Less searching. Less booking. More automating.
From the first operation to final assembly, you know in real-time where every workpiece, every load carrier, and every operating resource is – automatically booked, seamlessly documented.
What slows down your production every day.
In production and assembly, lack of transparency costs production time, quality, and nerves every day.
The customer-specific order is somewhere – just not where it should be
In mechanical and special vehicle construction, every order runs differently. Without real-time visibility, every part gets lost in the factory circuit – and your employees search instead of producing.
Downtime because material is missing – not because machines are failing
In HMLV assemblies, the line waits for assemblies that are long in the house – just not findable. Every minute of downtime costs. And no metric shows you why.
Manual feedback – outdated as soon as it is recorded
ERP bookings by hand, clipboards on the shop floor, status queries via shout: Your system never shows the real status. Decisions are based on yesterday's data.
You only recognize bottlenecks when the damage has already occurred
Congestion at the test field, blocked goods receipt, endless rework loop – in medical technology and the building elements sector, these are not only efficiency problems but compliance risks.
What Track & Trace specifically changes in your production.
This is how our solution brings transparency to your production and assembly.
Real-time order transparency
Live dashboard of all orders, zones, and load carriers – without manual queries.
Automatic zone booking
As soon as an order enters a zone, the system automatically books in the ERP or MES.
Real-time bottleneck detection
Dwell time analyses show where WIP is accumulating – before the backlog escalates.
Seamless traceability
Every movement, every zone, every timestamp is documented. Audit-proof without additional effort.
ERP & MES integration
Open API, direct SAP connection – no parallel universe alongside your IT landscape.
Flexible by technology
Indoor with high precision? BLE. Outdoor? GPS. Mixed environments? Hybrid.
Who is our Track & Trace solution suitable for?
Depending on the role, Track & Trace has a different lever. For all three, it applies: more transparency, fewer inquiries, reliable data instead of phone calls.
The Production Manager
"“I never know exactly how many orders are stuck where. By the time I have answers, the situation has long changed.”"
- Needs real-time OEE and throughput metrics without manual recording
- Wants to see bottlenecks before delivery dates are at risk
- Must dynamically control order priorities – for any batch size
- Requires reliable data for capacity and resource planning
The Assembly Team Leader
"My people spend too much time searching for parts instead of assembling. It eats up the shift."
- Wants to locate every tool and fixture at the push of a button
- Needs status overview without inquiries to other shifts
- Must trace and document rework loops
- Relies on less administrative effort – more time on the product
The right Track & Trace solution for your industry.
Each industry has its own requirements for location and tracking. Choose your industry and we will show you how our Track & Trace solution works in practice.
Order tracking in single production
Every workpiece follows an individual route. RTLS Tags track assemblies through all production stages – status changes are automatically transferred to the ERP.
Equipment & tool management
Special tools, fixtures, and measuring devices are located, and their use is logged. Your team finds what it needs – without search time.
WIP tracking of large assemblies
Chassis, superstructures, vehicles in raw construction: Even large-volume objects are tracked with robust GPS or BLE Tags. Production managers see the current order status.
Traceability & compliance documentation
Every movement of a product or semi-finished part is documented with a timestamp. Audit trails for MDR and FDA are automatically generated.
Material flow & bottleneck control
In assemblies with high variant diversity, the system shows where buffers build up, where material flows stagnate, and which stations are underutilized.
Talk to us about your use case.
In 30 minutes, we show how Track & Trace can work in your environment – industry-independent and concrete.
These companies already trust our Asset Tracking in their production.
Leading industrial companies rely on our solutions and feel a difference from day one.
No more flying blind in production
In our document, you will learn how real-time tracking prevents bottlenecks and reduces your costs. Download the free PDF now.
