Case Study: A Hybrid Tracking Solution for Automotive Manufacturing Efficiency
An automotive manufacturer faced challenges tracking large, identical semi-finished vehicles spread across vast indoor and outdoor areas. Manual efforts failed, causing delays. Bit Tonic implemented Quuppa’s RTLS with AoA technology, enabling seamless, automated tracking—boosting efficiency and eliminating costly setbacks.
Background
A company in the automotive sector manufactures very large vehicles in high volumes. During the early stages of production, these semi-finished vehicles are indistinguishable from one another. Due to the nature of the production process, these items are temporarily stored—often without proper tracking—in areas that can be hundreds of meters away from where they are eventually needed.
Challenge
The semi-finished products are stored both indoors and outdoors, making the use of GPS technologies unfeasible. An initial attempt to track items by assigning the responsibility to forklift drivers failed due to the excessive manual effort required to collect accurate location data. When an item went untracked, it would effectively exit the production process and only reappear once it was eventually identified—sometimes weeks later. This led to cascading delays and made it difficult to monitor production. The search process often involved covering large areas by bicycle or forklift.
Solution
To overcome these challenges, our solution partner Bit Tonicimplemented a Quuppa solution—equivalent to AccuRTLS—using AoA (Angle-of-Arrival) technology. This cutting-edge solution enables real-time tracking with location accuracy down to a few tens of centimeters in real-world industrial environments.
Each semi-finished product was fitted with a BlueUp Forte+ tag compatible with Quuppa’s infrastructure, enabling traditional indoor tracking via ceiling-mounted antennas. For the expansive outdoor areas—spanning several square kilometers—a fully autonomous drone system was developed. The drone is capable of autonomous take-off, landing, and navigation along predefined flight paths covering typical storage zones. Equipped with an AoA antenna, it can locate tagged items with one-meter accuracy. In adverse weather conditions or when flying is not possible, a similar tracking device mounted on forklifts—combined with GPS—was used to detect nearby assets during normal operations.
Results
The customer now has real-time visibility into the location of his semi-finished products, without requiring workers to perform manual tracking. This streamlined system has significantly improved production efficiency and reduced delays.
About BIT-TONIC
Bit Tonic Srl, based in Turin (Italy), is a Software Solution Provider company specialized in customized cloud, web, mobile and desktop applications and localization systems.
Bit Tonic develops solutions for logistics and warehouse management, worker safety, and building management, also utilizing AMR autonomous guided rovers and drones. Bit Tonic solutions help companies and organizations to manage their processes in order to increase efficiency and offer new services or, in other words, reduce costs and increase revenue.
Bit Tonic provides a turnkey custom solution to satisfy the Customer need starting from localization data and integrating them with the existing Customer applications or ERP. Bit Tonic takes care of the system design, hardware supply, support during the hardware installation, system configuration and testing and maintenance during the entire lifetime.
Bit Tonic is the one-stop shop for all your localization needs.
PostNord’s Hakkila terminal in Finland faced challenges in operational efficiency and process visibility—until they introduced a powerful new digital thread solution. By combining Quuppa’s real-time location technology with computer vision and analytics, PostNord gained a 25% boost in sorting efficiency and a 32% increase in parcels handled per hour.
ALL SYSTEMS GO!
Improving operational efficiency in a sorting center is always front of mind for managers, but it can often be challenging. At PostNord’s Hakkila terminal in Finland, for example, management faced challenges when trying to optimize the facility’s sorting processes.
The terminal had problems maintaining operational quality, due to site design, fluctuating volumes and changing management and processes. There was also a lack of oversight of resource use and process compliance, and an inability to measure performance.
“The terminal was fairly new but had become congested quickly due to the volumes coming in,” explains Christian Østergaard, PostNord’s lead visionary and senior group strategist. “They had just gone through their first peak, which management felt had been quite disorganized and inefficient, so they reached out to our team to see how we might help them address issues around productivity, throughput and efficiency.”
The timing couldn’t have been better for Østergaard and his colleagues as they had something new they wanted to trial: a digital thread sorting solution.
”WE WANTED TO BE ABLE TO MONITOR ALL OUR INTERNAL PROCESSES AND TO SEE WHERE OUR WORKERS WERE, TO SEE IF THE PROCESSESWERE OPTIMAL”
Christian Østergaard, PostNord
When looking to improve operational efficiency, the focus is often on working out which of the many sorter and process flow configurations is optimal for a specific facility. However, what is regularly overlooked is improving visibility across the site – of everything from execution flows and resource allocation through to movements and internal transportation.
Most managers won’t have access to such information, which means decisions are often based on personal experience or a ‘gut feeling’, and will differ from leader to leader. Being in constant operational mode also limits managers’ ability to think about these details, which is why PostNord wanted to trial this new solution, which would introduce more data-driven ways of working and just-in-time thinking.
Digital thread sorting solution
PostNord’s digital thread sorting solution creates a real-time representation of the entire sorting center across all assets and moving parts, thereby improving the understanding of process flows.
LEFT: The digital thread sorting solution uses a real-time location system to ensure workers are in the optimal place.
RIGHT: The solution enables PostNord staff to quickly identify areas of concern within the sorting machines
It is the result of several technology projects across the organization that Østergaard and his colleagues realized could be amalgamated and developed into an overarching sorting solution.
“The idea was to use computer vision together with a real-time location system (RTLS),” Østergaard explains. “Putting sensors in different places across the terminal would enable us to collect data in real time. We wanted to be able to monitor all our internal processes and to see where our workers were, to see if the processes were optimal or whether there was room for improvement.”
Digital thread benefits
An operational efficiency gain of more than 25% in sorting operations
A 32% increase in the number of parcels sorted per hour
Percentage of sorting staff meeting KPIs has risen from 20% to 54%
ROI of technology pilot was less than four months
Gaining trust
The rollout of the digital thread sorting solution took place in stages, working in close collaboration with the local management team.
“When you come in with a new technology, it’s important to gain the trust of the people who will use it. We had a list of the things we wanted to do but began by asking them if they had specific problems that they wanted us to look at,” Østergaard reports.
