BLE and RFID-based Work-in-Progress (WIP) Tracking on the Shop Floor System

GAO’s BLE and RFID-based Work-in-Progress (WIP) Tracking System provides real-time visibility and control over production units, semi-finished assemblies, and subcomponents on the shop floor. RFID-only deployments offer rapid batch scanning at assembly stations, conveyors, and storage racks for high-speed identification. BLE-only deployments deliver continuous location telemetry and environmental data for tools, jigs, and materials moving across dynamic production cells. Hybrid BLE+RFID implementations allow enterprises to combine instantaneous identification with movement analytics, enabling predictive maintenance, throughput optimization, and automated workflow orchestration. GAO’s system integrates handheld readers, fixed RFID portals, BLE beacons, and IoT-enabled conveyor sensors to track operators’ interactions, tooling, and assembly line progress. Leveraging four decades of engineering experience and robust R&D, GAO supports manufacturers, aerospace firms, automotive assembly lines, and government contractors across the U.S. and Canada with secure, compliant, and highly scalable shop floor WIP tracking solutions.

Description, Purposes, Issues Addressed, and Benefits of GAO’s WIP Tracking System

How GAO’s System Works

• RFID or BLE tags are attached to subassemblies, pallets, bins, work-in-progress skids, and tooling fixtures.
• RFID-only setups allow high-throughput scanning at assembly stations, staging areas, and automated storage systems.
• BLE-only deployments continuously capture position, movement patterns, and proximity data for production cells, operator stations, and automated guided vehicles (AGVs).
• Hybrid BLE+RFID configurations merge real-time identity verification with continuous telemetry for actionable analytics on cycle times, bottlenecks, and operator efficiency.
• Gateways, BLE beacons, fixed RFID readers, and handheld devices integrate with ERP, MES, and SCADA systems to provide centralized WIP visibility.

Purposes of the System

• Enable end-to-end traceability of WIP units from raw material intake to finished goods.
• Reduce bottlenecks and optimize production flow across multi-line or multi-site facilities.
• Improve adherence to takt time, cycle time, and throughput KPIs.
• Provide audit-ready logs for regulatory compliance, ISO, and Lean manufacturing standards.
• Enhance workforce accountability and resource allocation.
• Minimize misplacement or loss of subassemblies, tools, and fixtures.

Issues the System Addresses

• Delays caused by misplaced WIP items or misrouted subassemblies.
• Lack of real-time visibility into production line throughput.
• Inconsistent quality checks due to misaligned or skipped inspection stations.
• Inefficient manual tracking of assembly stages, operator tasks, and tooling usage.
• Difficulty synchronizing automated and manual production operations.
• Limited traceability for audits, compliance, or root cause analysis.

Benefits Delivered by GAO

• Real-time dashboards provide operational insight into WIP status, line balancing, and bottlenecks.
• Improved cycle time monitoring and workforce efficiency.
• Reduction in production downtime and lost materials.
• Automated alerts for delayed or misplaced WIP units.
• Enhanced quality control and audit readiness.
• Supported by GAO’s extensive R&D, quality assurance, and on-site/remote expert support.

Comparison: RFID Alone vs BLE Alone vs Hybrid BLE+RFID

RFID Alone

• Best for rapid batch scanning at conveyors, workstations, and staging areas.
• Provides precise identification and inventory validation of WIP items.
• Suitable for environments where event-driven tracking is sufficient.

BLE Alone

• Continuously monitors location, operator interaction, and material flow.
• Ideal for dynamic production floors, AGV paths, and multi-cell manufacturing zones.
• Supports real-time workflow analytics and operator activity logging.

Hybrid BLE+RFID

• Combines high-speed identification with continuous telemetry for deeper operational insights.
• Enables predictive maintenance, advanced analytics, and automated production orchestration.
• Optimal for large facilities, aerospace, automotive, or high-mix production lines.

Applications of GAO’s WIP Tracking System

• Assembly Line WIP Monitoring
  Tracks subassemblies and semi-finished goods along multiple workstations for real-time production flow visibility.
• Palletized Component Tracking
  Monitors WIP pallets on conveyors, racks, and automated storage to prevent misplacement or delay.
• Operator Task Verification
  Logs operator interactions with components, tools, and machines for process compliance and efficiency.
• Fixture and Tool Usage Logging
  Captures usage of jigs, gauges, and fixtures to ensure accurate assembly and prevent tool misplacement.
• Automated Workflow Routing
  Guides components to correct stations using real-time location and production instructions.
• Production Cycle Time Analytics
  Measures stage-wise processing times to identify bottlenecks and optimize throughput.
• Quality Control Checkpoint Tracking
  Verifies WIP units have passed required inspection or test stations before moving forward.
• Subassembly Bin Management
  Tracks bins containing partially completed assemblies to prevent cross-contamination or loss.
• AGV and Material Handling Oversight
  Monitors autonomous guided vehicles moving WIP units across shop floor zones.
• Line Balancing and Workload Management
  Provides analytics to evenly distribute WIP across production cells and operators.
• Just-in-Time (JIT) WIP Verification
  Ensures components arrive at assembly stations precisely when required, reducing staging inventory.
• Multi-Facility Production Visibility
  Aggregates WIP status across plants for centralized monitoring and operational decision-making.
• Root Cause Analysis Support
  Provides historical WIP tracking data for defect or downtime investigations.
• Preventive Maintenance Integration
  Correlates tool and machine usage with WIP flow to schedule maintenance without disrupting production.
• Kanban and Pull System Optimization
  Integrates WIP telemetry to support Lean pull production methodologies and Kanban systems.
• Cycle Counting and Inventory Reconciliation
  Automates WIP inventory counts to minimize errors and maintain production accuracy.
• Temporary Workstation Allocation Monitoring
  Tracks WIP units moved to temporary or ad hoc workstations for flexible production lines.
• High-Value Component Protection
  Monitors movement of expensive subassemblies to prevent theft or misplacement.
• Environmental Condition Tracking
  Logs temperature, humidity, or vibration affecting sensitive WIP components.
• Operator Safety and Compliance Oversight
  Ensures WIP units and tools are handled safely, supporting OSHA and ISO compliance.

