How RTLS Is Driving Transformation in Aerospace and Automotive Manufacturing
In an era defined by complexity, customization, and pressure for efficiency, aerospace and automotive manufacturers are facing unprecedented challenges. From managing high-value assets and tooling to orchestrating increasingly flexible production lines, traditional tracking and coordination methods are no longer fit for purpose. That’s why manufacturers across both industries are turning to Real-Time Location Systems (RTLS) — and to Ubisense — to gain a deeper understanding of what’s happening on the shop floor.
RTLS is not just a visibility tool; it’s a foundation for transformation. By precisely tracking the real-time location, movement, and interactions of tools, components, and people, RTLS unlocks a new level of control and insight — enabling smarter, safer, and more responsive manufacturing.
What Is RTLS — and Why It Matters
RTLS uses a combination of location-tracking hardware (such as Ultra-Wideband (UWB) sensors and tags), spatial intelligence software, and integrations with existing IT infrastructure to deliver accurate, real-time location data within complex industrial environments.
In contrast to traditional barcode or RFID systems, RTLS (particularly when combined with spatial intelligence platforms like SmartSpace® by Ubisense) offers dynamic, continuous insight — not just static records of where something was. That difference is key when you’re dealing with the kind of scale, complexity, and time sensitivity found in aerospace and automotive production.
Whether it’s helping to locate a torque tool within a multi-bay aircraft hangar or ensuring a vehicle chassis has reached the right station in a flexible automotive assembly line, RTLS enables manufacturers to track and control what really matters — with bolt-level accuracy and real-time responsiveness.
RTLS in Aerospace Manufacturing: Managing Complexity at Scale
Aerospace assembly is one of the most demanding manufacturing environments imaginable. Long production cycles, massive components, mobile tooling, and strict quality controls all converge in a space where every misstep is costly — both financially and in terms of safety.
RTLS from Ubisense supports aerospace manufacturers by delivering accurate, up-to-the-second visibility into the physical reality of operations. Key applications include:
1. Tool Control and Compliance
Tracking the movement, calibration status, and usage of critical tools is essential. SmartSpace, in conjunction with RTLS, ensures that tools are in the right place at the right time — and used correctly. If a tool enters an unauthorized zone, or is used out of calibration, the system can trigger alerts or even interlock the tool to prevent misuse.
2. Work-in-Progress (WIP) Tracking
Aircraft often move between stations at irregular intervals depending on technician availability, parts arrival, and inspection timelines. RTLS enables dynamic WIP tracking, providing teams and planners with real-time data on where each unit is, how long it’s been at a station, and whether any bottlenecks are developing.
3. Zone-Based Workflow Automation
Using location as a trigger, manufacturers can automate certain processes based on proximity or movement. For example, entering a new work zone might automatically update a digital workflow system, log a timestamp, or start a checklist for safety compliance — all without manual input.
RTLS in Automotive Manufacturing: Powering Production Line Flexibility
Automotive production is built around speed, precision, and volume — but today’s demand for vehicle customization and production flexibility adds layers of complexity. Traditional linear production lines are being replaced by modular and flexible assembly cells, where products follow non-linear paths through various stations.
RTLS is central to managing this kind of flexibility without sacrificing control or throughput.
1. Dynamic Line Balancing
With Ubisense’s RTLS and SmartSpace software, manufacturers can monitor real-time flow and cycle times across multiple production areas. This allows for dynamic line balancing, where work can be redistributed or rerouted in real-time based on actual production rates rather than static schedules.
2. Location-Driven Task Management
By knowing the exact location of a vehicle, a worker, or a tool, SmartSpace can trigger the right task at the right time. For example, a technician arriving at a station may be automatically assigned a task relevant to that vehicle’s build variant — helping reduce errors and training overhead.
3. Material and Asset Tracking
Keeping track of mobile assets like kitting carts, AGVs, or battery packs is vital. Ubisense RTLS ensures materials are delivered to the right place at the right time, reducing wait times and avoiding costly misdeliveries — especially important as electric vehicle production adds new logistical challenges.
Safety, Efficiency, and Data-Driven Improvement
Beyond operational control, RTLS provides a wealth of data that can be used to drive long-term improvement. Time-in-zone analysis, asset utilization, idle time monitoring, and heatmaps all contribute to continuous improvement initiatives and help identify waste that might otherwise remain invisible.
Moreover, integrating RTLS data into wider systems — such as MES, ERP, or digital twin platforms — enables smarter decision-making at every level, from shop floor supervisors to plant managers and enterprise-level operations teams.
In both aerospace and automotive, worker safety is another growing area of focus. With real-time personnel tracking, SmartSpace can be configured to monitor restricted areas, enforce social distancing protocols, or respond rapidly in emergency evacuations.
Why Ubisense?
Ubisense is a recognized leader in spatial intelligence for industrial environments. With decades of experience in deploying high-precision RTLS solutions in some of the world’s most demanding manufacturing environments, Ubisense is trusted by major brands across the aerospace and automotive sectors.
Unlike off-the-shelf tracking solutions, Ubisense works with manufacturers to tailor each deployment to specific needs — whether that means integrating with existing systems, working in highly reflective environments, or tracking hundreds of concurrent assets with high accuracy.
SmartSpace, Ubisense’s flagship software platform, goes beyond location tracking to provide the context and intelligence needed to make that location data actionable — from automation triggers to process visualizations and predictive insights.
Get in Touch
RTLS is not just a tool — it’s a strategic enabler for digital transformation in manufacturing. Whether your goal is to eliminate waste, increase traceability, or enable a more flexible and responsive operation, Ubisense can help you get there.
To find out how SmartSpace and RTLS solutions from Ubisense can support your aerospace or automotive facility, get in touch with our team of experts today.
You can also learn more about specific case studies and deployment strategies by visiting ubisense.com.