Asset tracking is an innovative technology that is used in logistics and production to control important operating resources (assets). Both on the production line and in the warehouse, it is possible to track where which items are located when and in which process step. This provides a clear overview of how operating resources are distributed. The process flow and the actual status of things can be monitored live. Such comprehensive control goes far beyond the previous knowledge, which consisted at most of how items were booked. With asset tracking, the actual status is recorded in real time for the first time.

The technological implementation

Various technologies have become established for the implementation of asset tracking. Depending on the purpose and location, RFID tags, Bluetooth low-energy tags or ultra-wideband tags are suitable for indoor tracking. In addition to these three transmission technologies, GPS technology is also suitable for outdoor tracking.

The actual asset tracking process has a modular structure. Three building blocks form a three-part architecture consisting of sensors, gateway and software. Small sensors are usually attached indirectly to trolleys that transport the assets. They send out a signal. Any number of these sensors can be used. The signal from the sensors is recorded by a gateway. The gateway converts the signal into information and forwards the data to a cloud.

The information is recorded in software in the cloud. Here, the pieces of the mosaic now form a comprehensive overall picture, which then provides the respective employees with a digital overview of all processes on a tablet or desktop - in real time. Several software systems can be connected to a gateway, for example ERP, MES, BI or AI solutions. However, the following aspects must be taken into account.

What is allowed with asset tracking?

Asset tracking as monitoring of operating equipment is permitted in German-speaking countries. There are no restrictions on tracking this equipment with signals, especially if your own production or storage facilities are to be monitored. However, it is very important that no personal data is recorded in this process. In Germany, Austria and Switzerland, it is not permitted to subject employees to tracking, nor may they be indirectly monitored using localization measures. A special look at the individual process steps is necessary here: If a means of transportation is equipped with a sensor, the driver is also indirectly tagged and tracked. As a result, rest periods of the means of transport can also provide clear information about the driver's whereabouts.

If the process steps are zoomed in too closely and it can be assigned exactly which employee has worked on which assets because they are responsible, legal problems are the result. Comarch always draws attention to such legal requirements in projects in German-speaking countries. Technically, however, the global IT manufacturer uses solutions for tracking employees in other countries, for example with transmitters in the form of a wristband around the arm. In this country, it is not possible to track and monitor employees in this way. However, there are so many other legally compliant options for optimization in Germany that asset tracking is likely to play a much greater role in the future.

How asset tracking is used today

RFID chips are already widely used in German warehouses. They are used here, for example, to track pallets. What is not recorded is the exact location of the assets on these pallets. In addition, no information is automatically transferred to connected systems. These shortcomings are currently being addressed in a number of projects. Individual warehouses are virtually divided into zones. This enables geofencing, i.e. the automated triggering of an action when a geolocalized boundary is crossed.

Integration with ERP and BI

If you want to know exactly where the forklift truck and the load it is transporting are located, you should opt for a dual solution: With ultra-wideband tags on the forklift truck and RFID tags on the pallets, the exact location of assets in the warehouse can be tracked. Intelligent linking of the individual technologies is currently cutting edge, state of the art in terms of IoT innovations. This technology also enables live tracking with spaghetti diagrams.

Although already technically feasible, these are relatively new features that are not yet widely used in German production halls and warehouses. It also paves the way for comprehensive warehouse optimization: the additional data and the evaluation by artificial intelligence enable precise analysis so that forklift drivers can drive optimized routes. If, for example, waste products have to be collected from production, the concept of intelligent logistics comes into play. The analysis shows what quantities of metal, cardboard and aluminum are produced at what time. An optimized route is then taken based on the analysis.

In general, product integration with other systems (such as ERP, MES, BI) opens the door to comprehensive process automation. The generated reports and analysis tools help to identify bottlenecks and optimize the use of resources. Looking into the future enables more precise planning and real-time analysis.

The article appeared in materialfluss 3/22.