“They raised two areas of concern: an underperforming machine and making sure the first-in, first-out principle was being used when it came to storage. For the first issue, we were quickly able to establish functions that enabled staff to see what was going wrong in the process, so it could be resolved. For the second, we visualized things for them, so they could see what was happening. This built the trust and it then became a question of okay, how do we go ahead and roll out everything else?”
At each stage of the rollout, solutions were reviewed and tweaked if necessary. “It was a great collaboration, where there was the strategic team looking at how we can get the technology to work, our partner vendors, who were focused on making it work, and the local tech-savvy management, who were keen to use technology to improve efficiencies,” comments Ravi Kiran Kotty, digital transformation technology strategist at PostNord.
“They’d say, ‘Okay, we think we can be more efficient here’, and we’d sit down and come up with a solution. If the first iteration didn’t work exactly as they wanted, then we reconfigured it so that it was fit for their purpose.
“It was a slow evolution,” Kotty continues. “We went use case by use case. Once it was implemented, we would evaluate whether it added value before moving on to the next one. We’d identify an asset, try to generate data from it, then the value, before looking to add additional assets. There was no big bang, it was a progressive thing, which added value exponentially with every use case.”
”EVERYONE LIKES SIMPLICITY. THEY DON’TWANT A LOT OF DATA,JUST QUICK ANSWERSOR SIMPLIFIED GUIDANCE”
Ravi Kiran Kotty, PostNord
A collaborative partnership
After launching its new sorting facility in September 2022, PostNord faced challenges with productivity KPIs such as parcel throughput and production efficiency. The need for reliable tracking and monitoring led to the implementation of Quuppa’s RTLS technology. By tracking mobile devices and forklifts, PostNord gained real-time visibility of transportation movements and resource allocation, especially in critical areas like sorting machines and cross-docking zones. This visibility allowed for the identification of process inefficiencies, enabling optimization of workflows.
The collected KPIs and analytics are computed in near real time and provided directly to the relevant people within the facility, allowing PostNord to optimize work floor and sorting chute handling, monitor the number of trips between overflow chutes and improve the use of the cross-docking areas. These improvements have resulted in a more than 20% increase in efficiency and productivity.
The technology also enables data-driven decision-making, moving away from guesswork to fact-based planning. Real-time insights allowed better resource allocation and shift planning, improving operational processes and reducing internal lead times. This shift has helped PostNord to achieve higher delivery quality and improve parcel throughput.
By integrating the system into a digital twin model, PostNord has advanced toward its 2032 vision of touchless parcel handling, improving both operational efficiency and sustainability.
PostNord partnered with two key vendors on the development of the digital thread solution: Tata Consultancy Services (TCS) and Quuppa. TCS helped the post build its computer vision models, while Finnish startup Quuppa provided high-precision indoor tracking technology.
Work on the project began back in May 2023, with the digital thread solution completed by the end of January 2024. The biggest integration of new technology into the terminal was the installation of Quuppa’s RTLS technology. This entailed a full site survey to assess what was needed in terms of physical infrastructure.
“The first part was installation, which took some time, but after that we were able to deliver new use cases every couple of weeks,” Kotty notes.
ABOVE: The solution provides a real-time overview of parcel volumes.
LEFT: A spaghetti diagram of internal transportation volume in the sorting terminal.
One of the first use cases was employing PostNord’s existing security camera system to monitor movements and processes, to identify areas of concern. “The good thing with computer vision is that if you already have the cameras, you just need to introduce an ‘intelligent filter’ that is trained in what to identify and measure,” says Østergaard.
Improving visibility
PostNord says the digital thread is helping to measure two key areas: productivity and internal transportation. Productivity is assessed in an anonymized way, examining processes and supporting functions using existing handheld devices.
“We don’t want to know who each worker is – we simply want to know where people are and what they are doing at any given time. We ‘Smurf’ them, because our system shows them as blue,” Østergaard chuckles.
This enables management to see whether the site or workflow is designed in a way that adds leakage. They can also evaluate different processes and identify any wasted productivity and the reason behind it.
In terms of internal transportation, visualization, control points, flow optimization and new data help PostNord achieve better use of assets like forklifts, employees and floor space.
Benefits to all
The digital thread benefits all levels of staff, from those on the shop floor through to shift leaders and process designers. The business case has already been proved at Hakkila, where the terminal has seen a more than 25% increase in operational efficiency in sorting, in addition to increased productivity, improved quality, the removal of bottlenecks and the establishment of performance measurement.
“We regularly check in with the Hakkila team and each time we speak they’ve consistently improved,” enthuses Kotty.
“That’s possible because we’ve created a ‘blue ocean’ of data; some that had never been looked at before,” Østergaard adds.
A standout use case at Hakkila has been the introduction of a simple traffic light system to communicate needs to terminal staff. PostNord has a staff turnover of 8% a month in this specific terminal, so it needed something straightforward and self-explanatory that everyone could understand straight away. It therefore introduced a visual tool where screens show areas of the facility as green (low attention), yellow (high attention) or red (critical) to let staff easily see where they’re needed. “If they see a red or yellow area on the screen, they know they can be useful there. This visualization enables them to make better use of themselves without the need for management to intervene,” continues Østergaard.
By giving staff continuous information on where they were most needed, the number of parcels they could handle per hour increased by almost 30%, notes Kotty. In addition, before the introduction of the traffic light tool, only 20% of those on the floor were able to meet the KPI targets PostNord had set – now 54% can. “They’re able to work more efficiently,” he enthuses.
ABOVE: A traffic light visual tool ensures the system is easy for new staff to understand
Modern image
The introduction of the digital thread has had a positive impact on the company’s image, with many employees saying that they regard PostNord as a modern employer.
“Many of our employees are gamers; they have a vacuum cleaner robot at home; they’re tech savvy and have an expectation that their employer will be too.
So it’s been very positive for the company’s brand,” explains Østergaard. “It’s also easier to teach people new functions.”
“Indeed, we always want to trust simplicity rules, and this project helped us validate that,” notes Kotty. “Everyone likes simplicity. They don’t want a lot of data, just quick answers or simplified guidance.
