Missing parts on a manufacturing floor is a major problem, often acting as a “silent killer” of productivity. Parts may be misplaced into the wrong bin or even forgotten during handling. This causes operational disruptions and hidden expenses such as expedited shipping, emergency labor premiums, and overstocking. In a highly automated environment, some stations may still require operators to manually load and unload parts. However, as these facilities have significantly fewer operators, there may be no one around to attend to the station at crucial moments, leading to unplanned downtime. Therefore, an effective solution is needed to address these issues.
Our solution uses a central server with Web GUI, indoor tracking sensors, and wearable devices to manage the floor. High-value parts are paired with wireless tags at the staging area, and their location is tracked all the way to the final assembly. The whereabouts of production personnel are also tracked through wireless tags, allowing the system to locate the nearest personnel and send an alert to their wearable device when a machine needs handling or assistance.
The Indoor Tracking System increases the OEE of the production process by reducing unplanned downtime spent searching for parts or waiting for an operator to attend to a machine. By using the Web GUI to monitor the production process in real time, management can optimize production workflows. Overall, the system has increased productivity and reduced the hidden expenses from missing parts.
