Real-Time Tracking is the continuous monitoring of physical location, status, and movement of materials, work-in-progress, finished goods, tools, and assets throughout manufacturing facilities and supply chains, providing instant visibility into where items are, what state they’re in, and how they’re progressing through operations. Unlike periodic inventory counts or manual status updates that create information lag, real-time tracking uses technologies like barcode scanning, RFID tags, GPS devices, and IoT sensors to automatically capture and update item locations and conditions as events occur. For manufacturers, this eliminates the “black holes” where materials disappear into production with no visibility until they emerge hours or days later, replacing uncertainty with precise knowledge of every job’s current location, which operation it’s at, and whether it’s on schedule or delayed.
The technology enabling real-time tracking has advanced significantly. Barcode systems require manual scanning at checkpoints throughout the facility, creating tracking events as operators scan job travellers or product labels at operation completion. RFID technology automates tracking further, with readers at doorways, work centres, or mounted on forklifts automatically capturing tags as items pass by without requiring deliberate scanning actions. GPS trackers on vehicles, containers, or high-value assets provide location data across wider geographic areas for supply chain visibility. IoT sensors embedded in products or packaging can report location, temperature, humidity, shock events, and other environmental conditions throughout transit. Manufacturing execution systems integrate these tracking technologies, maintaining centralised databases showing current location and status of every work order, material lot, tool, and asset, accessible through dashboards, mobile apps, or integration with ERP systems for enterprise-wide visibility.
The business benefits extend across operations. Production managers locate jobs instantly when customers inquire about order status rather than walking the floor or calling around. Planners identify bottlenecks by seeing where work queues up, enabling dynamic resource allocation or priority adjustments. Quality teams trace defective products back through production history to identify which operations, materials, or conditions were involved. Maintenance departments locate tools and equipment without searching, improving utilisation of expensive assets. Inventory accuracy improves as system records reflect actual physical locations continuously rather than relying on periodic counts. Customer service provides accurate, current delivery estimates based on real production status rather than outdated information. For manufacturers managing complex multi-step processes, high-mix production, or strict traceability requirements, real-time tracking transforms operations from reactive searching and guessing into proactive management based on accurate, current information about everything flowing through the facility.