“The ROI is between three and four months, again validating this as a good approach to take. Of course, there are a couple of prerequisites: you need an organization that’s tech savvy, and people who are open to change and will support your implementation. But there are not many use cases where you can see productivity increases of this ratio, with this kind of payback.”
What lessons has POSTNORD learned?
Tech-savvy local management and workers are key to implementing and adopting new technology in operations
You can make use of lots of your existing infrastructure to gain new insights into how your processes are running
Collaboration between all parties is essential
Keep communication of data simple and straightforward
Next steps
Next steps The development of the digital thread is an important step toward hyper-automation of PostNord’s terminal operating execution model. The post says it’s been a perfect playing field for operations, innovation and IT to evaluate and implement the right changes and at the right time.
It plans to continue bringing many of its use cases together as part of the digital thread, including asset tracking, forecasting and digital twins.
Based on the success at Hakkila, PostNord is now rolling out the digital thread solution in Denmark. Once the first site has been successfully completed, the plan is to scale it to the country’s two largest terminals.
PostNord is the leading provider of parcel and logistics services in the Nordic region. Formed through the merger of Sweden’s Posten AB and Denmark’s Post Danmark, PostNord delivers efficient, reliable, and sustainable logistics solutions to businesses and individuals across the Nordics and beyond. With a strong focus on digital transformation, innovation, and customer satisfaction, PostNord plays a key role in enabling the flow of goods and communication in an increasingly connected world.
The climate is changing. Nowhere is that more apparent than in our oceans, marked by crashing fish stocks and an abundance of floating plastic waste. These shifts are not just statistics—they are visible in real time to those who spend time on the water.
Finnish sailor and environmental advocate Tapio Lehtinen has witnessed these changes firsthand over decades of sailing, and his experiences have driven him to advocate for solutions that address climate change. Some can be found in surprising places. Lehtinen is now partnering with companies in the logistics and technology sectors to support his sailing expeditions and bring visibility to climate solutions.
As a CEO of a technology company and an avid sailor and nature lover myself, Lehtinen’s goals resonated with me. Addressing climate change requires interventions across multiple sectors, including technology-driven approaches that improve efficiency and reduce waste.
I believe one solution to our planet’s abundant waste problem comes from smart asset management, real-time location systems (RTLS) and location-based services (LBS). But you may ask, what does asset tracking have to do with tackling the climate crisis? By knowing exactly what you have and where you have it, companies can limit both overstocking and plastic production. Let me explain further how the two can support one another.
How Location Services Support Sustainability
Location services and sustainability are more closely linked than they may seem at first glance. In a world where reducing waste and conserving resources are critical, the ability to track assets in real-time has become an essential part of sustainable operations. Location technology can also be used to track visitors, monitor maximum capacity and reroute guests in crowded museums or prevent overtourism in national parks, for instance. In manufacturing and logistics, location-based technology helps businesses use resources more efficiently, reducing their environmental impact while also improving operational performance.
Let’s start by explaining how it works. RTLS functions by using tags or QR codes attached to mobile assets, equipment and inventory. These tags communicate with a network of fixed receivers, which can compute their position to provide live location updates. RTLS uses a variety of technologies and methodologies—including Bluetooth low energy (BLE), radio frequency identification (RFID) and GPS—to offer asset tracking with varying levels of precision.
Data collected from RTLS is processed through software platforms that provide real-time visibility, analytics and automation capabilities. Operations managers can use RTLS to find any asset in an industrial-sized warehouse and to keep an automatically updated, complete inventory of assets. From simple forklift vehicle spare parts to parcels for e-commerce, the underlying idea is that before ordering more, you can check what you already have.
In industrial environments, the technology helps streamline supply chain operations. For example, it can reduce energy usage by optimizing forklift routes inside the warehouse, ensuring that tools are readily available at the working stations and avoiding both shrinkage and overstocking.
Building A Circular Economy
As industries face growing pressure to transition to a carbon-neutral circular economy, the focus is shifting from a linear “take-make-dispose” model to one that prioritizes products that are designed for reuse, refurbishment and recycling. In a circular economy, assets can be repurposed to create a closed loop of materials. This shift reduces reliance on virgin raw materials, minimizes waste and lowers environmental impact.
By providing precise tracking of materials within and around industrial facilities, RTLS helps repurpose resources and materials more effectively, extend product life cycles (improve predictive maintenance, increase product lifetime, avoid breakage and reduce production downtime) and reduce unnecessary manufacturing and stocking of tools and spares. This level of efficiency directly supports sustainability goals.
Reducing Plastic Waste
You may still be struggling to see the connection between asset management and ocean conservation—and why Lehtinen is advocating for this technology. But consider that plastic pollution is one of the most pressing environmental challenges, with an estimated 200 million tons of plastic waste already in the oceans, increasing by over 8 million tons each year. RTLS can play a critical role in reducing the excess manufacturing of items that, whenever ordered without clear asset management visibility, are eventually lost or will never be used in daily operations.
RTLS also enhances recycling efforts by providing better traceability of spare parts, materials and vehicles used to support daily activities. The packaging of such items is often made of plastic, which often ends up in landfills or the ocean. By integrating RTLS into their operations, businesses can take a proactive approach to reducing plastic waste, supporting sustainability goals and healthy oceans.
Challenges And Opportunities
As explained in a previous article, sustainability regulations are not always considered profitable for business. Unfortunately, companies often think the opposite, assuming that the green economy is a limit to their business capabilities. This is far from the truth, especially when analyzing daily operations in terms of both productivity and running costs.
But where to start? The first step is to consult an expert vendor or a consultant with a strong track record in location solutions for industrial facilities. A knowledgeable partner can quickly assess your needs, gather feasibility requirements and propose one or two solutions that balance initial investment costs with expected returns. This early evaluation helps ensure that the chosen solution aligns with both operational goals and budget constraints.
Once a potential solution is identified, it’s crucial to test it in a real-world setting before committing to a full-scale rollout. Budgeting for a time-limited pilot test—typically lasting three to six months—within your facility allows businesses to evaluate the technology’s performance under actual operating conditions. While many providers can showcase impressive demos in controlled environments, only a real industrial site can uncover potential limitations.
