Understanding RTLS: What are Real-Time Location Systems?

Shannon McGarry Shannon McGarry December 24, 2024

5 min read

Real-Time Location Systems (RTLS) enhance manufacturing operations by providing real-time tracking and data integration in order to optimize asset utilization, inventory management, production efficiency, safety, and decision-making.

In the fast-evolving world of manufacturing, staying competitive means constantly seeking ways to enhance efficiency, accuracy, and productivity. One technological advancement that has significantly impacted the manufacturing sector is Real-Time Location Systems. This article will explore what RTLS is, its applications in manufacturing, and Autodesk manufacturing solutions that leverage this technology to drive operational excellence.

Warehouse employee using RTLS

What is RTLS?

Real-Time Location Systems (RTLS) are advanced technologies designed to automatically identify and track the location of objects or individuals in real-time within a specific area. These ares typically include manufacturing plants, warehouses, or industrial facilities. RTLS employs various technologies, including Radio Frequency Identification (RFID), Wi-Fi, Bluetooth, and Ultra-Wideband (UWB), to provide precise and continuous location data. The system consists of tags or transponders attached to the items or people being tracked. These emit signals detected by strategically placed readers or receivers. The signals are then processed by a central software platform that calculates and visualizes the exact positions of the tracked entities on a digital map. Thus offering comprehensive real-time visibility into their movement and status.

The primary goal is to enhance operational efficiency, accuracy, and safety by providing real-time insights into the location and movement of assets, materials, and personnel. This technology is particularly valuable in complex environments where the timely and precise location of resources is critical to maintaining smooth operations. Organizations can optimize asset utilization, streamline inventory management, improve production workflows, enhance workplace safety, and ensure compliance with industry regulations. The integration of RTLS data with other business systems, such as Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES), further amplifies its benefits. Ultimately, enabling data-driven decision-making and more efficient resource management across the entire operation.

How does it work?

The software platform processes the location data using algorithms that determine the precise position of each tagged item or person in real-time. This data can be visualized on a digital map of the facility, providing a comprehensive overview of the movement and status of all tracked elements. The integration of this real-time data with other systems such as ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems) further enhances operational efficiency and decision-making processes. Thus, ensuring that manufacturers have the information they need to optimize their workflows and resource management.

Inventory management using RTLS

Applications in manufacturing

RTLS offers a wide range of applications in the manufacturing industry, enhancing various aspects of operations through real-time data and location tracking. Here are some critical applications of RTLS in manufacturing:

Asset tracking and management

RTLS enables manufacturers to track the real-time location of critical assets such as machinery, tools, and equipment. This ensures that assets are available when needed, reducing downtime and improving overall equipment utilization.

Inventory management

By tracking the location of raw materials, components, and finished products, RTLS helps optimize inventory levels, reduce stockouts, and minimize excess inventory. It also enhances the accuracy of inventory counts and streamlines the replenishment process.

Work-In-Progress (WIP) tracking

RTLS provides real-time visibility into the movement and status of WIP items on the production floor. This helps identify bottlenecks, optimize production workflows, and ensure timely completion of manufacturing tasks.

Quality control

RTLS can be used to monitor the movement of products through quality control processes, ensuring that each item undergoes the necessary inspections and tests. This reduces the risk of defects and enhances product quality.

Logistics and supply chain optimization

RTLS enables manufacturers to track the movement of goods within the supply chain, improving visibility and coordination. This leads to more efficient logistics, reduced lead times, and better supplier management.

Maintenance and service management

RTLS helps track the location and usage of equipment, facilitating predictive maintenance and reducing unplanned downtime. It also ensures that maintenance tasks are performed on time and in the correct locations.

Industries that use RTLS

Automotive

The automotive manufacturing industry extensively uses Real-Time Location Systems (RTLS) to track and manage vehicles, components, and tools throughout the production process. RTLS provides real-time visibility into the location and status of work-in-progress (WIP) vehicles and assembly parts. This helps manufacturers to optimize workflows and reduce bottlenecks. By ensuring the right components are available at the right time, RTLS helps streamline assembly lines, improve efficiency, and reduce lead times. Additionally, RTLS enhances inventory management, minimizes excess stock, and ensures timely equipment maintenance, leading to cost savings and improved product quality.

Aerospace and defense

In the aerospace and defense industries, precision and efficiency are paramount. RTLS tracks high-value assets, components, and tools within production facilities and across supply chains. This results in real-time monitoring of parts and assemblies to ensure critical components are available and reducing delays. RTLS enhances compliance with industry regulations by providing traceability and documentation. By optimizing inventory management, scheduling, and resource utilization, RTLS helps aerospace and defense manufacturers improve efficiency and maintain high standards of quality and safety.

Electronics manufacturing

The electronics and semiconductor manufacturing industries require precise tracking of materials and components due to product complexity and high value. RTLS provides real-time visibility into raw materials, WIP items, and finished products, optimizing production schedules and reducing cycle times. By tracking sensitive components, RTLS helps prevent damage and ensures proper handling. Additionally, RTLS improves inventory accuracy, reduces waste, and enhances overall efficiency. This leads to cost savings and faster time-to-market for new products.

Autodesk solutions to integrate with RTLS

Autodesk offers powerful tools for integrating, visualizing, and analyzing real-time location data. This gives manufacturers the tools they need to make data-driven decisions and optimize their processes.

Vault

Vault is a data management tool that helps organize, manage, and track design data. By incorporating RTLS data, Vault can provide real-time visibility into the location and status of design assets. This ensures that the right resources are available when needed. This integration enhances collaboration, reduces errors, and improves project outcomes.

Fusion Operations

Fusion Operations offers integration capabilities, real-time data visualization, advanced analytics, and collaborative features make it an excellent complementary solution for leveraging RTLS technology in manufacturing. By using Fusion Operations in conjunction with RTLS, manufacturers can enhance visibility, improve efficiency, reduce costs, ensure safety and compliance, and ultimately drive operational excellence.

By integrating RTLS manufacturers can future-proof their operations. Ultimately, maintaining competitiveness in a rapidly evolving industry through advanced technological adoption and streamlined processes.

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We use RollWorks to deploy digital advertising on sites supported by RollWorks. Ads are based on both RollWorks data and behavioral data that we collect while you’re on our sites. The data we collect may include pages you’ve visited, trials you’ve initiated, videos you’ve played, purchases you’ve made, and your IP address or device ID. This information may be combined with data that RollWorks has collected from you. We use the data that we provide to RollWorks to better customize your digital advertising experience and present you with more relevant ads. RollWorks Privacy Policy

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We can access your data only if you select "yes" for the categories on the previous screen. This lets us tailor our marketing so that it's more relevant for you. You can change your settings at any time by visiting our privacy statement

Your experience. Your choice.

We care about your privacy. The data we collect helps us understand how you use our products, what information you might be interested in, and what we can improve to make your engagement with Autodesk more rewarding.

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Explore the benefits of a customized experience by managing your privacy settings for this site or visit our Privacy Statement to learn more about your options.