Asset Tracking and RTLS: Using Tracking Technologies in the Smart Factory

The use of tracking technologies in industry is key to the smart factory: Asset tracking is used to record detailed data on the location and status of resources. The RTLS (Real-Time Locating System) can be used to determine the position of orders, materials, load carriers, etc. in real time.

Networking tracking technologies with ERP systems provides an incredible degree of transparency across the supply chain and also makes it possible to optimize and automate material flow. Long search times are a thing of the past—with a tracking system you always have an overview of your resources. In the age of Industry 4.0, it is therefore hard to imagine a smart factory that doesn’t use tracking solutions.

What do asset tracking and RTLS mean?

Many of us have experienced those eternal search times for orders, tools and vehicles, specific materials, or other objects in production and warehouse management. Not only does this eat up a lot of time, but it also leads to disruptions or downtime in processes. This is precisely where asset tracking and real-time locating systems come in, enabling the reliable location and tracking of resources in the company. While the term asset tracking generally describes the tracking of goods in industry, an RTLS (Real-Time Locating System) goes even further. This is a system for locating and tracking resources in real time.

How asset tracking works in industry

Depending on the requirements, different tracking technologies can be used for this purpose. With RFID, UWB, or GPS, assets can be located within logistics and production environments—both indoors and outdoors, depending on the technology selected. The information about where an object is located and at which point in a process step is recorded by the RTLS. When connected to the ERP system, a comprehensive tracking solution is created that ensures data transparency across different areas of the company.

Tracking options: Real-time location and pinpointing

Depending on the technology used, a distinction is made between two types of tracking system: comprehensive, active real-time location with RTLS and pinpointing. Comprehensive tracking can be realized, for example, with UWB (Ultra-Wideband). With the RTLS, it is always possible to obtain the precise location of the assets within a particular network in real time. This means that the routes covered can be tracked exactly.

However, such precise continuous tracking is not always required. Depending on the use case, passive pinpointing may suffice, for example using RFID (Radio Frequency Identification). In this case, information is only sent when certain gates or trigger points are passed, for example, when an order has reached the next work step. The routes in between are not recorded, which is why this type of asset tracking is also called zone or area tracking.

Advantages of tracking assets with an RTLS

Time and cost savings through automation

Reduction of search times

Simplified workflows due to digital processes

Ability to plan ahead

Real-time connection to the ERP system

Data transparency across the supply chain

Optimized material flow

Increased efficiency in production and logistics

Less idle time and downtime

What a tracking system can do for you

First, asset tracking software provides a digital overview of the flow of materials in the company. By evaluating the data obtained, areas where there is potential to optimize the production process are quickly revealed. Second, tracking technologies support your employees in their daily tasks, as processes can be carried out more efficiently. Depending on the requirements in the company, asset tracking can improve many processes and solve problems.

There are numerous possible areas of application—from order and material tracking, through goods issue inspection, to route optimization for your forklift drivers. However, asset tracking also offers opportunities beyond company boundaries. It is suddenly possible to provide customers with precise information or for suppliers to know exactly when material needs to be replenished. Networking within and outside the company ensures end-to-end transparency and simpler processes.

In the video, we show you what tracking solutions can look like in digital production.

Added value of a tracking solution for your company
In our free demo, we show you how to use L-mobile asset tracking to automate and simplify your processes, and make them more transparent.
Live demo of tracking with RFID and RTLS
We provide an overview of the most popular applications and show you the solution live in our Digital Factory.
Helpful practical examples
Gain fascinating insights into real-life applications and find out how our customers have been able to significantly improve their workflows by using tracking technologies.

View demo for free

Asset tracking use cases

Examples of how L-mobile tracking solutions are used

Order
tracking Real-time
location Material
flow Route
optimization

Previous Next

Order tracking using RFID technology

Do you often wonder where a particular order is, how long it’s been there, or what its status is? Then asset tracking in the form of order tracking might be of interest to you. RFID technology, for example, is suitable for this, where each order is allocated an RFID tag at the beginning. By “pairing” the tag and manufacturing order, they are linked to each other and assigned a unique ID. The various steps that the production order goes through in the company are defined as virtual zones and equipped with RFID gates or readers.

