Empowering Lean Manufacturers with Smarter Technologies

Eliminate search time, shorten lead-times, and expose flow interruptions with RTLS built for the shop floor – not IT.

Spot WIP queues and bottlenecks in real time
Cut motion and search waste for operators and leaders
See standard vs. actual flow across every line and cell

Trusted by lean, multi-site manufacturers to keep flow visible from dock to dock.

Get your RTLS value map

Share a few details about your plant, and we’ll map where real-time location data can remove waste in your value streams.

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Typical response time: under 1 business day. We never share your information.

Designed with operators, supervisors, and lean leaders on the shop floor.

See your flow like a value stream map that updates itself

Gemba Systems connects tags, assets, and WIP locations so your lean team can see true flow in real time – without walking the entire plant every hour.

Expose hidden WIP and queue time instantly
Alert leaders when takt is missed at any station
Quantify motion and search waste with hard data

Outcome: faster problem solving at the gemba, less firefighting, and a flow picture leadership can act on daily.

Typical impact in 90 days

Based on results from mid-volume discrete manufacturers implementing RTLS with a single pilot area first.

Search time

-40–60%

Operators & leaders

WIP visibility

>95%

Tagged critical items

Expedites

-20–25%

Firefighting orders

From tags to actionable signals in weeks, not years

Gemba Systems is built for focused, high-ROI pilots that scale. We’ll meet you at your current lean maturity and IT constraints.

1. Align on value stream & problem

We start at the gemba with your team: current state map, constraints, and where you suspect flow is breaking (queues, changeovers, handoffs).

2. Deploy tags & location anchors

We instrument selected assets, WIP, or containers with tags; anchors read position data and stream it securely to Gemba Systems in real time.

3. Turn data into lean signals

Flow dashboards, queue alerts, standard vs. actual heatmaps, and reports shaped for daily tier meetings and leadership reviews.

Where lean teams start with RTLS

Focus on a single constraint or high-variance area first. Common starting points for Gemba Systems customers:

Final assembly & kitting

Track WIP carts and kits through each station. Spot where work piles up and how long it sits before assembly, test, or pack-out.

Internal logistics & supermarkets

Monitor tugger routes, milk runs, and material presentation so operators never wait for parts and supermarkets stay balanced.

High-value assets & tools

Know exactly where fixtures, gauges, and shared equipment are being used and where they wait idle between shifts or changeovers.

Measure what matters for flow, safety, and delivery

Instead of more static reports, Gemba Systems gives your team live, operational metrics that update every few seconds.

Actual lead-time by product family and route
Queue and dwell time at each key location
On-time completion vs. plan by cell or line
Heatmaps of congestion and blocked pathways

Use the data in daily tier meetings, kaizen events, and leadership reviews to prove impact and prioritize the next improvement.

RTLS real-time flow dashboard mockup for lean manufacturing

See where RTLS pays back in your plant

In a 30-minute walkthrough, we’ll map your current flow, highlight candidate pilot areas, and outline the data you’d see in the first 90 days.

Request walkthrough

We’ll follow up with 2–3 time options for your team.

RTLS questions from lean manufacturers

If you don’t see your question here, share it in the form and we’ll address it directly in the walkthrough.

How big of a pilot do we need to see value from RTLS?

Most customers start with a focused pilot area: one assembly line, a shared supermarket, or 50–100 tagged assets/WIP units. The goal is to prove value around a specific constraint – such as long search time or unpredictable lead-time – within 60–90 days, then expand once the team is comfortable using the data.

What does IT need to provide to get started?

For most pilots, we require network access (wired or secure wireless) for anchors and a secure connection to the Gemba Systems cloud. We work with your IT and security teams on standards, data retention, and user access control. Hardware is typically segregated and does not touch production control systems.

Can you integrate with our MES or ERP?

Yes. We can associate RTLS data with work order, product, and customer information from MES/ERP systems. Many teams start with a standalone pilot for speed, then connect selected signals (e.g., lead-time by product family, WIP status) to existing systems once the use cases are proven.

How accurate is the location data?

Accuracy depends on your environment and technology choice, but for most indoor factory use cases we design around zone-level and work-area accuracy (e.g., which cell, which supermarket, which aisle). For high-precision needs, we can design pilots that achieve sub-meter accuracy in critical areas.

How long before our operators and team actually use it?

We focus on adoption, not just data. After hardware install, we usually run in shadow mode for a short period, validate signals, and then co-design dashboards and alerts with operators and leaders. Many teams use RTLS insights in daily tier meetings within a few weeks of deployment.