FactorySense RFID Enables CAES Systems by Honeywell to Control Work in Progress

About Honeywell CAES Systems

In the high-stakes world of defense electronics manufacturing, where precision, efficiency, and cost control are critical, CAES Systems by Honeywell (CAES) stands as a recognized leader. As a key supplier to the aerospace and defense sectors, CAES delivers advanced electronic solutions vital to national security. Despite its leadership, CAES encountered operational challenges, particularly in tracking work in progress (WIP) and obtaining real-time data across its production floors. To overcome these issues, CAES sought a transformative RFID solution that would provide end-to-end visibility, ultimately turning to FactorySense.

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The First Attempt at RFID

Before collaborating with FactorySense, CAES had deployed an active RFID system to manage inventory and monitor work in progress (WIP). Although the system was effective initially, it exposed several significant limitations over time. The battery-powered tags needed frequent replacements, causing downtime and increasing maintenance costs. Furthermore, the legacy RFID system offered inconsistent data reliability, which made it challenging to maintain real-time visibility and accurately track the location of materials on the production floor.

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“FactorySense significantly improved our efficiency. We no longer waste time searching for missing items.”
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- Adam Overbo, Materials Manager

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“The old RFID system was useful at first, but as we expanded, its limitations became evident. Maintenance and tracking accuracy were ongoing challenges.”

The absence of a reliable, real-time view of work in progress (WIP) forced production teams into a "search and rescue" mode whenever components went missing. This reactive approach not only caused production delays but also impacted inventory accuracy and control. CAES required a more durable, cost-effective, and precise solution.

To address these challenges, FactorySense proposed a fully integrated passive RFID solution, combining durable passive RFID tags, readers, printers, and the powerful FactorySense.io software platform. Unlike the active system, FactorySense's passive RFID technology removed the need for battery-powered tags, drastically reducing maintenance demands and long-term costs. With strategically placed readers and real-time data integration, FactorySense enabled CAES to achieve unparalleled tracking accuracy, offering clear, actionable insights into WIP on the factory floor.

The passive RFID system was deployed to provide automated, continuous updates on asset locations and statuses. This approach not only improved WIP tracking but also enhanced the accuracy of locating materials across the production floor, cutting down the time spent searching for misplaced units and allowing for quicker root cause analysis.

We moved from “Go find” to “Go Get” with FactorySense.

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Immediate Benefits

The shift to FactorySense’s passive RFID solution yielded immediate, measurable benefits for CAES. Maintenance costs dropped substantially as battery replacements became a thing of the past, and the reliability of passive RFID tags ensured consistent, real-time updates without data disruptions. The “Be On the Lookout” (BOLO) process, once a resource-intensive necessity for locating missing assemblies, was effectively eliminated. Accurate tracking data now allows CAES to maintain tighter control over production timelines, improving overall efficiency and streamlining operations.

Fresh View of the factory

Additionally, CAES has identified new potential applications for the FactorySense system, such as tracking mobile assets like carts, which would further increase visibility and reduce asset loss. This scalable, cost-effective solution not only optimized CAES’s current operations but also laid the groundwork for future expansion in asset tracking capabilities.

Driving Customer Success through High-Touch Service

An essential part of FactorySense’s partnership with CAES is its commitment to exceptional customer service. The FactorySense team’s rapid response times and their willingness to go above and beyond to address any issues have been instrumental in CAES’s smooth transition to the new system. FactorySense’s customer-centric approach has not only ensured seamless implementation but has also provided ongoing support to help CAES maximize the system’s value.

“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