When the order passes through a gate or is positioned in front of a reader, it is recognized by means of auto ID (automatic identification and data capture). On the one hand, information about the order can then be accessed via the unique ID, such as the parts to be picked or the work steps to be carried out. On the other hand, information is collected at the same time, such as the time required for the order in the respective manufacturing step or downtimes between operations. This traceability of the production process is particularly advantageous in quality assurance.

But the identification of orders offers even more potential. This is because order recognition can be used to automate certain actions. If, for example, label printers are connected to the RFID system, the appropriate label is printed straight away. Signal lights can also be used to visualize order recognition. The required order information is displayed at assembly or machine work stations and workers can easily report data by means of integrated production data collection. Hardware peripherals, such as scales, transfer the recorded data for the order directly to the QA system. Thanks to asset tracking, manufacturing is transformed from a black box to a transparent process chain.

Mobile WMS for Microsoft Dynamics NAV and Business Central Stock Info — MS Dynamics Stock Info

In combination with electronic labels (E-Labels)

Electronic labels (E-Labels) are increasingly being used to support order tracking. In this context, the L-mobile E-Label replaces the analog accompanying document in manufacturing and can be combined with tracking technologies such as RFID or UWB. E-Labels are available in a range of versions and sizes, with the energy-saving display always showing the latest information about the order—a major advantage over conventional labels. Outdated data and paperwork in production are now a thing of the past.

Real-time location of resources with RTLS

For many companies, it is helpful to be able to access exact data about their assets. Particularly in complex production environments, where important or valuable items are located within a building, indoor positioning with UWB solves many problems. Where is the required tool or workpiece, where is a specific load carrier or vehicle? Thanks to UWB technology, RTLS is accurate to within inches. To set up UWB positioning, the resources are equipped with UWB tags. The installation of access points throughout the building establishes a network to locate the tags.

However, an RTLS is not only useful for indoor position detection. Based on defined geofences, areas can be defined that automatically trigger certain actions when the UWB tag enters them. These can include posting in the ERP system, lighting up signal lamps, or even automatically starting a manufacturing order. The available position and movement data can also be used for stock control to manage assets. In line with the principles of lean production, UWB technology offers a wide range of possible applications.

Digital material flow with automated replenishment management

Asset tracking is frequently used to digitalize material flow. If material flow has not yet been digitalized, it often takes a long time to search for a material or the material is only provided when called for. The material is then unavailable at machines and systems, causing delays and downtime. This is a major problem for companies, as capacity utilization is crucial to efficiency. Here too, there are various use cases and possible solutions. One example is the optimization of material flow through automated replenishment management.Using an electronic Kanban system (E-Kanban) ensures a constant supply of materials to manufacturing, such as C-parts and other production items. L-mobile E-Kanban also works across company boundaries. Depending on the requirements, there are many other options for implementing asset tracking in material flow.

• Produzierte Waren als Zugänge an das Lager verbuchen – schnell, einfach und an Ort und Stelle: Mit dem Lagerverwaltungssystem Navision Microsoft Dynamics NAV und Business Central — MS Dynamics Production Put

Intelligent intralogistics and route optimization

For processes in internal logistics (intralogistics), a tracking system can be a real asset. In addition to the digitalization of material flow, tracking technologies are often used in this context for internal transport systems. A common example here is the route optimization of forklifts, automated guided vehicle systems, and industrial trucks. Without digital processes, companies often have to contend with frequent empty runs, high instances of idle time and incorrect loading, as well as long search times for materials.

An intelligent forklift management system such as the L-mobile forklift guidance system (FGS) ensures efficient processes and transparency here. The flexible and precise forklift tracking system works outdoors using GPS technology. Forklifts are equipped with a GPS antenna and a terminal that allows the forklift driver to access mobile warehouse management software. Connected to the ERP system, the FGS guides your forklifts on efficient routes through your warehouse so that transport order processing is clear and paperless. Thanks to this tracking, it is always clear where certain goods have been stored, for example. This is where asset tracking ensures better coordination and stock reliability in your logistics. But route optimization for vehicles is also possible indoors, so instead of GPS, technologies such as UWB or RFID are used. Hybrid forms of the technologies can also be used to meet individual requirements.

