Application

Live Tracking of Industrial Tools and Critial Equipment Management


Sectors

Automotive, Automotive Components, Aerospace and Defense, Heavy Engineering, Electronics, Electronics Components, Electrical, White Goods & White Goods Components, Pharmaceutical & life Sciences, Mining, Oil & Gas, Construction

Tags

Industrial Tracking, Track and Trace, Asset Tracking, Tools, Dies, Molds, Casts, Press, Power-Tools, Digital Supply Chain, Lean Methodology, Industry 4.0, Smart Manufacturing


Context

With the market moving from high volume low mix to low volume and high mix due to an increased focus on personalized responsiveness to varied customer expectations, flexibility in the manufacturing process becomes important. Customers today want tailor-made, custom-built products in the shortest possible lead time. For this flexible production approach, many specialized tools and equipment of different styles support a platform of customized products. These specialized tools could be fixed or portable assets such as dies, casts, press, molds, consumables, chainsaws, jackhammers, power drills or other equipment required for manufacturing or assembly process.
For managing and auditing the tool and equipment usage throughout the shop-floor, a tool crib manager or shop-floor operators typically use paper-based work-orders and schedules or a manual one.


Challenges
  • Most shop-floors have faced situations where some tools or kits or equipment get either lost or misplaced and operators have to spend productive time tracking them
  • A temporary delay in the availability of tools can stop a manufacturing process and affect productivity
  • Inaccurate usage of tools due to human error can affect the quality of the production for the entire batch of parts
  • To avoid the high downtime costs due to lost or misplaced tools, organizations invest in excess or obsolete buffer tool stock
  • Tedious audit process for a live tools stock count or measuring actual tool utilization, especially for rented tools and consumable tools
  • Lack of a system for scheduling repairs or maintenance results in higher running costs for tools and equipment

Schedule a Demo
Solution Approach
  • A sensor tag attached to the tool and a web portal to ‘enroll’ the tool with information to be added such as ID, type, photos, maintenance and repair schedules etc.
  • A web application to create a tool usage plan and create digital work orders to assign tools to employees with a scheduled usage time and configure usage location station area of the facility
  • Virtual set-up of location monitoring fence in the shop-floor and warehouse on the web application
  • No tool scanning activity or manual entry needed for employees
  • Real time up to 30cm precise 3D location tracking of tools with Clean Slate’s inLocate 6.0 RTLS
  • Dynamic navigation instructions on a mobile or a desktop interface to the tool or equipment’s current location searchable through asset ID and tool types
  • Live deviation alerts on a web dashboard for incorrect tool usage shop-floor stations against the tool assignment plan to spot and prevent quality issues
  • Live violation alerts on a web dashboard if tools are taken out of the assigned station or location zone or into a restricted area in the facility without authorization
  • Live deviation alerts on unauthorized use beyond the schedule or usage past the maintenance date on the web dashboard
  • Streamlined auditing of violations and deviations with accountability of tools to the assigned employee or contractor
  • Live tool stock count along with tool wise KPIs such as average utilization, average run time, idle & down-time on the web dashboard
  • Tool-wise Heat-map and Spaghetti diagram analysis on a web dashboard to visualize the historical usage, location trail and identify bottlenecks
  • Custom auto-generated audit reporting frameworks
  • Integration with existing ERP or MES to trace and audit the production batch built with the specific tool

Benefits
  • Reduction in losses due to unproductive operator time spent on tracking critical tools
  • Lowering of the tool stock count and annual budget by increasing the average tool utilization
  • Higher efficiency & accuracy of tool crib manager in counting, managing and auditing the tool stock
  • Decrease in production quality losses by eliminating inaccurate usage of tools at the shop-floor