m² area, including multiple vertical levels and high-risk zones, presented unique challenges in monitoring movement, controlling access, and responding to emergencies.
The Challenge
There is always a vast mix of operational blind spots and safety concerns that are present in manufacturing facilities:
- tracking staff movement in large, multi-level plants
- monitoring access to restricted areas
- spotting inefficiencies in real-time
Traditional methods often fall short, whether due to a lack of precision, human error, or outdated infrastructure.
In the presented case, a major manufacturing site required enhanced oversight over 20,000 m² of floor space and multiple levels, all within a harsh radio frequency (RF) environment. The primary goal is to improve safety, simplify operations, and increase transparency in daily workflows.
What the Chemical Manufacturing Facility Needed
To meet modern demands, the key requirements of the facility were as follows:
- Accurate, real-time tracking of personnel and operations
- Zone-based monitoring for restricted or high-risk areas
- Actionable analytics to optimize space utilization and staff efficiency
- A system compatible with Wi-Fi and BLE, and adaptable to IoT devices, including smart helmets
- A scalable solution to handle complex layouts and RF interference
As this is a chemical industry facility, safety, efficiency, and regulatory compliance are of the utmost importance. Intelligent tracking solutions became necessary due to the complexity of workflows and the presence of hazardous materials. The real-time monitoring of assets and personnel significantly helps enhance operational control. At the same time, the solution could minimize risks and improve response times in emergencies.
The Navigine Staff Tracking Solution
Navigine delivered a comprehensive real-time location tracking and analytics platform tailored to the facility’s infrastructure and goals.
Navigine Tracking
A location-aware platform for Digital Transformation of Enterprises.
Key components of the solution included:
- Digital map with real-time staff tracking, visualizing movement across all facility levels
- Advanced analytics, including heat maps and detailed operational reports
- Zone control features, ensuring only authorized personnel can access specific areas
- Integration with Wi-Fi, BLE tracking, and IoT-enabled helmets, enabling seamless indoor navigation
By combining these elements, the facility gained full situational awareness, turning location data into actionable operational insight.
Why Choose Navigine
Several reasons made Navigine the perfect fit for this project:
- Hardware agnostic: works with existing Wi-Fi and BLE infrastructure
- Scalable and customizable: can be adapted to a multi-floor complex
- Sensor fusion and smart analytics: overcomes signal interference and delivers accurate insights
- User-friendly visualization tools: helps managers make faster decisions
Since the primary focus was on getting highly accurate real-time tracking in a tough chemical industry environment, the client highlighted several key reasons why they chose Navigine over others. The clincher was the ability to provide indoor and outdoor positioning, advanced security, and compliance with industry regulations. Additionally, the system's scalability to monitor multiple sites, ease of integration with existing infrastructure, and support for smart wearables. Navigine’s proven track record of delivering accurate asset and personnel tracking made them the winner.
Key Advantages
After implementation, the facility saw several measurable benefits:
- Up to 20% increase in employee productivity, thanks to performance tracking and KPI measurement
- Improved space utilization using heat map analysis and activity-based layout insights
- Stronger control of periodic tasks and workflows
- Faster response in emergency scenarios, improving overall safety protocols
These improvements collectively changed daily operations, making the facility more efficient and resilient. With automated real-time insights, management gained deeper visibility into workforce performance, enabling optimized task allocation and resource distribution. The enhanced safety measures, enabled by intelligent tracking, not only reduced risks but also boosted compliance with industry standards. As a result, the facility now operates with better performance, ensuring consistent coordination and responsiveness across all areas.
The Results
With Navigine’s solution in place, the facility quickly saw tangible results. Within the first few months of deployment, employee productivity rose by 20%, downtime decreased, and workflow efficiency improved across all shifts. The integration of real-time tracking helped take operations to the next level, enabling better task management and faster response times in emergencies. As a result, the company strengthened its safety measures while creating a more transparent and data-driven work environment, setting the stage for ongoing innovation and operational excellence. Overall, the solution provided both immediate improvements and long-term value.
Ready to digitize your staff tracking operations?
Navigine’s real-time tracking solution helps factories reduce losses, improve workers' safety, and cut operational costs. Our system brings transparency and efficiency to every m². Contact us today to explore how RTLS can increase your chemical factory's effectiveness.