Technology As A Climate Solution
Real-time location tracking is not a standalone fix for the carbon footprint of the logistics sector, but it is part of a larger ecosystem of solutions. As businesses increasingly prioritize asset management for cost reduction, this will positively impact the overall sustainability, essentially creating a more resource-efficient and low-carbon future.
This article was originally published on Forbes.com.
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Fabio Belloni
Fabio Belloni is the Co-founder & Chief Executive Officer at Quuppa. He is also a member of Forbes Technology Council – A Community for World-Class CIOs, CTOs, and Technology Executives. (Read more here)
When implementing real-time location systems (RTLS) in logistics, the amount of data generated can at first be overwhelming. By tracking how assets are moved across a facility, RTLS generates abundant streams of new data, which can exceed a few gigabytes per day, depending on the number of tracked assets and the update rate.
Before RTLS, only limited information was available on where assets were and how they moved in real time at the granular level. Now, you can know precisely how assets are moved, but you may not know what to do with that information.
What’s the answer? Artificial intelligence (AI) in logistics. I’m not referring to AI to automate tasks and processes, but in using AI to generate insights into your process flow by digging into the data. Without AI, logistics operators may be getting little value out of the mountains of data generated by RTLS.
To overcome this, logistics operators must develop a game plan to store, train, process and analyze all this new data. Here’s how.
Building Models
The central challenge of implementing AI in industrial environments is pretty apparent: Once you collect data, how do you use it? In short, you have to sort it to train and build models that produce insights.
Once the data is collected from all sources (e.g., RTLS, cameras, sorting machine, vehicles, etc.) and cleaned, it is divided into training, validation and testing sets. The training dataset is used to teach the model to recognize patterns and relationships within the data.
For example, in logistics, the model might learn to predict delays based on historical asset movement or suggest optimal temporary storage layout based on both real-time item flow patterns and available resources. The validation dataset is then used to fine-tune the model, ensuring it generalizes well and doesn’t overfit to the training data. This step helps balance the model’s accuracy across a variety of scenarios it may encounter in real-world operations.
The final stage involves using the testing dataset to evaluate the model’s performance on unseen data. This provides a measure of how well the model can make accurate predictions or deliver actionable insights in practical applications. If the results are unsatisfactory, the model might require adjustments, such as reconfiguring algorithms, incorporating additional data features or refining the training process.
Challenges To AI Adoption
Even if you follow the aforementioned steps to the letter, several common pitfalls can derail AI implementation.
1. Unreliable Or Untrustworthy Data Feeds: Poor-quality data leads to poor-quality results. Or as the old adage goes, garbage in, garbage out. Without clean, consistent and trustworthy data, AI models cannot deliver consistent and accurate insights. AI models are highly dependent on the data they are trained on and fed, and if the data is inaccurate, inconsistent or incomplete, the resulting insights will be flawed. For example, malfunctioning sensors, unreliable asset location or gaps in data collection can produce incorrect conclusions about asset movement, leading to questionable insights.
2. Lack Of Expertise Among Employees: AI and ML are powerful tools, but without the right expertise, their potential often goes untapped. Many logistics facilities lack team members with the skills to implement, manage and interpret AI models effectively. This can result in a range of challenges, from inefficient use of resources to an inability to troubleshoot AI-related issues.
3. Blind Faith In AI-Generated Analysis: While AI can offer valuable insights, relying on it without understanding how it arrives at its conclusions can be a major pitfall. Blind faith in AI can lead to misguided decisions, particularly if the underlying data or models are flawed. For instance, if an AI system suggests optimizing inventory placement based on incomplete data, the result could be increased inefficiencies rather than improvements.
Solutions
To successfully integrate AI into industrial operations, it’s essential to address these challenges head-on, starting with data quality. Reliable, consistent, high-quality data provides a solid foundation for process analysis and optimization.
Often, it is very valuable to also capture the level of noise or confidence (e.g., through variance) of the measurement data itself. Many organizations use a data lake to store vast amounts of raw data in its original form, allowing them to sort and analyze it later. This approach ensures that valuable information is preserved and can be leveraged for deeper analysis when needed.
Equally important is the need for expertise in AI and ML within the workforce. Hiring specialists with experience in these fields can help an organization implement AI effectively, but companies should also focus on upskilling existing employees.
Training programs, workshops and collaboration between logistics and AI teams can foster a deeper understanding of AI systems. This not only improves implementation, but it also ensures that the workforce can actively contribute to AI-driven initiatives, making the technology a practical part of daily operations.
Finally, it is vital to address the issue of blind faith in AI-generated analysis. Leveraging explainable AI (XAI) can be a crucial step to ensure that operators understand how AI arrives at its conclusions. XAI provides transparency into the decision-making process, explaining the logic behind each recommendation and highlighting the data used. This allows operators to evaluate the credibility of AI-generated insights and make informed decisions.
By providing transparency, XAI fosters trust and encourages broader adoption of AI within the organization. It also helps overcome employees’ reluctance to rely on AI, as they can see the rationale behind its suggestions and feel more confident in its recommendations.
Final Thoughts
By focusing on data quality, expertise and transparency, logistics operators can effectively leverage AI to turn a vast amount of raw data, including RTLS and location information, into actionable insights.
When implemented strategically, AI can create more efficient, agile and resilient supply chains, positioning logistics operators for long-term success in an increasingly competitive market.
This article was originally published on Forbes.com.
Get Latest Updates On Location Technologies!👇
Fabio Belloni
Fabio Belloni is the Co-founder & Chief Executive Officer at Quuppa. He is also a member of Forbes Technology Council – A Community for World-Class CIOs, CTOs, and Technology Executives. (Read more here)
Quuppa — a leading company in real-time, high accuracy positioning solution, is thrilled to announce the appointment of Fabio Belloni as its new Chief Executive Officer, effective January 8, 2025.
Fabio Belloni is a familiar face to many, as one of the co-founders of Quuppa and central in supporting many customers’ projects since the Company’s infancy. With the previous role of Chief Growth Officer, Fabio has been responsible for the Company’s growth initiatives. Fabio’s enthusiasm for embracing cutting-edge technologies and fostering a culture of innovation will be instrumental in driving Quuppa’s continued growth and market leadership.
