Why most RTLS projects fail after installation
Installing anchors and tags is the easy part.
Most RTLS failures appear after installation—when systems are expected to behave consistently
under real movement, obstruction, and operational load.
The difference between a stable RTLS and a “demo system” is a disciplined deployment and commissioning process.
This checklist reflects what experienced teams actually validate before go-live.
Phase 1: Site survey (before any hardware is ordered)
1.1 Define operational zones and events
- Which zones matter for safety, compliance, or dispatch?
- Which events must trigger (enter/leave, proximity, dwell)?
- Where is the worst-case zone for each event?
1.2 Identify physical constraints
- Metal density (racks, tanks, cranes, vehicles)
- Ceiling height and mounting options
- Areas with moving obstructions
- Indoor–outdoor transition points
If these questions are not answered during site survey,
they will reappear later as unexplained instability.
Phase 2: Anchor layout and infrastructure planning
2.1 Anchor geometry planning
- Ensure target zones have sufficient anchors simultaneously visible.
- Avoid layouts where anchors sit on one side only.
- Pay special attention to corners, aisle ends, and doorways.
2.2 Power and backhaul decisions
- Wired PoE: predictable power and timing, higher installation effort.
- Wireless / cellular: faster deployment, higher operational discipline required.
- Gateway-based: required when public networks are restricted.
Phase 3: Installation verification
3.1 Physical installation checks
- Anchor height and orientation match design drawings.
- No anchors mounted behind large metal surfaces.
- Cabling, grounding, and connectors are secure.
3.2 Infrastructure validation
- Stable power under load.
- Network latency within expected bounds.
- Time synchronization status verified across anchors.
Phase 4: Calibration and baseline testing
4.1 Coordinate and map calibration
- Anchor coordinates verified against site reference.
- Floor levels and elevation handled consistently.
- Coordinate orientation checked against physical layout.
4.2 Baseline movement tests
- Slow walk paths through all target zones.
- Repeat paths to check consistency.
- Verify anchor visibility statistics along the path.
Phase 5: Worst-zone and stress testing
5.1 Worst-zone definition
Worst zones are not theoretical—they are the places where people work:
- Near racks, tanks, and machinery
- Under cranes or moving equipment
- At indoor–outdoor boundaries
5.2 Stress scenarios
- Normal traffic density
- Peak traffic or shift changes
- Vehicles crossing between anchors and tags
A system that works only in quiet conditions is not production-ready.
Phase 6: Acceptance testing (event-based)
6.1 Define acceptance criteria
- Which events must trigger?
- Where must they trigger reliably?
- What latency is acceptable?
6.2 Validate by event, not by map
Acceptance should be based on event correctness:
Did the alarm trigger when it should?
Did it trigger too late?
Did it trigger when it should not?
Phase 7: Go-live and operational handover
7.1 Operator training
- Explain what the system guarantees—and what it does not.
- Define how to interpret alarms and exceptions.
7.2 Maintenance and re-validation rules
- Battery replacement schedules (for tags/beacons).
- Re-validation after layout changes.
- Periodic spot checks of worst zones.
Commissioning mindset: stability over perfection
A stable RTLS that behaves predictably under real conditions
will always outperform a fragile system tuned for ideal scenarios.
Commissioning is the discipline that turns positioning into operations.
TL;DR
Most RTLS projects fail not during installation, but during commissioning and handover.
A successful deployment follows a disciplined sequence: site survey → anchor layout → calibration → worst-zone testing → acceptance → operational handover.
Skipping steps or compressing them into a “demo day” produces systems that look correct on maps but behave unpredictably in real operations.
Key takeaways
- RTLS commissioning is a process, not a configuration screen.
- Worst-zone testing matters more than average accuracy.
- Geometry, time sync, and power stability must be validated before tuning algorithms.
- Acceptance criteria should be event-based, not map-based.
- Handover to operations must include maintenance and re-validation rules.
Quick facts
FAQ
Can RTLS commissioning be done in one day?
For demos, yes. For production systems, no. Worst-zone testing and acceptance require time under real operating conditions.
Why do issues appear only after go-live?
Because traffic density, moving equipment, and shift patterns change RF conditions compared to installation tests.
What is the most commonly skipped step?
Worst-zone testing. Teams validate center areas and assume edges will behave similarly.
Should acceptance be based on accuracy numbers?
Acceptance should be based on event behavior—accuracy is only meaningful in that context.
When should a system be re-validated?
After layout changes, equipment relocation, or major workflow changes.