RFID WIP tracking that keeps production records in step with the work.
See which jobs have reached the next operation, how long they have waited, and where a handoff was missed. FactorySense turns RFID reads at selected points into reliable production updates, whether you track parts, kits and fixtures, or the totes and carts that carry them.
Know where jobs are between operations.
Work-in-process (WIP) tracking records where unfinished jobs are and how they move through production. In many plants, a move reaches the system only when someone scans a barcode or signs a traveler. Miss that step and the job can sit at the next station while the record still shows it somewhere else. Supervisors end up walking the floor or sending emails asking people to look for it.
RFID readers at the handoffs you choose capture arrivals and departures. FactorySense.io matches the reads to the work order, so your team can see where a job was last confirmed and how long it has been waiting. Those movements can also update your MES or ERP.
RFID checkpoints in medical-device manufacturing
A medical-device manufacturer installed fixed RFID readers at its WIP handoffs and used handheld readers to check jobs. FactorySense connected the movement records to its ERP. Its existing quality procedures did not change.
Read the medical-device WIP case studyWhat to look for in WIP tracking software.
Try it with a job from your own plant. Follow it through a few stations, check the waiting times and compare what happened on the floor with what the work order says.
Each tag should point to the right job. Totes and fixtures get reused, so ask to see how the software handles a new assignment, a split job or work moved to another carrier.
Arrival and departure timestamps show how long work waits at each station. Set a limit for the queues that matter and choose who gets an alert when a job stays too long.
A job may go back for rework or wait for inspection. The software needs to recognize those moves as well as the normal route, and flag a handoff that skips a required step.
Choose which movements should update job status in your MES or ERP, and which should only be logged.
Some reads will be missed or unclear, and networks occasionally go down. Your team should be able to see the read history, find the gap and correct the job record. Include these cases in the pilot.
What happens when a job reaches the next operation.
Take a job traveling on a tagged cart from Op 20 to Op 30. At Op 30, FactorySense.io checks that the cart is still assigned to that job and that it has reached the expected station. The software logs its arrival and starts the queue clock.
If the job waits past the limit you set, the supervisor gets an alert, and the arrival is posted to the work order. A read the software can't confidently interpret waits for someone to review it.
Prove one handoff, then build out.
A good pilot shows the workflow holding up during an ordinary production week.
Define the operating question
Pick one route, queue or handoff where better visibility would change a decision someone makes. Agree on who owns the records and what counts as arrival, departure or completion.
Engineer and test the read point
Try tags, mounting, antennas and reader placement in the real environment, around metal, nearby traffic and at actual line speed, using the parts or carriers you plan to track.
Validate the event and transaction
Check that the filtering and rules produce the right event. Then test record mapping, duplicates, rejected transactions and recovery before anything writes to your production system.
Measure and expand
Look at missed reads, false events and how often someone had to step in, and ask whether the data is helping. Add stations once the first workflow meets the criteria you agreed on.
See WIP on your floor map.
A floor map or factory digital twin can show where work was last confirmed and how long it has waited. Read points tell you when a job arrives or leaves. Following its position continuously takes a different setup. We design the view around what your team needs to see.
Connect WIP events to your systems
See how RFID reads become updates in your ERP, MES or WMS.
Explore enterprise integrationTrack materials before they enter production
Before material is released to a job, you need to know what you have and where it is stored. Inventory tracking answers those questions. WIP tracking follows the job once production starts.
Explore RFID inventory managementRFID WIP tracking questions
Straight answers for planning your WIP tracking.
What is RFID WIP tracking?+
RFID work-in-process tracking uses RFID tags on the work itself, or on whatever carries it, and readers at selected points in the plant to record when jobs arrive, wait and move between operations. Software turns those reads into production events that can update your MES or ERP.
Can we track WIP around metal machinery?+
Usually, yes. Metal changes how RFID behaves, so tag choice, mounting and antenna placement matter, and they need testing with your actual parts and equipment. A site assessment and pilot will show what works in your plant.
Does every part need its own RFID tag?+
No. Many plants tag the traveler, fixture, tote or cart instead of each part. The link between carrier and job must stay accurate, especially when work is split or reassigned to a different carrier.
Can RFID replace all barcode scans?+
RFID can automate selected movements, while barcodes remain useful for exceptions, workstation checks and steps that need operator confirmation. We choose the capture method for each step in your process.
Will RFID update our MES or ERP automatically?+
Yes. We connect the movements you want to record to the matching updates in your production system, then test them before deployment. An arrival read does not by itself confirm that an operation is complete.
How much does RFID WIP tracking cost?+
It depends on how many read points you need, what you tag, the installation work at each location and how deep the integration goes. Most projects start with a single handoff or route, and a site assessment gives you a scoped estimate before you commit.
What should we evaluate in WIP tracking software?+
Run one of your own jobs through it and compare the software's record with what actually happened on the floor. The section above lists what to check.
Can WIP tracking identify jobs that have been waiting too long?+
Yes, at stations with read points. The software can alert the person you choose when a job waits longer than your limit. Check for a missed departure read before treating it as a production delay, since the job may already have moved on.
Let's discuss the handoffs slowing your production.
Tell us what moves through your process, where you lose track of it and which systems need updates. We'll help you identify the right workflow to start with.