Häufige Fragen zu unseren Lösungen
Track & Trace in production is the automatic recording of the position and status of all moving objects in the hall, such as workpieces, assemblies, tools, load carriers, and other assets, without manual scanning. Unlike traditional BDE booking, the information is not generated by an employee's action but by the information sent by the Tracker and the information that is thereby kept up to date in the IT systems. ERP, MES, and Kanban board always show the real state that you actually find in the hall and not the one that was last booked.
In a BDE or MES solution, data is recorded that an employee manually enters. In contrast, the end devices of the Track & Trace solution, such as Trackers or Tags, generate this data themselves. To illustrate the difference with an example: An MES booking states that order 4711 was registered at station 12 three hours ago. With a Track & Trace solution, you know that order 4711 has been at station 12, buffer place B, and quality assurance in the last three hours and is currently on its way to assembly. Both systems are not mutually exclusive but complement each other: Track & Trace provides the MES with real-time data that represents the reality on the shop floor.
Track & Trace solves four recurring problems in production and assembly: Firstly, it reduces the search times of factory workers for individual parts, assemblies, or other assets, which typically range from 30 to 60 minutes per shift. Secondly, the dwell time of WIP is reduced because no one in the hall knows that the order is ready for the next production step. Thirdly, it closes the gap between SAP and the reality in the hall due to forgotten, incorrect, or delayed bookings. Fourthly, it increases traceability for audits, complaints, and quality deviations. All four problems have one thing in common: they require manual recording, which is replaced by the Track & Trace solution.
The choice depends on three factors: desired location accuracy, movement radius, and unit costs per asset. RTLS based on modern radio standards offers room to zone accuracy and is the right choice for tool, fixture, and WIP tracking in assembly. Active RFID BLE Tracking provides zone accuracy between 5 and 15 meters at significantly lower tag costs. This is the right lever for large quantities of small load carriers, special load carriers, or standard tools. GPS Tracking covers everything outside the hall, from the factory yard to the extended workbench. In practice, we combine technologies. Which mix is right for your situation, we clarify in the discovery workshop.
Especially in small series or variant-rich production (High Mix, Low Volume production), the use of a Track & Trace solution is worthwhile. Because mass production has usually automated its bookings via line takt and Kanban. In variant-rich single and small series production (mechanical engineering, special vehicle construction, medical technology), every order is different, every path through the hall is individual, every assembly station has different tools. This is exactly where manual recording systematically loses, and this is exactly where search times and dwell times are highest.
To introduce a Track & Trace solution, you need to change very little on the shop floor. An RTLS or Active RFID infrastructure consists of passive anchors on hall supports or ceilings, a Gateway per 2,000–5,000 m², and Tags on the objects to be located. The anchors are glued or screwed, usually without interfering with the building structure. The anchors run on battery power with a multi-year lifespan. The commissioning of a typical assembly hall (5,000 m²) takes two to five days.
Our Track & Trace solution can be connected to existing systems via standardized interfaces such as REST-API, OPC UA, and SAP-specific adapters. The movement data flows as events into your target systems. You can store the logic for this in our platform rule-based, without needing developer knowledge.
In production, our Track & Trace solution provides reliable levers for search times (~ 80%), booking efforts (~ 90%), and against shrinkage (towards 0%). In a manufacturing operation with 200 workers and an average of 45 minutes search time per shift, the search time lever alone amounts to about €1.5 million per year. Thus, the investment in infrastructure and Tags pays off in most projects within 8–15 months. We are happy to calculate specific numbers in discussions with you.
We implement our Track & Trace solution in the production environment at customers within 6 to 8 weeks with clearly defined use cases. The specific duration until go-live depends on the scope of the assets and the environment.
Our Track & Trace solution works without additional infrastructure across multiple plants and external partners. Multiple plants run tenant and location-capable in one view. Assets that go to external partners are equipped with GPS Asset Trackers that autonomously send via mobile network.
Are untraceable parts slowing down your production?
We understand the challenges of production & assembly through our long-standing support of our customers. Contact us and we will find the right solution for your challenges.
