More and more industrial companies are digitizing their processes and operating largely paperless. These digitization initiatives are typically based on a vast network of systems: ERP (Enterprise Resource Planning), MES (Manufacturing Execution Systems), maintenance management, security systems, CRM (Customer Relationship Management), HR platforms, and many more. Ideally, all these systems are seamlessly interconnected to map out all operational processes. A Real-Time Location System (RTLS) can enhance these systems with valuable location data, marking a significant milestone in the automation agenda. However, this only works if the RTLS can be smoothly integrated into the existing system landscape. In three examples, we show how a fully integrated RTLS can be profitably applied in Industry 4.0:

 

Optimised Manufacturing Processes

An RTLS integrated with an MES transmits the real-time location of machines, tools, and materials to the system. One such tool is the Favendo RTLS Suite: Using the Favendo Tagger, assets can be easily connected with an BLE-tag. Their location is accurately tracked and can be viewed at any time via the Favendo Viewer. So-called e-ink tags show the responsible employee in which zone or workstation the asset is located. Depending on the availability and position of the resource, the production plan can be adjusted accordingly—automatically in some cases, based on the MES. This minimises production downtime and delays. Based on the collected data, detailed reports and analyses of the entire production chain can be generated. How long did it take for goods to be retrieved from the warehouse? What amount of time is required for processing a component at a specific station in the production line? This allows bottlenecks to be identified more quickly, enabling targeted optimization measures to be implemented.

 

Efficient Warehouse and Inventory Management

ERP and warehouse management systems are the backbone of logistics. An RTLS integrated into both systems enables precise location tracking of goods in the warehouse. With Bluetooth Angle of Arrival (BLE AoA), assets can even be tracked with within a few centimetres. Additionally, custom, location-based, or user-defined event routines can trigger automated actions. This creates the ideal foundation for fully automated inventory management: Staff can get real-time insights into the current warehouse status—whether the goods are in receiving, storage, or the packaging and shipping area. Thanks to zone-based tracking, the system also generates automatic notifications when goods leave the warehouse. If inventory falls below a predefined threshold, the system automatically triggers reorders—without manual intervention. This ensures continuous inventory availability and prevents shortages.

 

 

Workforce Planning and Safety

In combination with an HR system, an RTLS enables precise tracking of employee positions on large factory grounds, construction sites, or in mines. This allows workforce planning to be flexible and dynamically adjusted. At the same time, safety is increased as it can be tracked in real time where employees are located. If people are in critical areas, appropriate measures can be taken immediately. Wearable devices, such as beacons on wristbands, allow employees to trigger an alarm at the push of a button in dangerous situations, enabling the operations team to respond quickly and provide assistance.

 

The Benefits of Fully Integrated RTLS Solutions:

1. Tailored Customisation: The integration is precisely tailored to the specific requirements of each company. This allows even highly specialised processes to be mapped.
2. Open Interfaces: RTLS solutions like those from Favendo offer open interfaces that can be connected with minimal effort—saving programming costs and time.
3. Seamless System Landscape: Homogeneous and interconnected systems ensure smooth process flow and transparency across all areas.

Seamless Integration for Transparent Processes and Optimised Planning

An RTLS tailored to a company’s needs not only offers maximum flexibility but also provides deeper insights into real-time data. When using a system like Favendo’s, the effort and costs for programming are kept in check. By using existing infrastructure, such as access points, companies save additional costs on implementation. Custom solutions and a homogeneous system landscape not only increase transparency across all processes but also enable optimised planning and control. This creates the foundation for continuous process improvement—from production to logistics and safety.