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Zero Waste with Productivity Hero - Smart Factory Location Tracking Solution
Apr 10, 2025
The Importance of Location Tracking Solutions in Smart Factories
Real-time tracking of asset locations at manufacturing sites is essential for improving productivity. This need becomes critical in complex indoor settings like semiconductor fabs, where lacking precise location information can lead to extended search times, resulting in increased downtime and reduced productivity.
Advantages of Implementing a Location-Based Asset Management Solution:
Significant reduction in time required to locate assets, thanks to real-time monitoring
Enhanced operational efficiency through analysis of equipment movement and usage patterns
Strengthened security by preventing unauthorized access to equipment
Streamlined management operations through the digitalization of asset status
Location information is integral to the functionality of smart factories, extending to include synchronization with inventory systems, optimization of equipment maintenance schedules, and management of worker safety. In sites like semiconductor factories, which house numerous expensive equipment and special environments such as cleanrooms, accurate location tracking is especially critical.
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Location-Based Asset Management System Development Process
Developing an effective location-based asset management system necessitates a systematic approach that includes a thorough analysis of the onsite environment and a clear definition of requirements. It is critical to understand the specifics of the indoor space, the types of assets to manage, the required precision of positioning, and the monitoring intervals to design a solution tailored to these needs.
IPIN LABS utilizes RF SLAM technology to efficiently leverage existing on-site RF signal infrastructure, such as Wi-Fi and BLE, to maintain cost-effectiveness. By creating a Location Tracking AI model with RF data collected at the site and registering the assets to be tracked, a location tracking system can be quickly and economically implemented.
The platform for managing assets based on location is designed to facilitate seamless collection, analysis, and visualization of location data. Through the web portal, users can view asset locations on blueprints and access movement paths along with various statistical data. Moreover, by integrating with existing MES/ERP systems via API, the platform can retrieve location information, advancing the digital transformation of asset management. This arrangement enables real-time data-driven decision-making, substantially enhancing industrial site efficiency.
Actual Implementation Case and Impact
At the domestic semiconductor manufacturing plant of S Company, the deployment of a location-based asset management solution facilitated by IPIN LABS technology is underway. It is projected that the real-time location tracking of tens of thousands of manufacturing equipments within the semiconductor fab will immediately reveal the status of both new and idle equipment. This capability is expected to reduce the time required to locate equipment by over 90%. In addition, the implementation is anticipated to significantly enhance security levels through controlled access and personnel counting in secure areas.
Anticipated KPI Changes Post-Implementation:
Equipment search time: Reduced from an average of 27 minutes to under 2 minutes
Equipment operational efficiency: Increased from 78% to approximately 92%
Time spent on documentation related to equipment movement: Decreased from an average of 2 hours per day to 10 minutes
Managerial workload: Reduced by more than 40%
ROI analysis suggests that the implementation will generate cost savings in the hundreds of billions of Korean won. The primary factors contributing to these savings include reduced downtime, optimized workforce management, and enhanced asset utilization. Notably, the utilization rate of high-value assets such as semiconductor equipment is expected to increase by over 14%, potentially allowing for an increase in production without the need for additional equipment investments.
Considerations for Effective Solution Implementation
When implementing location-based asset management in smart factories, where such advancements significantly enhance productivity, several key factors must be considered for an effective deployment. Security and privacy protection are essential, especially in sensitive settings like semiconductor fabs. In such environments, constructing an on-premise server might be necessary to prevent the external leakage of location data.
Communication disruptions can critically affect production environments, making stability a crucial consideration. Incorporating local caching features ensures that the system can maintain asset location data even during temporary network disruptions. Since manufacturing sites are constantly evolving, a system that offers scalability and compatibility is necessary. An API-centric design facilitates smooth integration with existing MES and ERP systems, while a cloud-based architecture provides the flexibility to adapt to future production line expansions or the introduction of new equipment.
Future Prospects for Location-Based Asset Management
Location-based asset management technology is set for significant advancement through its integration with 5G technology. Utilizing private 5G networks, which are known for ultra-low latency and high reliability, will enable more accurate location tracking compared to current technologies that rely on Wi-Fi or BLE. This accuracy is critical for implementing sophisticated smart factories that require centimeter-level precision for tasks such as semiconductor equipment alignment and robot collaboration.
In smart factories, location-based services extend well beyond simple asset tracking, enhancing the entire production process. By combining asset location data with AI analytical technology, factories can evolve into intelligent production systems capable of autonomously optimizing both resource placement and workflow. Ultimately, the digitalization of location information will emerge as a key technology, driving a new manufacturing paradigm focused on eliminating waste and maximizing productivity.
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