Intelligent tool management - from manual handling to automatic operation

In this case, the company faced challenges in managing tools across the production line:

• Manual transport of tools between workstations and maintenance
• Lack of real-time insight into tool location and usage
• Risk of bottlenecks, errors and unnecessary production downtime
• Limited data for planned and predictive maintenance

To support an Industry 4.0 strategy, a solution was needed that could automate tool logistics, collect data close to production, and operate stably in a demanding industrial environment.

The solution - delivered with Sensorec products

The solution was designed as a holistic solution based on robotic automation, AGVs (Automated Guided Vehicles) and industrial IoT.

At the core of the solution is an industrial edge computing platform where a robust IoT gateway is installed directly in the production environment. The gateway acts as the link between:

• RFID readers on tools
• AGVs and robotic cells
• Production and cloud systems

By processing data locally (edge computing), pause time, network load and dependence on external systems are reduced - while critical decisions can be made in real time.

ROI & TCO - measurable business value

Not only is the solution technologically advanced, it's also economically attractive.

Reduced TCO (Total Cost of Ownership)

• Less manual handling and lower labour costs
• Fewer errors and reduced waste
• Robust industrial hardware with a long lifespan
• Less need for subsequent customisation and service

Improved ROI (Return on Investment)

• Increased uptime and more stable production
• Faster tool flow and shorter cycle times
• Better utilisation of existing equipment
• Data basis for ongoing process optimisation and maintenance planning

In practice, this means that the investment is quickly recouped through lower operating costs and higher productivity.

The result

After implementation, the company has achieved:

• More automated and transparent tool logistics
• Significantly improved overview of tool utilisation
• Reduced downtime and increased production stability
• A solid foundation for predictive maintenance and further digitalisation

The industrial solution is designed to operate in demanding conditions - including temperatures from -25°C to +70°C, vibrations and continuous operation - making it ideal for modern production environments.

Perspective - ready for the industry of the future

The case demonstrates how Sensorecs combines industrial hardware, edge computing and system understanding into solutions that create real business value. An approach that enables manufacturing companies to take the next step towards a more intelligent, data-driven and efficient factory.