Fabio is poised to lead Quuppa into a new era of success — with his long history with Quuppa, commitment to learning and innovation, and his unique mix of technical skills and leadership abilities.
Please join us in extending a warm welcome to Fabio Belloni as he embarks on this exciting journey as our CEO. We wish Fabio great triumph in the new role!
With the advent of real-time location systems (RTLS) in manufacturing, an unprecedented amount of data is being generated. But now, a new question arises: How do facility operators and operation managers effectively use this data?
Although RTLS produces vast amounts of data that can be used to monitor daily operations across facilities, understanding the data and responding to it is not necessarily straightforward. Every site or facility has uniquely designed processes that require expert knowledge to create a digital representation of the process and visualize the data. In other words, to leverage data effectively, it needs to be organized and mapped to derive trends and gain novel insights.
I’ve previously discussed how data can be visualized on the manufacturing floor, but now I want to focus on visualizing data in the backend or on the management side. Instead of workers being directed to the next step in a process or given specific instructions, this approach involves deeper data analytics. The idea is to first highlight quantifiable bottlenecks and then point to measurable operational improvement.
Why Visualize Data?
RTLS deploys advanced technologies to track the precise location of assets, inventory and equipment within a defined area, be it indoors, outdoors or a hybrid environment. By utilizing various types of sensors and communication technologies, RTLS provides continuous, real-time visibility into the movement and status of these items. This technology tells you what you have, where you have it and how it got there. However, there are different ways to effectively display and communicate this location-enabled information.
There are primarily two distinct approaches to data visualization. The first one relates to displaying location-enabled data directly on the factory floor via strategically mounted displays that depict the real-time status of the operational flow. For example, these displays can be used to share real-time information on the resource allocation and machine yield, so that the shift manager can decide on possible corrections to meet daily targets.
On the other hand, the data could also be displayed in a central monitoring system to benefit the team leaders, factory managers and all other relevant personnel who monitor the operational flow on a larger scale. Essentially, it’s about showing location data on the floor to improve a specific site’s efficiency versus monitoring across many, possibly different, sites to dive deeper into trends and overall key performance indicators (KPIs).
How Can You Use This Data?
Because RTLS processes require substantial upfront investments, industrial operators will want to use the systems to their maximum potential to generate revenue. However, effective data utilization is not merely about collecting information but about transforming it into actionable intelligence that can drive process improvements and revenue growth for each site on many production threads, 24/7.
Focusing on the data analytics side, let’s explore how end customers—facility managers, shift leaders, users of services in a logistics facility, the chief operating officer (COO) and others—can utilize this data to optimize operations. Again, understanding the movement and utilization of assets within a facility is crucial for optimizing logistics. By analyzing RTLS data, managers can track how assets are being used, identify underutilized resources and make adjustments to improve efficiency.
For COOs and other top-level executives, the ability to visualize data in real time from a central dashboard provides valuable insights into the overall health of logistics operations. They can track key performance indicators (KPIs), monitor operational efficiency and make strategic decisions to drive the business forward. For instance, by analyzing data from RTLS, facility managers can identify inefficiencies in the process flow of assets. They can monitor lag times, highlight unneeded process steps and determine where processes can be improved.
Additionally, if RTLS data highlights recurring delays at a particular stage in the production line, managers can investigate the underlying causes—whether mechanical issues, staffing shortages or process inefficiencies—and implement targeted solutions to address these problems. RTLS may also highlight how the flaw is in the process design itself, not necessarily in the implementation.
Challenges To Implementation
The sheer volume of data generated by RTLS can be overwhelming. Without proper data management strategies, organizations may struggle to make sense of the data, leading to analysis paralysis and missed opportunities.
Consequently, implementing a robust data management framework is essential. This includes defining clear data governance policies, employing data filtering and aggregation techniques to focus on the most relevant data and using advanced data visualization tools to present actionable insights. Training staff on how to interpret and use the data effectively is also crucial to avoid being overwhelmed by information.
Even with advanced tools, interpreting the data generated by RTLS can be complex, particularly for organizations that lack data science expertise with specific processes and industrial operational knowledge. Misinterpretation can lead to poor decision making. This is why organizations may consider hiring or consulting with data scientists who can provide expert insights and ensure that the data is being interpreted correctly.
Many wrongly assume AI can be the answer to these challenges, but it’s important to recognize that AI is not a magic box of answers. The quality of AI outputs is directly related to the quality of the data and the models built upon that data. For logistics operators, this means that the first step is to understand how to capture and interpret data effectively. Once a solid data foundation is in place, AI can then be deployed to answer complex questions about process optimization.
Final Thoughts
Capitalizing on the new data streams generated by RTLS in logistics is not just about collecting information—it’s about making that information work for you. The potential to optimize operations, enhance decision making and drive revenue growth is immense, but it requires a strategic approach.
Successful implementation of RTLS and data analytics hinges on overcoming challenges such as data overload, integration complexities and the need for robust data management frameworks. By investing in the right tools, training and expertise, logistics operators can transform raw data into valuable insights that propel their business forward.
This article was originally published on Forbes.com.
Get Latest Updates On Location Technologies!👇
Fabio Belloni
Fabio Belloni is the Co-founder & Chief Executive Officer at Quuppa. He is also a member of Forbes Technology Council – A Community for World-Class CIOs, CTOs, and Technology Executives. (Read more here)
Leveraging both Technologies to Drive Better Patient Outcomes and Streamlined Processes Across Healthcare Facilities
Quuppa, the global leader in real-time location systems (RTLS), and ZulaFly, a renowned innovator in healthcare and critical industry asset management solutions, are thrilled to announce a partnership set to redefine the landscape of location-based services. This collaboration brings together two industry giants, combining their strengths to deliver unparalleled precision, innovation, and value to businesses worldwide.
A Synergy of Expertise
Quuppa’s cutting-edge technology, renowned for its unparalleled accuracy in real-time location tracking, will seamlessly integrate with ZulaFly’s advanced asset management and safety solutions. Together, the two companies are poised to create a robust ecosystem that addresses the growing demand for precise, real-time data in environments where safety, efficiency, and security are paramount.
