The client is a Tier‑1 supplier producing safety‑critical components for European OEMs. The plant operates multiple CNC lines, in‑process inspection stations, and final assembly cells. Tooling includes calibrated torque tools, gauges, fixtures, and specialized changeover kits. In addition, the site uses returnable containers and kitting carts to feed line‑side workstations.

While the client had barcode processes and periodic audits, the reality of daily production—frequent tool handoffs, urgent maintenance calls, and fast changeovers—made manual scanning unreliable. When a missing tool delayed a line, teams often resorted to phone calls and physical searching.

The HSE and quality teams also faced a compliance challenge: for calibrated tools, it was difficult to prove where a tool had been used, for how long, and whether it had entered restricted areas (e.g., quarantine racks for out‑of‑tolerance tools).

Key challenges identified during discovery included:

• Tool “last‑known location” was not trustworthy. Barcode scans were missed during handoffs, especially during peak production hours and shift changes.

• Line stops and delayed changeovers. When a changeover fixture or inspection gauge could not be found quickly, the line waited.

• Calibration & compliance gaps. The quality team needed stronger traceability for calibrated tools: location, dwell time, and whether a tool entered quarantine zones.

• High metal density environment. CNC areas, racks, and steel structures created multipath reflections and limited visibility for traditional positioning approaches.

• Mixed asset types. The client needed a single workflow to track hand tools, fixtures, kitting carts, and returnable containers without forcing a new process for every asset class.

The deployed solution combined:

1. UWB RTLS coverage in production and logistics zones
   UWB anchors were installed in a ceiling grid to provide consistent positioning across machining lines, tool storage, kitting, and inspection corridors. The system design ensured continuous multi‑anchor visibility across aisles and rack fronts so that tags could be located even in dense industrial layouts.

2. Rugged tags for tools, fixtures, and carts
   High‑value tools and fixtures were equipped with WZ Material Location Tags using magnetic mounting for fast deployment and easy reassignment between assets. A built‑in buzzer supported a “find‑my‑tool” workflow for technicians.

3. Operational workflows built around location data
   The RTLS platform provided:

• Real‑time map view of tools, carts, and containers

• Historical track playback for investigations and process review

• Electronic fences (geofences) to enforce quarantine zones and restricted storage areas

• Alerts for missing tooling, unauthorized movements, and long dwell times (e.g., carts left idle in staging lanes)

4. Integration readiness
   The client connected RTLS events to existing MES/quality processes, enabling automatic evidence for where calibrated tools were used and when they returned to the tool crib.

The project followed a phased rollout to minimize disruption:

Phase 1 — Site survey & coverage design (2 weeks)
GridRTLS mapped the facility into tracking zones (tool crib, calibration lab, CNC aisles, kitting lanes, line‑side racks). Anchor placement was modeled to maintain reliable positioning across rack fronts and work areas.

Phase 2 — Infrastructure installation (3–4 weeks)
UWB anchors were installed and connected using industrial PoE switches on a segmented network. The RTLS server was deployed on‑prem to align with the client’s IT and cybersecurity requirements.

Phase 3 — Asset tagging & workflow setup (2–3 weeks)

• Tools and fixtures were tagged and labeled with standardized naming rules.

• Kitting carts and returnable containers were tagged by asset class.

• Geofences were configured for quarantine racks and tool‑crib boundaries.

• Technician workflows were trained: “search + beep,” issue reporting, and exception handling.

Phase 4 — Go‑live & tuning (2–4 weeks)
During go‑live, the team tuned zones, alert thresholds, and map layers to reduce false alarms and align with real production behavior (e.g., temporary staging during changeovers).

Within the first quarter after go‑live, the plant reported:

• Tool and fixture search time reduced by ~80%. Technicians could locate assets from a console and confirm physical presence using buzzer‑assisted finding.

• Fewer line stops caused by missing tooling. When a tool was not in the expected location, the system provided the last movement path and current zone, enabling faster recovery.

• Higher inventory accuracy for carts and containers. Real‑time counts by zone reduced reliance on manual cycle counts and improved kitting reliability.

• Improved calibrated tool compliance. Quarantine geofences prevented accidental reuse of tools flagged by quality, and location/time logs provided stronger audit evidence.

• A foundation for further lean initiatives. The site began using track playback and dwell‑time analytics to remove bottlenecks in kitting lanes and reduce “hidden WIP” in staging areas.