Real-Time Location Systems (RTLS) on the Shopfloor

RTLS technology tracks tools in all orientations and dimensions, providing a complete spatial understanding of every movement on the shopfloor. Unlike conventional tracking methods that rely on limited perspectives, RTLS continuously measures the exact 3D position from the top of each tool, ensuring consistent accuracy in every direction. As a result, it delivers reliable position data no matter how the operator holds or maneuvers the tool. Whether right- or left-handed, upright, angled, or inverted. 

Moreover, this capability enables manufacturers to maintain uniform assembly quality, reduce human variability, and achieve precise torque and sequence validation across all workstations. Ultimately, an RTLS system provides the confidence that every fastening, placement, or movement is completed with micron-level precision and repeatable accuracy.

RTLS solutions delivers reliable position tracking even in challenging or hard-to-reach areas, ensuring complete visibility across the entire shopfloor. Unlike traditional camera-based vision systems, which are inherently limited by their fixed field of view and line-of-sight restrictions, RTLS uses ultrasonic anchors that can be strategically placed to expand coverage seamlessly. As a result, the system can accurately monitor tools, materials, or operators in obstructed zones, under equipment, or inside large assemblies, areas where cameras often fail. Furthermore, extending the tracking range is as simple as adding additional anchors, without the need for complex recalibration or lighting adjustments.

This flexibility allows manufacturers to maintain consistent precision and data accuracy, even in environments where visual systems struggle, thereby enhancing productivity, process control, and quality assurance across every corner of the facility.

An RTLS system can also be applied to confirm manual events such as picking or kitting, adding a new layer of automation and process verification to manual operations. In addition, RTLS can act as a virtual button with a projector-based operator guidance system. In this setup, the projector displays a confirmation symbol or indicator on the workstation, and as soon as the operator’s hand passes through the projected area, the system automatically registers the confirmation and advances to the next process step. 

This interaction is made possible by the operator wearing a lightweight bracelet equipped with an RTLS tag, which precisely tracks hand movement in 3D space. As a result, manufacturers can replace physical buttons or scanners with a hands-free, intuitive, and hygienic confirmation method, improving both workflow efficiency and operator ergonomics while maintaining full process traceability.

Advantages  

• 3D spatial tracking: Continuously tracks the position of tools, materials, and operators in three dimensions.
• Wide coverage: Can monitor the entire shopfloor, not limited to a single camera’s field of view.
• Scalable architecture: Accuracy and coverage can be expanded easily by adding more anchors.
• Lighting-independent: Works reliably in low-light, dusty, or visually complex environments.
• Operator mobility: Enables tracking of moving tools and people without restricting their movement.

Trade-offs

• Initial Infrastructure Investment: Requires installation of anchors and tags across the facility.
• Tag Management: Each tool or asset requires an attached tracking tag, which involves minor setup and battery management to ensure continuous operation.
• Limited Visual Analysis: Cannot visually detect defects or product surface conditions like a camera can.

Advantages

• Visual Inspection: Ideal for surface quality checks, labeling, color, and pattern recognition.
• Defect Detection: Identifies scratches, misalignments, missing parts, or visual anomalies instantly.
• High Image Resolution: Offers detailed visual data for advanced inspection algorithms.
• Automated Quality Control: Reduces human error in visual inspection processes.
• No Tags Needed: Does not require physical tags or anchors for tracking visual elements.

Trade-offs

• Line-of-Sight Limitation: Can only monitor areas within the camera’s visible field.
• Lighting Sensitivity: Performance depends heavily on lighting, angle, and contrast.
• Fixed Coverage: Expanding monitoring zones requires additional cameras and complex setups.
• Limited Mobility Tracking: Cannot accurately follow moving tools or people outside its view.