Enhancing Manufacturing with RTLS

Introduction to RTLS in Manufacturing

For years, barcodes and RFID (radio frequency identification) have been the standard methods for tracking assets in manufacturing, providing basic visibility of tagged or labeled items. RFID in particular has become a foundational technology for automatic identification using tags and readers. But as factories evolve into highly connected and automated Industry 4.0 environments, it is increasingly clear that barcodes and RFID alone are no longer enough. They rely on active scanning through gates or mobile readers, create extra manual steps, are prone to errors, and most importantly, do not deliver real-time updates. This makes them difficult to use in highly automated and dynamic production flows.

For certain types of assets such as work-in-process orders, containers, material handling equipment, mobile robots or even operators themselves, manufacturers need continuous, real-time precision with effortless data capture across indoor and outdoor operations. This is where Real-Time Location Systems (RTLS) are becoming essential.

Modern RTLS solutions, including those based on UWB and BLE, now offer the accuracy and reliability required for real-time tracking in demanding manufacturing environments. At the same time, most factories continue to rely on a mix of technologies such as RFID, barcodes, 5G, camera or even GPS for different parts of their operations. This makes it important for RTLS software to work smoothly alongside these existing systems and help combine their data in practical, day-to-day workflows.

Learn more about how RTLS works in RTLS Explained and why UWB is leading the next generation of location technology in UWB versus Other Technologies.

In this article, we’ll delve in the main different use-cases of RTLS in manufacturing with some real-world examples and how it can be implemented within a manufacturing IT/OT ecosystem.

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Use-cases of RTLS in Manufacturing

Modern manufacturing facilities are complex ecosystems. Multiple production lines, automated machinery, warehouses, and logistics zones operate simultaneously, each generating massive amounts of movement and data. RTLS technology is used to optimize assembly lines by improving workflow, reducing bottlenecks, and enhancing inventory management, which increases overall efficiency and product quality. Manufacturing plants, in particular, present unique challenges due to their scale and operational complexity. Managing this environment efficiently requires more than manual scanning and reactive processes. It demands intelligent automation and real-time visibility.

While we have identified over 200 unique use-cases of RTLS in manufacturing, typically they can be categorized in these 5 distinct use-case groups:

• Search & Find: Instantly locate assets and reduce search time
• Automate: Streamline workflows and eliminate manual scanning
• Optimize: Maximize asset utilization and operational efficiency
• Report: Leverage data for compliance and full traceability
• Safeguard: Enhance safety and minimize operational risks

Across the industry, organizations like ArcelorMittal, Alcon, and Salco have experienced firsthand how automation powered by RTLS leads to safer, more efficient, and data-driven operations.

Solving Asset Tracking and Workflow Challenges

In busy manufacturing facilities, misplaced equipment and materials can create cascading disruptions. Even short delays in locating critical assets stall production, slow maintenance teams, and disrupt the supply chain. These inefficiencies increase operational costs through emergency replacements, duplicate inventory purchases, and wasted labor. For safety and operations teams, not knowing asset locations reduces responsiveness and limits the ability to perform preventive procedures efficiently.

Pozyx RTLS addresses these challenges by providing precise, real-time tracking of assets across indoor and outdoor spaces. Using UWB for high-precision indoor positioning, BLE for flexible and cost-effective coverage in diverse areas, and GPS for outdoor operations, the Pozyx platform ensures continuous visibility of every tagged item. In practice, this enables staff to locate essential assets almost immediately, eliminating unnecessary downtime and maintaining smooth workflow continuity. Managers also gain a comprehensive overview of inventory levels and resource allocation, ensuring that tools and machinery are available where they are needed most.

At ArcelorMittal, Pozyx RTLS improved warehouse operations by tracking raw materials and finished goods. The system not only reduced search times but also revealed inefficiencies in storage and handling. This enabled staff to optimize layouts, sequence tasks effectively, and anticipate congestion points, improving throughput and supporting consistent production under Industry 4.0 initiatives.

Workflow optimization goes beyond locating misplaced assets. By integrating real-time visibility with operational planning, teams can automate repetitive tracking tasks, maximize asset utilization, and proactively adjust processes to maintain steady production. Continuous data from RTLS allows manufacturers to make informed decisions quickly, supporting smarter operations across all facility areas.

For more on how RTLS automation supports lean manufacturing and workflow efficiency, see WIP and Material Flow.

Enhancing Workplace Safety and Equipment Reliability

Safety and equipment reliability are core to manufacturing success. Operators often work near heavy machinery, moving vehicles, and automated robots, creating potential risks that demand constant attention. Without real-time visibility, it is difficult to ensure that workers remain in safe zones or that machines operate within safe limits. RTLS solutions enhance safety by minimizing risks, ensuring compliance with safety standards, and optimizing overall safety performance within industrial environments.