“At Quuppa, we’ve always been driven by the vision of creating smarter, safer, and more efficient environments through our RTLS technology. Partnering with ZulaFly is a natural fit as we both share a passion for pushing the boundaries of innovation. Together, we are not just enhancing technology; we are transforming the way industries operate, enabling them to achieve unprecedented levels of accuracy and efficiency in their operations. This partnership represents a significant leap forward in the evolution of location-based services, and we couldn’t be more excited about the possibilities ahead.”
Fabio Belloni, Co-founder and CCO of Quuppa
This collaboration is particularly timely as industries such as healthcare, manufacturing, and logistics increasingly seek out advanced technologies to optimise operations and improve safety standards. The integration of Quuppa’s high-precision RTLS with ZulaFly’s sophisticated asset management systems will empower organisations to achieve real-time visibility of their critical assets, ensuring not only operational efficiency but also heightened safety for personnel and patients alike.
“In today’s fast-paced and ever-evolving industries, having access to accurate and real-time data is not just a luxury—it’s a necessity. At ZulaFly, we’ve always been committed to providing our clients with the best tools to manage their assets and ensure safety within their environments. Partnering with Quuppa allows us to take our offerings to the next level, providing our customers with a level of precision that was previously unattainable. This partnership is a game-changer for industries that rely on real-time data, and we are excited to work with Quuppa to deliver solutions that make a tangible difference in the world.”
Stephanie Andreson, CEO of ZulaFly
Looking to the Future
As the world continues to embrace digital transformation, the need for reliable, accurate, and scalable location-based solutions is more critical than ever. The partnership between Quuppa and ZulaFly is set to lead the charge in this new era, offering healthcare instatutions the tools they need to thrive in a rapidly changing landscape.
The combined expertise of Quuppa and ZulaFly will not only enhance existing solutions but will also pave the way for new innovations that address the evolving needs of industries around the globe. From healthcare facilities seeking to improve patient safety to manufacturing plants aiming for greater efficiency, the impact of this partnership will be felt far and wide.
About inTechnology Distribution
ZulaFly is an industry-leading software solution company that collects, processes, and analyzes critical enterprise data, and presents the output in a customizable, unified dashboard user interface. ZulaFly supports many operational and safety applications including Workflow, Patient Wander, Locating & Wireless Alerting, Asset Management, Environmental Monitoring, Staff Safety & Locating, Staff Rounding, Hand Hygiene, Mobility and many others. These critical applications can be managed at a single facility or across multiple campuses in a cloud-hosted environment. Hundreds of satisfied customer sites are enjoying the benefits of ZulaFly’s enterprise-class visibility solutions.
About Quuppa
Quuppa is a leading technology provider for real-time locating systems (RTLS) and indoor positioning systems (IPS). Established in 2012 as a spin-off from Nokia Research Centre, Quuppa has commercialised its Quuppa Intelligent Locating System™, a comprehensive platform for location-based services and applications. With over 200 global partners, Quuppa delivers accurate, real-time, and cost-effective location solutions across various industries.
In today’s rapid and sometimes chaotic industrial environments, tracking assets in real time is essential to optimize operations, maximize efficiency and reduce cost. Real-time location systems (RTLS) have proved valuable for these purposes, but recent advancementsoffer new potential for the technology.
Think of RTLS as the GPS of the industrial world, providing insights into the movement and location of equipment and assets, tracking everything from forklifts to shipping containers to consumer goods, indoors and outdoors. But instead of solely capturing asset coordinates, modern RTLS systems offer displays to communicate asset information in real time, showing where an asset has been and where it needs to go.
I’d like to explain more about data visualization with RTLS—and what problems can be overcome using it—with what I imagine is the next biggest trend in industrial logistics.
How To Visualize Data
While the visualization of location data in logistics is still in its early stages, digital displays tied to real-time information are already the norm in other vertical markets. Consider the recent adoption of electronic shelf labels (ESLs) in retail spaces, particularly at grocery stores. Food products are marked with digital labels to accurately reflect the unit price, daily discounts and stock availability, along with other relevant product information.
With the advent of ESLs, we’ve seen a major shift away from paper toward digital price tags; generally, these displays are more sustainable and less resource-intensive to maintain and operate.
But what’s the relevance of these displays to manufacturing? Mostly, data visualization tools enhance industrial RTLS projects by providing instructions in an easily accessible format and improving process flow.
Such instruction can be achieved by attaching digital displays to transport units—whether it’s a box, roller cage or palette—to reveal dynamic real-time information on asset storage and movement. For example, if an employee takes a forklift of boxes to the wrong location in a warehouse or on a factory floor, the display on the forklift, or the display directly mounted on the boxes, will change the text in real time to say “wrong destination, take me to this location instead.”
A more simplified example of this is pick-to-light technology: If an employee comes close to something they should grab, the display blinks at them. Digital location displays don’t necessarily have to display text, they can also be scannable barcodes or QR-codes that are displayed and dynamically updated or have a blinking LED light.
Why Visualize Data
With this advanced RTLS system in place, employees on the operations floor receive immediate dynamic feedback on whether they’re executing the right process or completing the right task. This all brings direct benefits to process optimization, reducing search time and minimizing human errors. Overall, a display tag guides an employee’s immediate actions to improve process flow across a facility.
Digital displays can also be leveraged to improve inventory management. By using electronic tags and displays, manufacturing plants and warehouses can track goods at every stage of the production process, both on the backend postal applications, as well as directly from the facility floor. Digital displays provide real-time information on inventory levels, locations and movements, ensuring resources are used efficiently and reducing the need for overstocking and waste.
Data visualization may also play a crucial role in improving sustainability along the supply chain. By tracking the movement of goods in real time, logistics providers can identify opportunities to reduce waste and optimize resource usage. Moreover, digital displays also reduce paper waste and related inefficiencies. Instead of constantly changing paper tags as asset information changes, the tag remains the same but the information displayed on it transforms.
Challenges To Implementation
While RTLS coupled with digital displays offers significant benefits, their implementation isn’t without challenges. Understanding and addressing these concerns is essential for a successful deployment.