Local Server Deployment

GAO’s local server solution keeps WIP tracking data within secure plant LANs. SQL-based storage engines, RFID/BLE middleware, and browser-accessible dashboards support real-time monitoring, role-based access for supervisors, operators, and quality managers, while integrating with existing MES and ERP systems.

Cloud Integration and Data Management

GAO’s cloud-enabled WIP tracking supports cross-site analytics, predictive workflow insights, and compliance reporting. BLE and RFID telemetry is encrypted and stored in high-availability cloud reservoirs. Enterprise dashboards provide multi-facility visibility, real-time alerts, and audit-ready historical records while controlling access by operator, supervisor, and management roles.

GAO Case Studies of BLE and RFID-based Work-in-Progress (WIP) Tracking on the Shop Floor Systems using BLE or RFID

USA Case Studies

• A Detroit automotive assembly facility implemented RFID tags to track WIP subassemblies across multiple stations, reducing delays and ensuring accurate throughput. GAO RFID provided system integration and workflow optimization support.
• A San Jose semiconductor fabrication plant deployed BLE beacons to monitor WIP wafers, enabling real-time location tracking and dynamic job scheduling. GAO RFID assisted with sensor deployment and network calibration.
• A Chicago electronics assembly shop relied on RFID to manage circuit board WIP, streamlining process handoffs and reducing misrouting incidents. GAO RFID provided configuration and ongoing system support.
• A Houston aerospace component manufacturer adopted BLE wearables for operators to track high-value WIP subassemblies, improving throughput and operational visibility. GAO RFID offered remote monitoring and calibration.
• A Los Angeles pharmaceutical production facility utilized RFID tags to track batch WIP and ensure compliance with regulatory standards, improving process visibility. GAO RFID integrated the system with existing MES platforms.
• An Austin heavy machinery plant combined BLE tracking for portable WIP assets with RFID for stationary components, enabling real-time floor visibility and workflow optimization. GAO RFID designed the hybrid solution.
• A New York City consumer goods assembly line deployed BLE beacons to monitor WIP flow across production stations, enhancing throughput analysis and operator efficiency. GAO RFID handled installation and analytics configuration.
• A Philadelphia precision machining shop implemented RFID tagging for work-in-progress components to track processing stages and maintain production KPIs. GAO RFID supported system integration and reporting dashboards.
• A Minneapolis food processing plant relied on BLE monitoring to track WIP trays and equipment, ensuring quality control and timely movement between stations. GAO RFID provided sensor placement and real-time data dashboards.
• An Atlanta electronics testing lab deployed RFID to monitor WIP boards through multiple test stages, reducing delays and human errors. GAO RFID assisted with software integration and workflow automation.
• A Boston medical equipment manufacturer used BLE-enabled tracking for WIP instruments and assemblies, enabling dynamic task allocation and efficient floor management. GAO RFID provided configuration and operator training.
• A Detroit automotive supplier combined RFID for high-value WIP components with BLE for movable subassemblies, ensuring hybrid real-time tracking across large-scale production lines. GAO RFID designed and commissioned the system.
• A Charlotte textile plant implemented RFID for WIP fabric rolls and intermediate processes, streamlining job routing and reducing bottlenecks. GAO RFID integrated the system with ERP and production tracking software.
• A Seattle printing and packaging plant deployed BLE tracking for WIP materials and operator assignments, improving throughput and minimizing misplacement. GAO RFID provided installation and system monitoring support.

Canada Case Studies

• A Toronto aerospace parts manufacturer deployed RFID tags to monitor WIP subassemblies, ensuring precise stage tracking and production compliance. GAO RFID provided integration and floor-level support.
• A Montreal pharmaceutical plant utilized BLE beacons to track WIP batches across multiple production stations, improving scheduling and quality compliance. GAO RFID assisted with beacon placement and analytics dashboards.
• A Vancouver electronics assembly line combined BLE for mobile WIP tracking with RFID for stationary components, enabling hybrid visibility and reducing workflow bottlenecks. GAO RFID designed and commissioned the integrated system.

Our system has been developed and deployed. It is off-the-shelf or can be easily customized according to your needs. If you have any questions, our technical experts can help you.

For any further information on this or any other products of GAO, for an evaluation kit, for a demo, for free samples of tags or beacons, or for partnership with us, please fill out this form or email us.