Pozyx RTLS strengthens safety and reliability through automated monitoring and geofencing. The system can create virtual safety zones that trigger alerts when personnel enter restricted areas or when unsafe conditions develop. This not only minimizes risk but also ensures that safety protocols are followed automatically, without manual supervision.

At Alcon’s facility in Puurs, Belgium, Pozyx RTLS was implemented to track worker movement and material flow in a clean-room assembly environment. RTLS is being used in a way that provides real-time workforce visibility, helping to enhance safety and improve workflow management. With real-time data from over 300 operators across three shifts, Alcon’s teams could immediately detect workflow disruptions or safety issues as they occurred, rather than waiting for end-of-shift reports. This proactive visibility allowed maintenance and safety teams to intervene early, reduce unplanned stops, and maintain a cleaner, safer environment for all personnel.

By combining safeguard with automate, Pozyx helps facilities prevent accidents before they happen while also improving machine reliability. Tracking usage patterns and asset movements enables predictive maintenance, ensuring that equipment receives service before failure occurs. RTLS technology also allows for tracking high-value assets, ensuring reliability and compliance in critical operations.

You can explore more applications of automated geofencing and proactive safety in Geofencing Examples for Enhancing Productivity.

Driving Continuous Improvement and Operational Efficiency

The next level of manufacturing performance comes from understanding not just where things are, but how efficiently they move and interact. With multiple sites and hundreds of interconnected assets, maintaining a consistent standard of performance requires reliable data and enterprise-wide visibility.

Pozyx RTLS converts live location data into actionable analytics that empower decision-makers to optimize workflows and report on performance across entire facilities. Through continuous monitoring, manufacturers gain valuable insights that drive improvements. Dashboards reveal movement patterns, machine utilization, and resource bottlenecks, allowing manufacturers to apply continuous improvement strategies backed by measurable data. Managers also gain insight into dwell time, allowing them to see how long assets remain in specific areas and identify bottlenecks in material flow.

At Salco, a Dutch manufacturer of custom industrial doors, production managers once relied on manual floor walks and personal observation to monitor work-in-progress. With Pozyx RTLS, tags on each order now automatically update workstation statuses, creating a live production overview. The RTLS software and RTLS platform enable real-time updates and visibility on the manufacturing floor and throughout manufacturing processes. RTLS technology streamlines and enhances various production processes by automating asset tracking, minimizing errors, and improving overall efficiency at every stage of production. The system reduced delays in detecting abnormalities by more than 50 percent and cut time spent on manual supervision by half. This improvement illustrates the power of automated reporting and optimization in supporting lean, data-driven manufacturing.

Through accurate report capabilities and optimization tools, Pozyx RTLS provides complete traceability. Compliance RTLS helps ensure compliance with industry standards during the production process, supporting continuous improvement across operations. Learn more about implementing these practices in Lean Manufacturing.

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RTLS Integration and Implementation

Successfully integrating RTLS solutions into manufacturing operations requires a strategic approach that considers both the technological and operational needs of the business. The process begins with selecting the right RTLS technology, such as UWB, RFID, or Bluetooth, based on the facility layout, asset types, and desired level of accuracy. Once the appropriate solution is chosen, RTLS tags are attached to assets, equipment, or personnel, and anchors or readers are installed throughout the facility to ensure comprehensive coverage.

A key advantage of modern RTLS deployments is their ability to bridge IT and OT environments without adding unnecessary complexity. Open standards like omlox make this possible by ensuring that different location technologies and vendors can work together reliably. At the center of this approach is the omlox Hub, a location middleware that provides a unified interface for exchanging positioning data. Instead of integrating each RTLS or tracking technology directly with every ERP, MES, WMS or maintenance system, the Hub uses standardized API's and MQTT to simplify distribution and reduce integration effort. This decouples the data layer from the underlying hardware and makes it easier to scale, replace or combine solutions from multiple vendors while keeping enterprise integrations straightforward.

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Conclusion

Manufacturers face ongoing challenges in quickly locating assets, automating workflows, optimizing operations, ensuring safety, and maintaining reliable equipment. RTLS technologies play an increasingly important role in meeting these needs by providing real-time visibility across indoor and outdoor environments. Pozyx contributes to this evolution with RTLS solutions that use UWB, BLE, and GPS to deliver accurate location data for assets, vehicles, and personnel. By offering tools that help transform raw positioning signals into actionable insights, Pozyx supports manufacturers in building more automated, data-driven, and resilient operations.

The experiences of ArcelorMittal, Alcon, and Salco demonstrate that by adopting Pozyx RTLS, manufacturers gain the tools to search & find assets in real time, automate key workflows, optimize operational efficiency, report on compliance and performance, and safeguard personnel and equipment. As industrial environments grow increasingly connected and complex, integrating real-time location intelligence is essential for transforming operational challenges into opportunities for safer, smarter, and highly responsive production in the era of Industry 4.0.