L-mobile, digital warehouse management, forklift guidance system, L-mobile forklift guidance system, SAP smart factory — L-mobile FGS—Forklift Guidance System

Fahrerlose Transportsysteme (FTS) in Lager und Produktion — Automated Guided Vehicle Systems

Tracking technologies are also used with automated guided vehicle systems (AGV systems). So it’s no wonder that automated guided vehicle systems are becoming increasingly popular with industrial companies—after all, the vehicles ensure that the right material is in the right place at the right time. As a result, automated guided vehicle systems can play a significant role in ensuring efficient intralogistics. Whether for transporting small load carriers, pallets, as narrow-aisle trucks, or for outdoor transport—they can be used for a wide range of applications.

Practical examples of asset tracking and RTLS: What our customers have to say

RFID tracking in goods issue at Leiner

Have the right packages left goods issue? Is the delivery complete and have all labels been scanned? Thanks to RFID gates and digital logistics processes, Leiner GmbH no longer has to ponder these questions. RFID chips in the shipping labels enable automated bulk reading and checking of goods in goods issue. In the video, the team at Leiner GmbH explains how logistics processes have changed since the tracking solution was introduced.

Smart factory with E-Labels and RTLS at Recticel Engineered Foams

A great example of how asset tracking is used in production can be seen at Recticel Engineered Foams Germany GmbH. Thanks to UWB tracking, the system checks whether the right material for the selected order is on the cart at the plant. Electronic labels on the carts provide up-to-date information about the order and enable clear identification. Read the case study to learn how Recticel Engineered Foams is saving time and money thanks to asset tracking.

“Our goal was to launch a smart factory and to drive forward the digitalization and Industry 4.0 agenda. We looked around the market and ultimately opted for the best provider—L-mobile.”

Jonas RueppelOperations Manager, Recticel Engineered Foams Germany GmbH

Previous Next

Case Study L-mobile production Recticel Engineered Foams Germany GmbH
Download

Download Show Details

L-mobile is your expert partner for implementing tracking projects in your company

Advice regarding optimal implementation
Examination of the conditions on site
Hardware and software from a single source

With many different technologies, areas of application, and use cases, the possible applications for tracking technology are extremely diverse. L-mobile will be happy to advise you on which asset tracking solution is best suited to your requirements. In doing so, we will examine the specific conditions in your company to ensure optimal technical implementation. A practical benefit for you: We have our own IT system company, enabling us to offer hardware and software from a single source.

Tracking technologies

Comparison of RFID, UWB, and GPS tracking

Technology	Type of tracking	Accuracy	Range	Pros	Cons	Application
RFID (Radio Frequency Identification)	Passive tracking with pinpointing	HF: 1–5 cm UHF: 5–10 m	HF: max. 1 m UHF: max. 20 m	Low cost, tags do not require batteries, no visual contact with the object necessary	No real-time location, problems with metals and liquids, inaccurate location	Indoor and outdoor zone tracking with a large number of assets (e.g., load carriers)
UWB (Ultra-Wideband)	Comprehensive, active tracking	10–30 cm	50–150 m	Very accurate, hardly any interference, up to 100 position updates per second, high flexibility	Higher costs, problems with metals, extreme heat or cold	Indoor and outdoor tracking with high precision requirements (e.g., tracking high-value tools)
GPS (Global Positioning System)	Comprehensive, active tracking	0.5–1 m	Unlimited	Outdoor availability everywhere, access to existing GPS infrastructure	Not suitable for indoor use	Outdoor tracking (e.g., of forklifts)

L-mobile tracking solutions easily integrated with your ERP system

Successfully navigate the path to becoming a smart factory through networked processes

As a strong partner and Industry 4.0 expert, L-mobile will support you on the path to digitalization

FAQs about asset tracking and RTLS

What is asset tracking?

Asset tracking is a generic term for locating and tracking resources in industry. For example, assets can be orders, materials, vehicles, or other objects. Various technologies can be used for this purpose. The best known are RFID (Radio Frequency Identification), UWB (Ultra-Wideband), and GPS (Global Positioning System).

What does RTLS mean?

The abbreviation RTLS stands for “Real-Time Locating System”. An RTLS enables the real-time location of goods. This means that objects can be located very accurately at any time, which can solve many problems in industrial companies. RTLS have therefore become indispensable, especially in Industry 4.0. UWB (Ultra-Wideband) is often the technology used for this.

Why do you need asset tracking and RTLS?

Asset tracking and real-time locating systems provide transparency regarding the resources within a company. Search times are reduced, processes are simplified, reliable planning is made possible, and there are fewer instances of idle time and downtime. In short, the digitalization and automation of processes saves time and money.

