The Project

FlexTrace – Manufacturing RTLS Traceability is a project aimed at developing a modular location product for material handling carts used in batch and make-to-order manufacturing. The project also focuses on creating a platform compatible with recent geolocation open standards to integrate this modular product and support other RTLS solutions.

Motivation

Manufacturing processes often face challenges such as:

Time wasted searching for lots or production orders: Hundreds or thousands of visually indistinguishable carts with identical products circulate on the factory floor, making it hard to locate specific lots or production orders.
Manual processes and errors: Manual data entry or barcode scanning for product movements are prone to errors and forgetfulness, leading to traceability failures and lack of visibility.
Reliance on short-lived paper: Information is often printed on paper, leading to constant waste, consumable costs, and printer maintenance.

The FlexTrace project addresses these issues by offering a real-time location system (RTLS) solution that improves efficiency, traceability, and sustainability in manufacturing environments.

Goals

The project has two main objectives:

Develop a modular RTLS product for material handling carts, consisting of:

- geolocating tag for real-time location and tracking
- “pick-to-light” LED for easy searching
- ePaper display to show product information

Create a geolocation platform based on open standards

Applications

The proposed FlexTrace solution extends beyond batch production, offering valuable applications in various manufacturing and logistics processes, including:

Make-to-order production: Managing specific orders from raw material to finished product.
Raw material management: Tracking incoming materials and their storage locations.
Finished product management: Monitoring the location and status of finished goods before dispatch.
Tooling and equipment tracking: Locating valuable assets within a facility.
Personnel tracking: Enhancing safety and efficiency by knowing where staff are.

Batch Manufacturing

Enhanced Worker Productivity: Workers can quickly find the right parts and tools, minimizing errors and saving time during production.

Improved Process Visibility: Managers gain a real-time view of all assets, helping them optimize workflows and identify bottlenecks for smoother operations.

Increased Quality Control: The system ensures the correct components are used for each batch, flagging errors instantly and displaying instructions to maintain quality.

Make-to-Order

Faster Order Fulfillment: By knowing the real-time location of all components, workers can eliminate searching, allowing for faster assembly and delivery of custom orders.

Reduced Material Waste: Precise inventory tracking and material flow management prevent the use of incorrect or expired parts, cutting down on waste.

Customization and Accuracy: Each order is built to exact specifications by tracking components and displaying custom instructions, preventing costly mistakes.

Warehouse Management

Optimized Inventory Management: The system offers real-time location tracking for every item, preventing stockouts and overstocking while making inventory counts more efficient.

Efficient Picking and Put-Away: Workers are guided with optimized routes and visual cues to the right items, significantly reducing errors and travel time.

Enhanced Asset Utilization: It tracks the location and usage of valuable assets, ensuring they are used efficiently, available when needed, and not misplaced.