Project – Indoor Tracking System

Real-Time Location System (RTLS) Enablement for Large Manufacturing Facility

Context

A large automotive manufacturing facility had deployed Cisco DNA infrastructure for indoor tracking, but the system was not usable for real-time operations.

Problem

Cisco’s coordinate system did not align with the plant’s internal XY grid used in facility layouts.

As a result:

  • Location data could not be mapped to actual production zones
  • Tracking lacked the precision required for operational use
  • Existing infrastructure could not support real-time decision making

Approach

Engineered a spatial transformation layer to convert Cisco coordinates into the plant’s grid system with high positional accuracy.

Key steps:

  • Mapped Cisco coordinate space to facility CAD layout
  • Built a grid-based alignment model reflecting real plant geometry
  • Calibrated positioning using known reference points across the floor
  • Refined logic to achieve zone-level and near real-time accuracy suitable for operations

Result

  • Enabled a functional Real-Time Location System (RTLS) across the facility
  • Achieved high-accuracy asset tracking aligned with production zones
  • Transformed unusable data into real-time operational visibility
  • Eliminated need for additional hardware investment
  • Reduced asset search time significantly by 95%

Tools & Methods

Python, spatial mapping, coordinate transformation, CAD integration

Notes

Details generalized due to confidentiality.

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