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Overcoming inefficient tracking of tools and work orders
Manufacturing facilities constantly struggle with inefficient tracking of tools and work orders. Relying on manual searches and paper logs creates severe blind spots on the factory floor. When technicians cannot quickly locate necessary equipment, maintenance operations slow down significantly. This lack of real-time visibility into tool locations and work order status disrupts daily workflows, causing unnecessary downtime and preventing teams from maintaining proactive maintenance schedules effectively.
These tracking inefficiencies directly lead to severe negative consequences for manufacturers. Unplanned downtime creates significant operational bottlenecks that result in high costs and lost revenue. Furthermore, misplaced assets require expensive replacements, while delayed work orders frustrate staff and reduce overall facility output. Without a clear digital system, these compounding issues severely damage your bottom line.
The tool and work order tracking solution
Modern automotive manufacturing requires seamless coordination to prevent downtime. By implementing the WT6400 Wearable Computer, ET401 tablet, TC78 mobile computer, and RFID Sleds, facilities gain complete control over their assets. These connected devices deliver real-time tracking of tools and the status of work orders across the factory floor. This comprehensive visibility directly drives increased technician productivity and reduced tool loss, keeping operations running smoothly.
Potential benefits
Transitioning to automated asset monitoring helps facilities overcome tracking challenges and realise tangible operational advantages. Implementing these Zebra solutions drives specific outcomes that support sustained business growth.
Increased technician productivity
helping teams complete more tasks in less time
Reduced tool loss
saving capital expenditure on unnecessary replacements
More efficient maintenance operations
minimising equipment downtime
How the solution works
Provide hands-free mobility to workers
Technicians need to keep their hands free while inspecting equipment and managing tasks. When a machine goes down on the plant floor, a notification can be pushed directly to the technician’s WT6400 Wearable Computer, allowing them to review the alert and accept the work order easily. WT6400 features a large display and integrated scanning, making it simple to update the status of work orders on the go. Its ergonomic design also reduces physical strain and keeps technicians focused on resolving maintenance issues swiftly.
Monitor repair progress and material needs on a rugged screen
The ET401 tablet gives supervisors or maintenance coordinators a larger, rugged screen for managing the repair from a broader operational view. After the technician accepts the machine-down work order on the WT6400 Wearable Computer, a supervisor can use the ET401 to monitor work order status, review machine details or schematics, and confirm whether tools or spare parts need to be requested. As the technician continues the repair, the ET401 helps coordinate the material handling handoff, so the tool order can be sent to the tool room.
Fulfil tool and spare part requests efficiently
While the technician works on the machine, the accepted work order can trigger a tool order to material handling for any required tools or spare parts. A tool room worker uses the TC78 Mobile Computer to receive the request, confirm item details, and move through the tool room with clear digital guidance, helping locate the right components quickly and accurately to support the repair.
Expand visibility with advanced data capture
RFID Sleds, like the RFD90, pair with the TC78 to quickly read tags on critical tools, spare parts, and components. In the tool room, the worker can leverage the RFID Sled to scan shelves, bins, and storage areas to find the items requested through the material handling order, reducing manual searches and helping ensure the technician receives the right tools or replacement parts without interrupting the repair workflow.
Increasing manufacturing asset visibility
Investing in real-time asset tracking capabilities provides substantial strategic value to manufacturing operations. Facilities benefit from optimised workflows and minimised disruptions, leading to robust financial returns and a stronger competitive position in the industry.
Note:
Use case figures, savings estimates and images are illustrative only and may be derived from customer data, projections, or controlled testing. They do not represent guaranteed results, and actual outcomes will vary by application; customers should consult a Zebra sales representative to evaluate their specific environment.