For one, implementing RTLS requires substantial investment in both technology and facility modernization. Many companies aspire to achieve digitization, Industry 4.0 standards, sustainability and reduced CO2 footprints. However, realizing these benefits necessitates upgrading infrastructure, which can be costly and time-consuming. Organizations need to carefully assess their readiness for such investments and plan for gradual integration to manage costs effectively.
Facilities also need to be prepared to analyze and leverage large amounts of data. RTLS generates vast amounts of data and insights into process flows, which can be overwhelming if not managed properly.
The key to leveraging this data is integrating it into existing processes and adapting performance metrics and reporting mechanisms accordingly. Organizations must establish robust data analysis frameworks and be prepared to act on the insights provided by RTLS. This requires a top-down mandate to drive change across the organization.
However, such mandates may not be well received. Introducing RTLS and digital displays in an industrial environment may meet resistance from employees who are accustomed to existing processes. Workers may feel that their knowledge and expertise are being undervalued. This mindset can create friction when new technologies are introduced.
However, it’s crucial to communicate that RTLS is not about replacing the workforce but enhancing their efficiency and streamlining their workflow.
Moving Forward
The integration of digital displays with RTLS is part of a wider global trend shifting away from static paper labels with outdated information to smart displays with dynamic information.
In logistics, that means asset information—be it product specs, expiration or shipping information—is clearly displayed with an asset anywhere in the facility. The goal is to optimize the process while minimizing unnecessary costs and efficiencies
In essence, this advancement enables the right information to be in the right place at the right time. That’s what RTLS is all about.
This article was originally published on Forbes.com.
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Fabio Belloni is the Co-founder & Chief Executive Officer at Quuppa. He is also a member of Forbes Technology Council – A Community for World-Class CIOs, CTOs, and Technology Executives. (Read more here)
Twinzo, a leader in cutting-edge no-code live digital twin technology, is pleased to announce a strategic partnership with Quuppa, a renowned provider of Real-Time Locating Systems (RTLS)
This collaboration aims to deliver innovative location-based technologies to a wider market, enhancing efficiency and innovation in various industries.
The partnership between Quuppa and twinzo is set to revolutionize location-based services market, introducing innovative technologies to the market and beyond. As a pioneer in RTLS technology integrations, we value Quuppa technology as reliable with a great value for money ratio, that can withstand industrial environments and provide a great variety of use cases from presence detection to accurate positioning.
“Quuppa RTLS not only met our stringent requirements but exceeded them. The system’s flexibility and precision in on-site installations offer our clients a highly adaptable tracking solution that significantly optimizes their operations. We are thrilled about this partnership and the opportunity to introduce Quuppa’s exceptional technology to our customers on a wider scope.”
Michal Ukropec, twinzo CEO
“We are excited to welcome Twinzo into the Quuppa Partner Ecosystem and extend our coverage to Slovakia. Twinzo digital twin combined with our reliable location information is a perfect match for track & trace, fleet management, and order automation in the industrial sector.”
Soile Kankaanpää, Quuppa CEO
About Twinzo
Twinzo specializes in offering advanced no-code live digital twin technology, which significantly optimizes intra-logistics by an average of 20% and reduces idle time in production facilities. Our solutions enhance operational efficiency and decision-making processes and next-generation analytical capabilities for optimisation of manufacturing and logistic facilities.
Special offer from twinzo: the first 10 customers will get 15% discount on licenses for the first year as a special offer.
Founded in 2012, Quuppa is a leading provider of Real-Time Locating Systems (RTLS). The Quuppa Intelligent Locating System™ is known for its superior real-time accuracy; It is a reliable and scalable platform for location-based solutions. To date, the Quuppa Ecosystem has over 200 partners and customers worldwide who rely on Quuppa to provide innovative solutions for various industries, including manufacturing and logistics, law enforcement and security, healthcare, retail, sports, and entertainment.
Oulu-based Haltian has successfully deployed its IoT solution at Milton Keynes University Hospital in England. According to CEO Pasi Leipälä, the project is a great example of the innovative application of digitalisation in healthcare.
Implementation and Features
The initiative at Milton Keynes commenced in the hospital’s Cancer Centre in 2022, and the Haltian Empathic Building Hospital solution has now been implemented in other wards as well. At its core is a digital map that provides real-time information on staff locations, the status of critical care equipment and room occupancy. This system utilises the Real-Time Locating System (RTLS).
The practical implementation involves various sensor devices installed in the rooms, on critical equipment and medication cabinet keys, and carried by the staff. Sensor data, such as temperature and location information, is transmitted to a gateway using the Wirepas MESH protocol over a Bluetooth® link and then transferred via a 4G link to the cloud.
Technology and Partners
Another key partner in this project include Quuppa, whose compact modules (tags) can be carried in the pocket. “We utilise positioning technology from partners such as Quuppa or Haltian’s own HITS system, depending on the specific requirements,” says Leipälä. The web-based software not only shows the location of critical equipment, but also that of the personnel on the screen. This visibility allows staff to spend more time on patient care, instead of searching for equipment.
Environmental Data Collection and Energy Efficiency
Haltian’s solution goes beyond location information. The company’s smart sensors gather data on various environmental factors, such as temperature, lighting, humidity and carbon dioxide levels. The collected data can be used to optimise the air conditioning of individual rooms in an energy-efficient manner. With the help of Haltian’s solution, Milton Keynes Hospital has managed to reduce building energy consumption by 40%.
Network and Expansion
Leipälä mentions that Haltian has been using the Wirepas protocol since around 2015-2016. Due to the MESH-type protocol, the devices automatically expand the network, eliminating the need for high-density gateways. In practice, one router per building floor is sufficient.
Expansion and Pilot Projects
The success at Milton Keynes has led to pilots in around 15 hospitals in the UK, Norway, Sweden and two in Finland. A significant collaboration was recently announced: Region Skåne, one of Sweden’s largest hospital districts, has agreed a four-year partnership with the Oulu-based company. The hospital district based its decision in favour of Haltian on the comprehensive nature of the solution, where one and the same partner supplies everything from the sensors to the user interface.
For Pasi Leipälä, Milton Keynes is an important reference point, as the National Health Service (NHS) is planning to build several new hospitals in the coming years, with some significant projects already underway. In addition, many old hospitals in England are set to undergo modernisation.
