RTLS in EV Manufacturing: Transforming Production Efficiency

The rapid growth of electric vehicle (EV) manufacturing is reshaping the global automotive landscape. As traditional automakers and new entrants alike race to meet demand, the need for agile, data-driven production processes has never been greater. A key enabler in this transformation is Real-Time Location Systems (RTLS)—a powerful technology that provides precise, real-time visibility into the movement and status of assets, tools, and people on the factory floor.

What is RTLS?

RTLS refers to a set of technologies that determine the real-time location of objects or people, typically within a confined area such as a manufacturing facility. Using a combination of sensors, tags, and software platforms, RTLS solutions track and monitor the movement of tagged items, offering real-time data that can be used to improve decision-making and operational efficiency.

While RTLS solutions vary in the technology used—ranging from Ultra-Wideband (UWB) and Wi-Fi to infrared and Bluetooth Low Energy (BLE)—they all serve the same goal: to eliminate blind spots in operations by giving manufacturers visibility over their critical resources.

To understand more about the different types of RTLS technology, this comprehensive guide by RFID Journal offers a useful comparison.

Why EV Manufacturing Needs RTLS

Electric vehicle production differs from internal combustion engine (ICE) vehicle manufacturing in several key ways. For one, the introduction of battery modules, high-voltage components, and specialized electronics has added new complexity to the assembly process. In addition, most EV production lines are relatively new, often built with a mix of legacy systems and new automation technologies that must be integrated effectively.

This complexity makes visibility and coordination absolutely critical—something RTLS is uniquely positioned to deliver. Here’s how:

1. Optimising Tool Availability and Usage

In EV manufacturing, certain tools—such as battery torque wrenches or high-voltage cable testers—are not only expensive but highly specialised. Ensuring that these tools are in the right place at the right time is crucial to avoiding delays and maintaining quality standards.

RTLS can track the real-time location and usage history of each tool, alerting operators or supervisors when a tool is in the wrong zone, missing, or due for calibration. This not only improves efficiency but also helps meet compliance and safety requirements.

2. Streamlining Material Flow

EV production requires precise coordination of materials—batteries, inverters, lightweight body panels, and more. With RTLS, manufacturers can monitor the flow of materials from receiving docks to line-side delivery, flagging bottlenecks or misrouted items in real time.

Some systems go even further by integrating RTLS data with existing MES or ERP systems to trigger alerts or workflow automations when materials are delayed or misplaced. This visibility reduces costly downtime and ensures that production keeps moving smoothly.

3. Enhancing Workforce Safety and Productivity

Many EV factories are introducing new safety protocols, especially around high-voltage battery handling and cleanroom processes. RTLS can be used to track personnel and restrict access to sensitive areas, or alert teams if someone enters a hazardous zone without proper authorisation.

In addition, by analysing location data over time, manufacturers can identify inefficient movement patterns or idle time among staff, helping to inform layout improvements or training needs.

4. Reducing Rework and Ensuring Compliance

As production volumes grow, so does the challenge of ensuring every vehicle meets regulatory and quality standards. RTLS can support digital traceability by logging each vehicle’s journey through the production process—what station it passed, what tools were used, how long each step took, and whether any deviations occurred.

This kind of granular data is invaluable during audits, investigations, or warranty claims, and it helps to create a culture of accountability and continuous improvement on the shop floor.

5. Enabling Flexible, Scalable Production

One of the major trends in EV manufacturing is the move toward more flexible production lines. Automakers want to be able to switch between models, or even between ICE and EV variants, without tearing down and rebuilding entire lines.

RTLS supports this by enabling dynamic workstations and digital instructions that follow each product through the line, regardless of its variant. This flexibility reduces the need for hard-coded automation and allows faster adaptation to changing market demands.

Real-World Results

Some of the world’s leading automotive manufacturers are already using RTLS to bring these benefits to life. In EV plants where RTLS is fully deployed, companies have reported:

  • Up to 30% reduction in time lost searching for tools and assets

  • Significant decreases in production delays due to material shortages

  • Improved safety compliance, especially in high-voltage zones

  • Better data for continuous improvement initiatives

RTLS Is No Longer a ‘Nice to Have’

As the EV market accelerates, the pressure to optimise every element of production is only going to increase. RTLS isn’t just a useful tool—it’s becoming a foundational layer for smart, responsive manufacturing.

Whether you’re launching a new EV platform, retrofitting a legacy site, or scaling up production across multiple facilities, real-time visibility can unlock powerful gains in efficiency, safety, and adaptability.

To see how RTLS is already transforming traditional automotive production, visit our Automotive Industry Solutions page.

A Smart Future Starts with Visibility

At Ubisense, we help manufacturers gain the real-time insight they need to thrive in fast-moving environments. Our RTLS platform powers some of the world’s most advanced factories—including EV production lines—by providing accurate, actionable data at every stage of production.

SmartSpace®, our location intelligence platform, plays a critical role in delivering this value by integrating RTLS data with factory systems to drive smart decisions and adaptive workflows.

If you’re exploring how RTLS can help you accelerate your EV manufacturing goals, get in touch—we’d love to help.