Industrial Equipment Manufacturer Enhances Asset Management and Calibration with RFID
Background
A global manufacturer of heavy industrial equipment produces machinery used in construction, mining, and energy sectors. With multiple production facilities worldwide, the company relies on a vast number of calibrated assets such as torque wrenches, pressure gauges, and measuring instruments that must be routinely maintained and calibrated to ensure product quality and compliance with industry regulations. Historically, the company used a manual barcode system to track calibration schedules and asset locations. However, as operations scaled, this approach led to lost assets, calibration lapses, and production delays, impacting both efficiency and regulatory compliance.
Challenges
Production downtime
Technicians spent excessive time searching for required calibrated assets, slowing down critical production processes.
Lack of real-time visibility
The company struggled to maintain an up-to-date inventory of tools in use, overdue for calibration, or out for servicing.
Inaccurate tracking of calibrated assets
Manual tracking resulted in misplaced tools, leading to delays in production and maintenance schedules.
Compliance risks failure
Failure to calibrate equipment on schedule resulted in potential audit failures and non-compliance with industry regulations.
High software costs
The company relied on an expensive third-party calibration management software, which added significant operational expenses.
Solution
To address these challenges, the company partnered with FactorySense to implement an RFID-based calibrated asset management system. FactorySense provided an end-to-end solution that covered hardware, software, and consulting, ensuring a fast and seamless pilot implementation.
A variety of RFID tags were applied to individual tools, ensuring that each asset could be uniquely identified and tracked. A network of sensors throughout the plant enabled real-time tracking of assets as they moved from one zone to another, significantly improving visibility into tool usage and location.
Geofencing technology was also deployed to ensure that tools remained in designated areas, preventing unauthorized movement and eliminating a large source of loss and misplacement. If a tool was detected moving outside its assigned zone, real-time alerts were triggered, allowing immediate corrective action. This further enhanced compliance and operational efficiency.
The solution included these applications
- RFID tagging of all calibrated assets
Tools and measuring devices were fitted with durable RFID tags to enable automated tracking. - A blend of passive RFID and FactorySense BLE tags
This hybrid approach allowed the company to maximize tracking efficiency by leveraging the benefits of both technologies, all within a single system behind a single pane of glass. - Fixed RFID readers at storage locations, calibration labs, and workstations
These ensured automatic check-in/check-out of assets as they moved through the facility. - Handheld RFID scanners for locating misplaced tools
Technicians used portable scanners in Geiger counter mode to quickly locate required assets. - Automated calibration scheduling and alerts
RFID data was integrated into the company’s enterprise asset management (EAM) system, automatically triggering calibration reminders and maintenance tasks. - Custom dashboards displayed on large TV screens
Real-time asset status and calibration schedules were visible across production areas, improving asset availability and compliance tracking. - Built-in calibration + asset location system
FactorySense’s system replaced the company’s expensive calibration management software, effectively covering most of the FactorySense software costs while improving asset tracking efficiency.
“With these enhancements, technicians no longer needed to waste time manually scanning barcodes or searching for tools in the massive plant, allowing them to focus on their core tasks. Workers can now just do their jobs instead of searching for equipment.”
Implementation & Results
Pilot program completed in 2 weeks- double digit savings
Once networking and security approvals were obtained, the pilot project at the pilot plant was completed within two weeks, demonstrating the efficiency of FactorySense’s deployment process.
The pilot implementation at the company’s largest manufacturing plant yielded immediate benefits
- 73% reduction in asset retrieval time
Technicians could quickly locate required tools. - 64% improvement in calibration compliance
Ensuring all assets were serviced on schedule. - 8% reduction in production line downtime
Calibrated assets were always available when needed. - Audit readiness improved
Real-time documentation and historical calibration records accessible at any time. - Software cost reduction
Our solution eliminated the need for the previous calibration management system, paying for most of the FactorySense software expenses. With these successes, leadership approved an accelerated rollout across multiple global sites.
Expansion to additional locations leading to more efficiencies
Following the success of the pilot, the RFID solution was expanded to the company’s additional production facility in an adjacent state. FactorySense’s cloud-based infrastructure allowed the company to scale the system rapidly, with minimal IT overhead. The expansion resulted in:
- Standardized asset tracking
Standardized asset tracking and calibration management across all locations. - Improved asset utilization
Reducing redundant tool purchases and maintenance costs. - Real-time calibration visibility
Minimizing regulatory risks and enhancing quality control., - Optimized workforce productivity
Employees could now focus on their tasks without unnecessary delays caused by misplaced tools.
“FactorySense’s ability to support large-scale enterprise deployments ensured a smooth expansion process, driving company-wide operational improvements.”
Key takeaways for decisionmakers
For maintenance managers and production supervisors, the RFID system eliminated inefficiencies in tracking calibrated assets, ensuring that all required tools were available and in compliance with calibration schedules. The combination of passive RFID and BLE tracking provided enhanced visibility and asset utilization across vast production environments.
For executives and compliance officers, the solution significantly reduced the risk of audit failures and regulatory penalties. The automated scheduling and real-time reporting provided a seamless way to monitor asset performance, reduce unnecessary expenses, and maintain operational efficiency. Additionally, eliminating costly third-party calibration management software significantly offset the investment in FactorySense’s platform, making it a financially strategic decision.
Conclusion
By implementing FactorySense’s RFID-based calibrated asset management system, this global heavy industrial equipment manufacturer improved asset availability, compliance, and production efficiency. The successful pilot program led to a rapid company-wide rollout, demonstrating how RFID technology can streamline calibration tracking, reduce downtime, and ensure regulatory compliance.
With FactorySense’s expertise in delivering a complete turnkey solution, the company now benefits from real-time asset visibility, reduced operational risks, and optimized manufacturing workflows. Most importantly, workers can now focus on their jobs instead of wasting time searching for equipment, leading to a more productive and efficient operation.