The article was originally published on www.etn.fi (in Finnish).
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Astor Mission Critical specializes in the development of effective and secure wireless communications solutions. With extensive experience as a distributor of industrial systems, Mission Critical offers technical support, training, and solution testing.
The partnership between Quuppa and Astor Mission Critical facilitates the delivery of reliable real-time locating solutions and the introduction of innovative technologies on the Polish market and beyond.
When we were looking for RTLS for our offering, we had several conditions that the technology had to fulfill: it had to be open for integrations and well documented, work with different tags and mobile apps, and be prepared for industrial conditions, which is the most important factor. Quuppa RTLS exceeded our requirements. Installed on-site and with different levels of accuracy, it offers our customers a flexible tracking tool. Quuppa RTLS saves time and money.”
Michał Łopata, Business Development Manager at Mission Critical by Astor
We are very excited about this partnership and entering the Polish market together with Astor Mission Critical. They have the right expertise, a long history working within IOT, and established relationships in the industry sector, which is our common target segment.”
Soile Kankaanpää, Quuppa CEO
If you wish to see our joint solution in action visit the Astor Mission Critical booth at the ITM Industry Europe in 4–7 June 2024.
About Astor Mission Critical
Wireless communication plays a vital role in the digitalization of industry, infrastructure, and logistics. That is why Mission Critical by Astor has established a competence center within the ASTOR Group since 2017, specializing in wireless technologies to support Industry 4.0 concepts. They provide training, solutions, and support to align their offerings with the development of the Industrial Internet of Things (IIoT) and networks.
Every business is different. Every communication matters.
About Quuppa
Founded in 2012, Quuppa is a leading provider of Real-Time Locating Systems (RTLS). The Quuppa Intelligent Locating System™ is known for its superior real-time accuracy; It is a reliable and scalable platform for location-based solutions. To date, the Quuppa Ecosystem has over 200 partners and customers worldwide who rely on Quuppa to provide innovative solutions for various industries, including manufacturing and logistics, law enforcement and security, healthcare, retail, sports, and entertainment.
Discrete manufacturing usually involves assembly lines or processes where parts are assembled or manufactured to produce finished products. Examples of discrete manufacturing include the production of cars, electronics, appliances, machinery and consumer goods. The items produced are unique and can be counted or identified as individual units.
Just as RTLS is transforming workplaces and hospitals, indoor positioning technology will redefine the way we approach manufacturing processes. Drawing on my own experience in this area, I want to share with you the five benefits that await you and how these advances could fundamentally transform discrete manufacturing.
1. Enhancing Efficiency in Operations
The use of indoor positioning technology in discrete manufacturing can significantly streamline workflows. By providing real-time data on the location of equipment, materials and personnel, decision-makers can optimise workflows and reduce downtime. Searching for a specific tool in a large manufacturing facility can be time-consuming, but with an indoor locating system, tools can be tracked and found within seconds, saving valuable time and increasing productivity.
Additionally, location-based services allow manufacturers to automate inventory tracking, which traditionally requires manual input and is prone to human error. With accurate location data, inventory levels can be continuously monitored. This ensures that materials are replenished when needed and production is not interrupted due to shortages. This level of efficiency is critical to remaining competitive.
2. Optimising Asset Utilisation
Asset management is an important part of discrete manufacturing, and indoor positioning systems play a critical role in maximising asset utilisation. By tracking the movement and utilisation of machines and equipment, manufacturers gain insight into their performance and maintenance needs. This enables proactive maintenance planning that not only extends asset and equipment life but also prevents unexpected breakdowns that can lead to costly production delays.
Understanding how assets and equipment are used throughout the manufacturing process will also help you identify optimisation opportunities. For example, if certain equipment is underutilised, it can be reallocated to areas of higher demand to ensure that every asset and each piece of equipment is used to its full potential. This strategic approach to asset management can lead to significant cost savings and a better return on investment.
3. Improving Workplace Safety
Safety is paramount in any manufacturing environment, and indoor locating technology contributes to creating a safer workplace. By monitoring employees’ positions in real time, the system can alert supervisors if an employee enters a hazardous area or if there is a potential for a dangerous situation, such as a collision between personnel and moving equipment. This immediate awareness enables rapid intervention to prevent accidents and injuries.
In addition to preventing accidents, indoor locating systems can also enable a faster response in an emergency. In the event of an incident, emergency responders can quickly locate the affected person, reducing response time and potentially saving lives. By improving safety measures, manufacturers not only protect their employees, but also minimise the risk of production downtime due to safety-related incidents.
4. Facilitating Data-Driven Decision Making
Data is a powerful tool for improving manufacturing processes, and indoor positioning systems provide a wealth of valuable data. By analysing the movement patterns of assets and personnel, manufacturers can identify bottlenecks and inefficiencies in their operations. This data-driven approach enables informed decision-making, where changes to the production layout or process can be made based on solid evidence rather than guesswork.
In addition, integrating location data with other systems, such as Enterprise Resource Planning (ERP) or Manufacturing Execution Systems (MES), can provide a holistic view of the manufacturing process. This integration allows manufacturers to fine-tune their operations, reduce waste, and improve overall productivity—all based on accurate and timely data.
5. Enabling Customisation and Scalability
One of the main advantages of indoor locating technology is its adaptability to the unique needs of each manufacturing facility. For example, Quuppa solutions can be customised to the specific layout and requirements of a facility to ensure that the solution is effective and adds value from day one. As the manufacturer needs to evolve, the system can be scaled up or adjusted to accommodate new processes or expansions, making it a future-proof investment.
Additionally, the system can be customised to achieve the level of precision required for different applications or extend to outdoor areas such as yards and loading docks. Whether a manufacturer needs sub-metre accuracy for intricate assembly work, zone-level accuracy or simply presence detection for warehousing, the system can be tailored to meet different needs. This flexibility ensures that manufacturers can utilise indoor positioning technology in the way that best suits their operational objectives.
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Martti Pinomaa is the Chief Sales Officer at Quuppa. He is experienced in defining and executing go-to-market strategies and nurturing partner ecosystems.
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