Honeywell Revitalizes RFID for WIP Tracking with FactorySense

In Brief

• Transformed a struggling RFID system into a high-performing work-in-progress tracking solution.
• Replaced active RFID with a streamlined passive system, eliminating maintenance burdens and cutting costs.
• Integrated RFID asset tracking and inventory management software to deliver real-time visibility on the production floor.

Transforming a Struggling RFID Rollout

RFID has long promised gains in efficiency, traceability, and compliance—but for many manufacturers, the path to realizing those gains has been fraught with false starts. That was the case at CAES Systems by Honeywell, a global defense electronics manufacturer whose initial RFID deployment failed to meet expectations.

The company’s legacy system relied on active RFID tags to track work-in-progress (WIP) across its facility. Over time, the tags’ reliance on batteries led to high maintenance overhead and reliability issues. Worse, the system’s inconsistent data rendered it ineffective for real-time asset tracking or decision-making. Instead of streamlining production, the system became a source of cost and operational noise.
CAES turned to FactorySense’s RFID consulting and turnaround services for help—not to start over, but to salvage and re-engineer what had been lost.

A Turnaround Approach to RFID Software Solutions

FactorySense initiated the engagement with a forensic assessment of the previous implementation. Our team diagnosed core issues in tag performance, reader coverage, data architecture, and integration gaps. With those insights in hand, we proposed a tailored RFID solution grounded in simplicity, reliability, and real-time control.

The new system transitioned CAES to a passive RFID infrastructure, eliminating the need for battery maintenance and reducing total cost of ownership. FactorySense deployed hardened RFID tags, optimized reader placement across workstations, and integrated everything through FactorySense.io, our enterprise-grade RFID inventory tracking software.

Unlike the previous system, FactorySense’s RFID asset tracking platform delivered actionable visibility. Factory floor personnel could now locate carts, assemblies, and tools in real time—without manual intervention. The software supported work-in-progress management, automated alerts, and reporting, ensuring that materials flowed predictably through the production process.

“The level of service from FactorySense is exceptional. Their quick response time and willingness to go above and beyond are truly appreciated. We have seen substantial cost savings since switching to FactorySense from our previous RFID solution. The FactorySense RFID solution is user-friendly and accurate. It has streamlined our operations and reduced errors.”
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- Adam Overbo, Materials Manager

Immediate Results, Long-Term Impact

The impact of the RFID system reimplementation was both immediate and measurable. With the passive RFID infrastructure in place and real-time visibility restored through FactorySense’s asset tracking software, CAES achieved renewed operational continuity. Maintenance demands dropped significantly with the transition away from battery-powered tags, and improved inventory accuracy allowed for better production planning and scheduling.

Equally important, confidence in the system grew. The new solution proved both reliable and scalable, prompting CAES to expand its use beyond work-in-progress tracking. The company now leverages the same RFID infrastructure to monitor mobile assets such as carts and tooling, reducing loss, increasing accountability, and enhancing overall production efficiency.

Lessons for RFID Stakeholders

This case illustrates a critical point for operations and IT leaders: a failed RFID project is not the end of the story - it’s often the beginning of a better one. FactorySense has a practice group dedicated to re-engineering under-performing RFID systems, providing the technical depth and operational experience needed to realign projects with business goals.

For companies in high-compliance sectors like defense and aerospace, the combination of RFID asset management software, real-time tracking, and consulting expertise isn’t just useful, it’s essential.