How accurately can objects be located using asset tracking?

GPS: In ideal conditions with good weather and visual contact with the sky, the accuracy is around 50 cm. In bad weather or snowfall, the accuracy can decrease to up to one meter. However, these deviations can be taken into account so that the functionality of the tracking solution is not impaired.

UWB: In this case, the accuracy depends on the hardware installed. The more hardware in use, the denser the anchor network and the more accurately the location can be determined. This depends on the individual requirements of the company, whereby an accuracy of 10 to 30 cm can be achieved.

RFID: RFID antennas in the UHF (Ultra High Frequency) range can identify objects within a radius of up to 15 meters. The accuracy is between 5 and 10 meters. With HF (High Frequency), the range is significantly smaller at around 5 cm, with an accuracy of 1 to 5 cm. Here too, the solution depends on the customer requirements and conditions within the company.

What are the key considerations when implementing asset tracking?

Before implementing a tracking project, you should consider the following questions: Which technologies can and may be used? What quantities need to be tracked? Can the necessary infrastructure be set up? Which transponders can be attached to the objects and what level of accuracy is required? What is the environment like in the company—for example, are there any metals or liquids that could interfere with the technologies?

How do I choose the right technology for my use case?

Return on investment (ROI) plays a big role. Ultimately, you want to get a lot of value out of it and make sure the investment pays off for your company. That’s why you should consider how accurate the tracking solution needs to be and what costs are compatible with your ROI.

Can different tracking technologies be combined, or will this cause interference?

GPS and UWB can be combined without any problems. UWB and WLAN can interfere with each other’s frequencies, but these problems can be circumvented by a simple software setting.

Which tracking technologies does L-mobile use?

L-mobile is currently implementing projects using RFID, UWB, and GPS technologies.

Can existing WLAN hardware be used for UWB tracking?

No, a separate infrastructure must be set up for indoor positioning with UWB.

How can L-mobile support me in implementing an asset tracking project?

At the outset, L-mobile primarily advises you on which technologies are appropriate for your specific case. We draw on our extensive experience to develop a suitable solution. The surrounding processes and ERP connection are also taken into account. We have our own IT system company, enabling us to offer hardware and software from a single source. By working with a single, dedicated partner, you can be sure of optimal interaction between the hardware and software.

How long does it take to implement a tracking project?

The duration of implementation depends very much on the conditions within the company. For example, the size of the area that needs to be covered, whether the solution will be used indoors or outdoors, and how swiftly L-mobile can get the information it needs (e.g., hall plans) all play a role. Technical implementation usually takes 4 to 8 weeks. On top of that, there’s the time it takes to roll out the software.

Asset Tracking and RTLS: Using Tracking Technologies in the Smart Factory

What do asset tracking and RTLS mean?

How asset tracking works in industry

Tracking options: Real-time location and pinpointing

Advantages of tracking assets with an RTLS

Time and cost savings through automation

Reduction of search times

Simplified workflows due to digital processes

Ability to plan ahead

Real-time connection to the ERP system

Data transparency across the supply chain

Optimized material flow

Increased efficiency in production and logistics

Less idle time and downtime

What a tracking system can do for you

Asset tracking use cases

Order tracking using RFID technology

MS Dynamics Stock Info

In combination with electronic labels (E-Labels)

Real-time location of resources with RTLS

Digital material flow with automated replenishment management

MS Dynamics Production Put

Intelligent intralogistics and route optimization

L-mobile FGS—Forklift Guidance System

Automated Guided Vehicle Systems

Practical examples of asset tracking and RTLS: What our customers have to say

RFID tracking in goods issue at Leiner

Smart factory with E-Labels and RTLS at Recticel Engineered Foams

Case Study L-mobile production Recticel Engineered Foams Germany GmbH

L-mobile is your expert partner for implementing tracking projects in your company

Tracking technologies

L-mobile tracking solutions easily integrated with your ERP system

Successfully navigate the path to becoming a smart factory through networked processes

Advanced planning and scheduling

Production data collection

Machine data collection

Electronic labels (E-Labels)

Worker assistance system

Reporting

Tracking technologies (RFID, UWB, GPS)

Automated guided vehicle system (AGV system)

Forklift guidance system (FGS)

Digital warehouse management

FAQs about asset tracking and RTLS