Real-Time WIP Tracking & Shop Floor Visibility
Manufacturing shop floor and production floor management software. Smart manufacturing functions have thousands of inventory or shop floor monitoring for a production unit to keep updated on the process aspects of the workflow. RipplesIPS Bluetooth RTLS for real-time location system can give a wide range of comparison reports to help improve factory floor and workflow process efficiencies through production bottleneck detection methods.
Low-cost deployment for Work-in-Progress (WIP) tracking, Bottleneck identification, and OEE (Overall Equipment Effectiveness) for implementing Digital Twin for factories for Real-time Shop Floor Data Collection.
WIP Tracking RTLS for Production Bottleneck Detection
- Gain new insights from the production shop floor dashboard
- Optimise production shop floor management with the help of indoor positioning
- Increase productivity using our production inventory tracking system search
- Plug and play RTLS solutions data collection for production inventory tracking, choke points to improve workflow
- Enable ease of inspection of plant and machinery in production tracking systems
- Integrated with Bluetooth AoA beacons, LoRaWAN gateways, RTLS anchors, and IoT asset management & data visualisation tools
- Easy to deploy workflow monitoring systems. No wiring or infrastructure costs
- Bin and Pallet tracking of raw materials and finished goods within the shop floor.
- Monitoring the workflow in production, logistics yard management, warehousing & other services
- Understand and analyse the time taken for a production pallet to move between zones
- Monitoring the movement and location of visitors and contractors using our connected worker safety tracking solutions for safety & security
- Understanding equipment utilisation & support staff visits for efficient maintenance
- 7-day deployment of IoT inventory tracking for the manufacturing shop floor.
Wireless Shop Floor Monitoring with Plug and Play RTLS
How do I manage my production shop floor? Ensure machine uptime in the factory shop floor to improve safety & factory efficiency, all in a box, fully integrated shop floor workflow monitoring, inventory tracking and a preventive maintenance suite to help you achieve real-time updates on all aspects of your shop floor operations. The wireless shop floor monitoring, pump motor monitoring, and indoor inventory tracking software with a monitoring dashboard comprises zone information, object count within zones, indoor positioning analytics, and anomaly detection functions such as temperature.
Track work orders in the supply chain, improve manufacturing processes and ensure production floor data collection for shop floor control. Preventive Maintenance aspects, such as technicians visiting for repair, inspection, abnormality manager, calibration records, etc., know about the shop floor digital twin for WIP tracking.
Shop Floor Data Collection & Pump Motor Monitoring with IoT
Ripples IoT BLE sensors clip directly onto pump motors, HVAC units, compressors and other rotating equipment without any wiring — deployable in minutes. Each sensor continuously monitors vibration, temperature and runtime hours, feeding live data into the shop floor dashboard. When a motor exceeds its vibration threshold or runs beyond its scheduled maintenance window, the system triggers an instant alert via SMS or dashboard notification — before the failure occurs. Maintenance teams can view the exact location of the flagged equipment on the floor plan, access its full usage history, and dispatch a technician with the right parts the first time. For facilities running 24/7 production cycles, this moves maintenance from reactive to predictive — reducing unplanned downtime, extending equipment lifespan and improving overall OEE without adding headcount or infrastructure.
Contractor & Connected Worker Tracking on the Production Floor
Managing contractors and temporary workers across a busy production floor presents a unique safety and compliance challenge — they are unfamiliar with the facility, often work in high-risk zones, and their movements are difficult to track manually. Ripples IoT deploys lightweight BLE wearable tags on helmets or lanyards, giving floor managers real-time visibility of every contractor’s location, zone entry and exit times, and time on site. Geofenced restricted zones trigger instant alerts if an unauthorised person enters a hazardous area — automatically logging the event for compliance reporting. For permanent workers operating alone in remote sections of the facility, the same system provides lone worker safety monitoring with a panic button that pinpoints their exact location within seconds of activation. All movement data is stored and exportable for contractor induction audits, insurance claims, and health & safety inspections — replacing manual sign-in sheets with an automated, tamper-proof digital record.
How does Production Floor Management Software improve shop floor efficiency?
Production floor management software provides real-time visibility into every stage of the manufacturing process. By using Bluetooth Mesh RTLS for manufacturing (Real-Time Location System), the software automates the tracking of Work-in-Progress (WIP) and assets. This eliminates manual data entry, reduces time spent searching for tools or materials, and identifies production bottlenecks instantly, leading to a leaner, more agile manufacturing cycle.
Can the Plug and Play RTLS software integrate with our existing ERP or MES?
Yes. Our production floor management solution is designed with an open architecture to seamlessly integrate with major ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems). This ensures that your real-time location data flows directly into your management systems, providing a “single source of truth” for inventory, asset utilisation, and production timelines through production bottleneck detection.
What is the difference between RFID and Bluetooth Mesh for shop floor tracking?
While RFID is effective for point-of-entry tracking, Bluetooth Mesh RTLS offers continuous, real-time monitoring across the entire shop floor. Bluetooth Mesh is generally more cost-effective to deploy at scale, offers higher accuracy in dense industrial environments, and provides a multi-hop network that ensures no “blind spots” in your production tracking. Learn about the shop floor tracking system pricing
How does the software help in reducing Work-in-Progress (WIP) lead times?
The software monitors the “dwell time” of products at each workstation. If a component stays in one zone longer than the predefined threshold, the system triggers an automatic alert. This allows floor managers to intervene in real-time, preventing the “invisible” delays that typically inflate WIP lead times and stall overall throughput.
Is the hardware durable enough for harsh industrial environments?
Absolutely. Our IoT sensors and gateways are built for Industrial IoT (IIoT) applications. They are designed to withstand high temperatures, vibrations, and electromagnetic interference common in manufacturing plants. The low-power consumption of our Bluetooth tags also ensures a long battery life (typically 3–5 years), minimising maintenance overhead.
IoT inventory tracking for manufacturing shop floors
Know more about our Industry 4.0, robust plug and play RTLS solutions for environmental monitoring, asset tracking, production inventory tracking, warehouse management and factory optimisation using a robust and resilient wireless mesh network.
Call us to learn more about factory floor tracking, remote worker tracking and production floor management solutions. The same BLE RTLS platform also powers real-time asset tracking in hospitals for surgical workflow and equipment monitoring