Production Line Asset Tracking

We recently completed an innovative asset-tracking modernization project for a long-standing and trusted customer who approached us with a critical operational challenge. Their existing RFID-based tracking system was becoming increasingly unsustainable due to high maintenance demands, ongoing performance issues, and escalating ownership costs. With global microchip shortages, inflated replacement prices, and fragile epoxy-embedded tags that were easily damaged, the system delivered a maximum success rate of only 80% and required an estimated 1,200 man-hours annually just to keep it functioning.

The customer engaged BTR to resolve the problem or engineer a more robust solution—and we delivered. After a detailed assessment, we implemented a vision-based asset tracking system that has achieved 100% successful reads since deployment. The new solution significantly reduces operational overhead, requiring less than 100 maintenance hours per year, while eliminating the costly and time-consuming repairs associated with RFID chips. To further streamline operations, all assets are now etched in-house, removing the need for specialized microchip tags and avoiding recurring replacement expenses. This transition has not only improved accuracy and reliability but has also provided the customer with a durable, scalable, and future-ready tracking method that enhances efficiency across their entire workflow.