Digitizing Asset and Calibration Tracking at Scale with RFID

In Brief

• A large global manufacturer of heavy equipment achieved a 73% reduction in tool retrieval times and 64% improvement in calibration compliance through RFID-enabled asset tracking.
• Replaced costly third-party calibration management software with FactorySense’s RFID built-in location and calibration management platform.
• Scaled a successful two-week pilot into a multi-site deployment, standardizing asset control across global manufacturing operations.

Reframing Compliance and Efficiency in Industrial Asset Management

A global leader in heavy industrial equipment manufacturing, with operations spanning construction, mining, and energy sectors, faced growing complexity in managing its calibrated assets. From torque wrenches to pressure gauges, the tools used on production lines were central to quality control and regulatory compliance. However, legacy systems—built around barcode scanning and spreadsheet tracking—were no longer sufficient.

As production volumes increased, the company began experiencing critical issues: delayed tool retrieval, unplanned downtime due to calibration lapses, and compliance vulnerabilities in audit situations. These inefficiencies were compounded by rising costs tied to third-party calibration management software, prompting a strategic shift toward digital transformation.

RFID as a Strategic Lever

FactorySense was selected as the RFID software company to architect and implement a scalable asset tracking solution that could meet the dual mandate of operational efficiency and regulatory rigor. The engagement began with a tightly scoped pilot at the manufacturer’s largest U.S. plant.

The solution combined RFID consulting services with a turnkey deployment of hardware, software, and integration support. Calibrated assets were fitted with durable RFID tags - both passive and Bluetooth Low Energy (BLE) - enabling precise, real-time location tracking within the facility. Fixed readers were installed at critical transition points including tool cribs, calibration labs, and workstations, creating automated check-in/check-out flows.

FactorySense’s RFID inventory tracking software, accessed via the FactorySense.io platform, provide full asset visibility across the site. Dashboards display current calibration status, movement history, and real-time alerts triggered by geofencing breaches or approaching maintenance deadlines. This eliminated manual log entries and allowed technicians to focus on execution rather than administration.

The system was further enhanced with handheld RFID readers operating in Sonar mode, enabling staff to locate misplaced tools in seconds - a critical capability in a facility of that scale.

Measurable Results

The pilot was deployed in just two weeks following security and IT approval, demonstrating the speed and flexibility of FactorySense’s implementation methodology. Within days, the manufacturer recorded a 73% reduction in time spent locating calibrated tools. Calibration compliance improved by 64%, as RFID data fed directly into the company’s enterprise asset management (EAM) system to trigger proactive scheduling.

Importantly, the new RFID software solution allowed the company to sunset its legacy calibration management platform, immediately reducing software spend while expanding functionality. Downtime on the production floor dropped by 8%, audit preparedness improved, and operational accountability rose across departments.

Scaling the Impact

With demonstrable ROI, executive leadership green-lit a rapid rollout across additional production sites. FactorySense’s cloud-based RFID asset management software enabled this expansion with minimal infrastructure overhead. New locations were brought online quickly, establishing a consistent and standardized calibration tracking framework.

Across sites, the company realized improved tool utilization, reduced redundancy in equipment purchases, and stronger compliance enforcement. The system also surfaced usage trends that helped inform purchasing and maintenance strategies.

Strategic Value for Multiple Stakeholders

For maintenance teams and line supervisors, the system ensured that calibrated assets were always available and audit-ready. For compliance officers, it delivered a real-time record of asset status and historical calibration logs. For executives, the project provided a rare convergence of operational improvement and cost reduction—offsetting software expenses while increasing productivity.

The solution reinforced FactorySense’s position not just as a provider of RFID tracking software, but as a strategic partner capable of delivering enterprise-scale transformation.